Energy Efficient Industrial Lighting

Roy Hughes, PEng, LC

• Energy Efficient Lighting Design • Dynamic Lighting Controls• New Technologies – Efficient Lighting• Future Vision

Energy Efficient Industrial Lighting

Lighting Design for Industry

Lighting can:

Allow for visual function

Critical Seeing Tasks

Lighting can:• Allow for visual function• Support the

Architectural Vision

Lighting can:

• Allow for visual function• Support the

Architectural Vision• Complement Form

Lighting can:

• Allow for visual function• Support the

Architectural Vision• Complement Form• Create visual

hierarchies• Direct the Eye

Lighting can:

• Allow for visual function• Support the

Architectural Vision• Complement Form• Create visual

hierarchies• Direct the Eye• Assist way-finding

Lighting can:• Allow for visual function• Support the

Architectural Vision• Complement Form• Create visual

hierarchies• Direct the Eye• Assist way-finding• Be dynamic

Lighting can:• Allow for visual function• Support the

Architectural Vision• Complement Form• Create visual

hierarchies• Direct the Eye• Assist way-finding• Be dynamic• Extend the work day

Lighting can:• Allow for visual function• Support the Architectural

Vision• Complement Form• Create visual hierarchies• Direct the Eye• Assist way-finding• Be dynamic• Extend the day• Transform spaces

Updated IESNA Standards

• ANSI/IESNA RP - 7- 01

• Recommended Practice for

Industrial Lighting

Daylight

– People like daylight– Improves productivity– Improves mood– Saves Energy

Diffusing skylights spread soft daylight evenly across this library space.

Photo credit SunOptics Skylights

Bringing Daylight Inside• SunPipe

It looks like an electric light, but is actually all daylight!

Available for Commercial/Industrial as well as Residential applications

Energy Efficient Industrial Lighting

• Dynamic Lighting Controls• New Technologies - Efficient Lighting

• Future Vision

• Manual zoned/ dimmed• Automatic - Occupancy

– Infrared/ Ultrasonic/ Dual sensors

– Time clocks– Timers

• Automatic - Light Levels– Photo cells (measured)– Load reactive (peak)– Time clock (predicted)

Dynamic/Controlled Lighting

Integrate the Lighting Controls

Wireless Lighting Controls• ZigBee Mesh Networking

– Microprocessor based devices with embedded radios– Lighting Ballasts become control and communication

nodes– Utilizes an open protocol for communication – ZigBee– Mesh Network - Scalable, flexible up to 65,000 network

nodes– 100% digital component based network of devices with

the lighting infrastructure providing the DLN backbone– Software and UI’s determine the user experience– Distributed control of lighting – From personal space to

enterprise control

Reduced cost and complexity of system installation

Simplicity of Commissioning

Simplify Lighting Control System design in both new construction and retrofit applications

Key value drivers of a Wireless Lighting Control system

Easy and intuitive to use facilitating improved worker productivity

Operating cost and complexity reductions

Improved energy management and control

Key value drivers of a Wireless Lighting Control system

Motion Vibration

Solar TemperatureDifferential

Self Powered switches and sensorsHarvesting Energy from

Everyday activities!

The mechanical push of a button and solar power is enough to power transmissions, 30M indoors through walls and 300M outdoors.

Switches & Sensors are Wireless

Wireless Motion Detection

Wireless SwitchWireless Thermostat

Room Controller

Wireless Humidity

Lights on/off - Dim up/down

Wireless Light Detection

Heat up/down - A/C on/off

Wireless Daylight Harvesting Control

• maximizes energy conservation using the principals of manual on, dimming, and auto off technology.

• in no time at all, retrofit your classroom, hospital room, office with a wireless self powered switch and photo sensor and a dimming controller designed to maintain the perfect light level by dimming down or turning off the lights.

• occupancy sensor available.

TM

Adaptive Lighting

Prince George Pilot ProjectPrince George Pilot Project

Located in Prince George, BC. 69 Luminaires were retrofitted with Adaptive Lighting controls on 2.5 km main arterial, commercial and

residential roadway. Transit line is operational until 8 p.m. with varying pedestrian conflict levels.

Annual Savings this Project (170 Luminaries)

47,000 kWh ($3100)Payback = 7 Years (worst case)

(Assuming $0.066 per kWh)

15th Street, a main arterial roadway in Prince George, BC. retrofit 171 Luminaires with new innovative technology on 2.5 km main arterial with commercial and residential roadway. Transit line operational until 8 p.m. with varying pedestrian conflict levels.Lighting was dimmed to 70% or 50% depending on changes in traffic patterns.

Prince George Pilot ProjectEnergy Savings

Dynamic Lighting Opportunities

Control/ call Centers

No wired switches

Industry

Inspection tasks

• Energy Efficient Lighting • Dynamic Lighting Controls• New Technologies - Efficient Lighting• Future Vision

What’s New in Lighting

Lamp Efficacy* Continues to Improve* the ratio of light out to power in lumens per watt.

• Incandescent - 5 to 20 l/w

• Halogen -15 to 35 l/w

• CFL - 20 to 80 l/w

• Fluorescent - 60 to 100 l/w

• HID - 25 to 130 l/w

• LED - 25 to 80 l/w

Lamp Life is Improving• Halogen

– 3500 to 5000 hrs

• CFL– 6000 to 18,000 hrs

• Fluorescent– 20,000 - 40,000 hrs

• HID– 6,000 to 40,000 hrs

• Induction & LED– 50,000 - 100,000 hrs

Lamp Lumen Depreciation Improves“The fractional loss of lamp lumens at rated operating conditions that progressively

occurs during lamp operation. ” IESNA

75

80

85

90

95

100

0 20 40 60 80 100Percent of Average Rated Life

% o

f Ini

tial L

umen

s

T5

T8 (265 mA)

Incandescnt

T12 (430mA)HPS

MercuryVapor

Improvements to incandescent• Lamp Filament

Design– Including HIR

technology• Reflector Design

– Shape and coatings• Bulb Coatings

– Improved colour• Gas Fill

– Krypton gas

• “Retail HIR”, new lamps combine a silver-coated reflector thin film HIR™technology. – 33% longer life and – 30% energy savings – 50% less heat in the beam.

• replace a 90PAR lamp with a 55PAR HIR lamp

…with no reduction in lumens

Improvements in Incandescent

Halogen to LED replacements

4.8 Watts 150 Lumens

20W equivalent (120V)Warm or cool white

4.5 W 4.5 W 150 Lumens150 Lumens

20W equivalent (12V 20W equivalent (12V -- 24V)24V)Warm or cool whiteWarm or cool white

11W R30 LED11W R30 LED500 Lumens500 Lumens

60W equivalent (120V)60W equivalent (120V)Warm or cool whiteWarm or cool white

• Pulse Start Technology - matures• Ceramic Metal Halide – more products

– from 20 to 400 Watts – Colour control rivaling fluorescent– Various shapes - single ended to PAR

Improvements to HID LampsImprovements to HID Lamps

Ceramic Metal Halide• Less colour shift• Lamp life shorter than HPS• Cold starting down to -12c• Orientation sensitive (V/H/U)

• Improved efficacy - L/W• Excellent CRI - 90 to 95%• Light output still drops off

over life - better than standard

Ceramic Metal Halide - improved arc tube

320 Watt replaces 400 Watt MH

320W POWERBALL®

The Best of the Best

0%

20%

40%

60%

80%

100%

120%

140%

320WPOWERBALL

M400/U MP400/PS BU-ONLY

MS400/PS BU-ONLY

Relative Mean Light Output Relative Wattage

Ceramic Metal Halide

Ceramic MH screw-in PAR38

• 3x less energy than standard PAR38 halogen lamps

• 10,500 hours rated life • 1220 initial lumens • 87 CRI for true color

rendition • Available in beam spreads

of 10º, 25º, & 40º• Easy upgrade and instant

retrofit for halogen PAR38

• “White” Light - less colour shift• Extreme high efficiency -• Universal burning position• Compact size – 50% smaller• Improved efficacy – 103 L/W• CRI - 66%• 2730K CCT

New generation Ceramic MH

60 Watt 6800 lumens

A New Generation of Outdoor Lighting

One new Lamp Category: “electronics only”Dedicated Electronic Ballast Platforms

New Lamp Family

Ballast Comparison

140W CPO-T Electronic

154 Watts

10%

Yes

150W HPS Type CWA

195 Watts

30%

Limited

Input

Losses

Dimmable

A New Age in Urban Outdoor

Lighting….

Optics+Luminaires

E-Ballast

SystemDevelopment

Lamps

CosmoWhite

A compact system of a lamp, socket, and ballast, specially designed for outdoor applications

Improvements to Fluorescent• Lamp Life

– More long life options• Colour Rendering

– 85 CRI or better• Colour Temperature

– Higher CCT available• Lumen Maintenance

– More light over life

Fluorescent Lamp size issues

• Cool White T12– 70 lpw– 62 CRI– flicker with magnetic

ballast– 20,000 hr rated life– LLD: 60 to 70%

• T8 / 80– 92 lpw– 85 CRI– Imperceptible lamp

flicker with electronic ballast

– 20,000 hr rated life– LLD: 80 to 90%– Better optical package

T-12T-8

T-5

• T5 / 80– 93(HO) – 104 lpw– 85 CRI– Imperceptible lamp flicker

with electronic program start ballast

– 20,000 hr rated life– LLD: 90 to 95%

– Best optical package

Do we have enough T8 lamps? - 97 choices!

2700 3000 3500 4100 5000 6500F32T8/25/8xx 2 2 2 2F32T8/28/8xx 3 3 3 2F32T8/30/8xx 3 3 3 2F32T8/30/8xx/long life 1 1 1 1F32T8/7xx 3 3 3 2 2F32T8/7xx/long life 2 2 2 1F32T8/8xx 3 3 3 3F32T8/8xx/long life 1 3 3 3 3 3F32T8/8xx/extra long life 1 1 1F32T8/8xx/HP 3 3 3 2F32T8/9xx 1

T8 Energy Saving - 25W• operate on instant start

ballast • Replace existing 32W

T8 lamps for an immediate savings of 7 watts - 25% energy savings.

• Replacing F34T12 magnetic systems with 25W T8 on Instant Ballast can savings of up to 60 watts/luminaire - or 40% energy savings.

High-Lumen T8 lamps

• “Premium / Super / Enhanced”• Produce 3100 initial lumens or more

• Maintain 2915 or greater mean lumens

• Slightly higher L/W than standard T8 (91 vs. 88)

• Provide 85 or greater Color Rendering Index

• Achieve a rated life of 30,000 hours or greater

Long life T8s

• 224 Watts replaces 455 Watts - 20% more light

• Better Quality - Control, Color and CRI - No Color Shift Lower Maintenance Costs - Replacement Material Lasts Longer and Costs Less

• Extra Features -Dimming, Occupancy Sensor, and Emergency Options

High Efficient FluorescentHigh Efficient Fluorescent

New T-5 properties• High Efficacy 100+ l/w• Low wattage 28• 5/8” profile optimizes fixture

performance.• Small diameter for smaller

fixture size.• Low LLD, 95%• T-5 High Output (HO)

– High surface brightness (glare)

– Can be a challenge to uniformity

Metal Halide Pulse Start Vs T5HO Fluorescent

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000Hours

Lum

ens

Standard400WPulse StartMetalHalideVenture320WPulse StartMetalHalideT5 HO 3Lamps perLuminaire

Lamp Lumen Depreciation

Improved Amalgam Technology

• More light output over a wider temperature range

• 90% light output from 5C to 75C

• New amalgam technology reduces warm-up time

• Quicker run-up to full brightness

Improved Amalgam Technology

Compact fluorescent lighting• Energy savings of 70-75% vs.

incandescent bulbs• Eight to ten times longer life• Huge implications when employed

on a larger scale

CFL Technology continues to mature• Lamps more like

incandescent - 80% energy saving

• New High Wattage CFL’s for industrial and commercial applications

• 1Watt to 200Watts

CFL Technology large lamps• 57W and 70W Plug-in• 42,000 - 53,000

Lumens• Approx. 7in - 8in

length• up to 200 Watts

High Lumen CFL’s

Courtesy: 1st Source, Sportlight, Lightedge, Metalux, Day-Brite

Alternative Low & High

Bay Luminaires

Induction Fluorescent

Compact Fluorescent

T8 or T5HO Fluorescen

t

Hill Air Force Base

High Wattage CFL

Courtesy: Sportlight

•High CRI•Instant start•Step Switched CFL Low Bay luminaires•(8) 10,000 hr lamps

•Plentiful Daylight•Photo Controls•Step Switched Biax CFL Low Bay luminaires•(8) 20,000 hr lamps

High Wattage CFL

Electrodeless Induction Lamps

• 100,000 hour lamp life• 70 lumens per Watt• Cold start to - 30 °C• instant re-strike• RE phosphors • 80+ CRI• Various color temps

Electrodeless Linear Induction• Lamp and ballast system

100,000 hour rated life• Instant on/instant restrike • 3500K and 4100K color

temperatures • 80 CRI • Starting down to - 40°C • 70% lumen maintenance at

60,000 hours ICETRON™

Courtesy: 1st Source,

•High CRI•Instant start•Step Switched Induction Low Bay luminaires•(2) 100,000 hr lamps Induction Lamps

• Principles of Energy Efficient Lighting Design

• Dynamic Lighting Design• Using Newer Technology for Efficient

Lighting• Case Studies in the Industrial Sector• What’s next?

Case study: Warehouse

• 320,000 square-foot warehouse originally lit with HID lamps, upgraded lighting to high-output T5 fluorescent lamps. Retrofit yielded consistent lighting levels, high color rendering and energy reduction of 36%.

Case study: Industrial Shop

• Industrial assembly plant originally lit with 400W HID lamps, upgraded lighting to 4 high-output T5 fluorescent lamps (240W). Lighting controls (occupancy sensors) included in the luminaires allow for additional energy savings where areas are unoccupied.

Case study: School gymnasium

• Gymnasium originally lit with HID lamps, directly replaced with 2’x4’ 6-lamp F32 T8 fluorescent lamps. Retrofit yielded brighter and whiter lighter output with energy reduction of 52%.

Arena - Before - T12HO and 2x400W Metal Halide

Arena - After – T8 HBF

Gym -Before - Metal Halide and Incandescent - low illumination.

Gym - After – T5HO and occ. sensors

Gym - Before – Combination MH+HPS

Gym - After – T5HO and occ. sensors

Gym - Before – HPS

Gym - Before – HPSGym - After – T5HO

Classroom - Before –T8 luminaires mounted too high- dark and non-unifo

Classroom - After –T8 but lowered – brighter- more uniform

Improvements to Ballast TechnologyImprovements to Ballast TechnologyThe Future is Electronic....Why?

Compact size

Performance:

Constant wattage

Energy efficiency & Economics

Controllability

High-Performance Electronic Ballasts

2 F32T8

Watts BF Watts BF Watts BF Watts BF Watts BFlow 50 0.77 48 0.78 48 0.77 48 0.78 47 0.77

lpwnormal 58 0.88 55 0.88 54 0.87 55 0.88 54 0.87

lpwhigh 77 1.16 73 1.18 74 1.15 74 1.20 NA -

lpw 89 95 92 96

97

89 94 95 94 95

90 96 95 96

ULTim8Standard ballasts

UltraMax/StartOptanium QHE / QTP

Electronic Fluorescent ballasts

1 & 2 lamp High Ballast Factor Electronic Ballasts deliver 36%36%more light than standard T8 systems. 2 - 32W lamps with 1.18BF ballast provide the samesame light output as a 3-lamp standard T8 system 2 - 32W lamps with 0.77BF ballast provide the samesame light output as a 2- 40W lamps, T12 system

Features:

1 & 2 lamp ballasts now available

low harmonic distortion (<10% THD).

5 year warranty

Electronic HID Ballasts

• 20 Watt to 200 Watt Metal Halide and HPS

• Multiple voltages –120 to 277V

• Constant colour• Improved regulation

Smaller, lighter ballasts lead to smaller, lighter luminaires– Smaller (less expensive?) enclosures– Less prone to vibration effects

(particularly for exterior)

2.5 lbs7 lbs

400W MH Lumen Maintenance400W MH Lumen Maintenance

Improved LLD = More Light = Fewer Luminaires

10,00015,00020,00025,00030,00035,00040,00045,000

4K 8K 12K 16K 20K100HOURS

LIG

HT

OU

TPU

T (lu

men

s)

Standard MH

Pulse Start MH

Affect of ElectronicBallast

HID Electronic ballasts

- 462 watts

- 400 watts

- 375 watts

HID Electronic Ballasts Lamp Life -improving

Changes to LEDChanges to LED’’ssMore products

more sizes and shapes

lower prices

higher efficiencies

better “white” LED’s

Light Emitting Diodes

•Solid State Light Source•Extremely Flexible•Potentially Long Lamp Life•Dynamic Color Opportunities•Poor White Color Rendering

Courtesy: Color Kinetics, Lumileds, Nichia

0

25

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1970 1980 1990 2000 2010 2020

Accelerated R&D for White Light SSL

Metal Halide Pulse start

T-8 lampT-12 ES

MonoOLED

T-12 fluorescent

MonoLED

White Light SSLLaboratory

Effi

cacy

(lum

ens

per w

att)

White Light SSLCommercial

SSL Laboratory and Commercial Curves, revised May 2006Year

Conventional Lighting Technologies Potential Growth

for Conventional Light Sources

http://www.netl.doe.gov/ssl/publications.htmlhttp://www.netl.doe.gov/ssl/publications.html

Energy Efficiency of White LEDsEnergy Efficiency of White LEDs

What do White LEDs cost?What do White LEDs cost?White LEDWhite LED’’s cost significantly more than traditional light sourcess cost significantly more than traditional light sources

Light Source Cost per 1000 Lumens

White LED $50.00

Incandescent $ 1.00

CFL $ 5.00

http://www.netl.doe.gov/ssl/publications.htmlhttp://www.netl.doe.gov/ssl/publications.html

Can LEDs finally replace conventional lamps?

IntelliWhite™ iW MR is • LED to retrofit standard

MR16 lamps• compatible with most

dimmers and transformers designed for use with incandescent 12 volt lighting systems

• 3000K, 3500K & 6500K

Color Kinetics• eW™ MR is a compact

lamp designed to retrofit into most standard MR16 fixtures and sockets. It is well suited for use with tracks, rails, cables, and pendants in interior architectural, retail, exhibit, and display applications.

• 2700K and 4200K and two beam angles: 10°and 25°.

• 7.3 to 13.8 lm/W• Not for use on Electric

Transformers

LumeLEX Series• Output of 1000 lumens,

equivalent to 75 watt • Dimming from 100% to

10% without color shift• 50,000 hour life• 35 watts total power • No UV or IR in beam• 28.5 lm/w

Application Efficiency

• Inherent directionality of the LED light source

• Lower fixture losses compared to bulb-shaped lamps

• More delivered illuminance for lower total lumens and lower energy consumption

Half of the light is lost in the fixture

LRC

PNNL

LED Roadway Light

Beta – The EDGE

Hankey Asia Ltd.

More Outdoor LED Luminaires

Municipal Garage Project• Commercially available LED lighting• 1:1 Retrofit of one floor of a parking structure• Delivering >40% total power savings

• Plus: Where would you rather walk at night?

LED Lights supplied by Lighting Science Group

www.ledcity.org

LED excels for low light applications

• especially where you can use colour

LED excels for specialty applications

Selection of promising near-term commercial applications

(there are many others)

• Linear by Lucere Lighting– 18 watts– Available through sales reps

Winner – Undercabinet

• Halley by Lucesco– 19 watts; dimmable

Winner – Portable desk/task

Downlights

Permlight Prescolite Progress Lighting

New on the marketLED Lighting Fixtures, Inc. (LLF)

Refrigerated Case Lights

Lumination (GELcore)

Nualight

Low Bay

Lighting Sciences

Before

After

City of Raleigh Municipal Parking Deck – Part of LED City Project

42 Watt LED replaces 175 Watt MH

42 Watt replaces 150 Watt HPS

LED Lighting

Outdoor Area/StreetlightingToronto Demonstration

Leotek Electronics

What changes are coming?

• Higher current and temperature tolerances• Better color quality and metrics• Better luminaire design• New standards

• Dynamic Lighting Controls• New Technologies for more Efficient

Lighting• Future Vision

Roadmap to Energy Efficiency- what are our options!

UBC Solar Canopy Project

Inside Solar Canopy Project

Solar Canopy

The CeeLite 7500 and 11000 Kelvin panels are the first flat flexible lightbulb to contain Light-Emitting Capacitor technology. Flatline inverters maintain 99% uniform backlighting and make it possible to offer motion and/or photo sensors with external sensing jacks, while providing dimming, fading and flashing standard features.

White Light High Flux LED SourcesWhite Light High Flux LED Sources

iLED Surgery LightingThe different coloured LEDs: • provide homogeneous

spectral light distribution• adjust the colour temperature

individually for optimal contrast and differentiation.

• reducing fatigue during night operations (a higher colour temperature improves the ability to concentrate

Trumpf

iLED Surgery Lighting

The different coloured LEDs:

• provide virtually shadow free illumination up to 160,000 lx

• over 180 light fields at different depths

• multifaceted LED lights can darken certain areas of the visual field while focusing illumination on others Trumpf

Skyport is a light collecting panel that sits on your rooftop to transmit light into your home. It uses a fibre-optic wire

to send the light to specially designed 'lamps'.

The light can be transported up to 15 meters. With a 7 meter cable, the light intensity can reach 4000 lux, and

with two Skyports mounted on an angle will bring in both morning and afternoon sun

Courtesy Gomez Paz

Natural Light Collector and Fibre Optic Diffuser

Courtesy Parans

Photonic LED Textiles TurnFabric into Intelligent

Displays

by integrating flexible arrays ofmulticolored LEDs into fabrics,lighting technologies willrevolutionize the very conceptof fabric and will open up awide range of applications inthe fields of • ambient lighting,• communication, and • personal health

Courtesy Philips

That’s What’s New in Lighting

!

Roy Hughes, PEng, LC&

WarehouseASHRAE 90.1 2004 space type models

Model

Building Type % Area FCWarehouse Task 30 30

General 70 30Space Type description Wtd Avg FC 100 30

Fine Material 30

LPD =1.4

42

Model

Building Type % Area FCWarehouse Task 30 30

General 70 15Space Type description Wtd Avg FC 100 19.5

Medium/Bulky Material 19.5

LPD =0.9

43

Alternative Low & High Bay Luminaires

Courtesy: 1st Source, Sportlight, Lightedge, Metalux, Day-Brite

• Induction Fluorescent

• Compact Fluorescent

• T5HO Fluorescent• T8 or T5HO

Fluorescent• Compact

Fluorescent

Lamp Efficacy

4.2 4.56.0

4.64.3

4.7

26.2

23.322.5

10.8

0

20

40

60

80

100

120

F32

T8/7

41

F32

T8/8

41

T8 (

HP

)

F28

T5/8

41

F54

T5/H

O/8

41

MV

(4

00

W)

MH

40

0U

MS

32

0/P

S

MS

35

0/P

S

HP

S (

40

0 W

)

Mea

n L

PW

Design guide for Warehouse – 400w Metal Halide