7 Energy-Efficiency Improvements in Lighting System _ EEP

7 Energy-Efficiency Improvement Opportunities In7 Energy-Efficiency Improvement Opportunities InLighting SystemLighting System

Lighting in industrial facilitiesLighting in industrial facilities

There are a lot of opportunities to optimise lighting system in (almost) any There are a lot of opportunities to optimise lighting system in (almost) any industrialindustrial

facilityfacility. Seven practical energy-efficiency opportunities to reduce energy use. Seven practical energy-efficiency opportunities to reduce energy use

cost-effectively are given below:cost-effectively are given below:

Lighting controlsLighting controls1.

Replace T-12 tubes by T-8 tubesReplace T-12 tubes by T-8 tubes2.

Replace mercury lights with metal halide or high pressure sodium lightsReplace mercury lights with metal halide or high pressure sodium lights3.

Replace metal halide (HID) with high-intensity fluorescent lightsReplace metal halide (HID) with high-intensity fluorescent lights4.

Replace magnetic ballasts with electronic ballastsReplace magnetic ballasts with electronic ballasts5.

Optimization of plant lighting (Lux optimization) in production andOptimization of plant lighting (Lux optimization) in production and

non-production departmentsnon-production departments

6.

Optimum use of natural sunlightOptimum use of natural sunlight7.

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1. Lighting controls1. Lighting controls

Lights can be shut off during non-working hours Lights can be shut off during non-working hours by automatic controlsby automatic controls, such as, such as

occupancy sensors which turn off lights when a space becomes unoccupied. Manualoccupancy sensors which turn off lights when a space becomes unoccupied. Manual

controls can also be used in addition to automatic controls to save additional energy incontrols can also be used in addition to automatic controls to save additional energy in

smaller areas.smaller areas.

The payback period for lighting control systems is The payback period for lighting control systems is generally less than 2 yearsgenerally less than 2 years..

Go back to Optimisation List Go back to Optimisation List

2. Replace T-12 tubes by T-8 tubes2. Replace T-12 tubes by T-8 tubes


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In industry, typically In industry, typically T-12 tubesT-12 tubes have been used. T-12 refers to the diameter in have been used. T-12 refers to the diameter in 1/8 inch1/8 inch

incrementsincrements (T-12 means 12/8 inch or 3.8 cm diameter tubes). The initial output for these (T-12 means 12/8 inch or 3.8 cm diameter tubes). The initial output for these

lights is high, lights is high, but energy consumption is also highbut energy consumption is also high..

They (T-12) also have They (T-12) also have extremely poor efficiencyextremely poor efficiency, lamp life, lumen, lamp life, lumen

depreciation, and color rendering index. Because of this, maintenance anddepreciation, and color rendering index. Because of this, maintenance and

energy costs are high.energy costs are high.

Replacing T-12 lamps with T-8 lamps Replacing T-12 lamps with T-8 lamps approximately doubles the efficacy of theapproximately doubles the efficacy of the

formerformer, thereby , thereby saves electricitysaves electricity..


3. Replace mercury lights with Metal halide or High pressure sodium lights3. Replace mercury lights with Metal halide or High pressure sodium lights

Where color rendition is critical, metal halide lamps can replace mercury or fluorescentWhere color rendition is critical, metal halide lamps can replace mercury or fluorescent

lamps with an energy savings of 50%. Where lamps with an energy savings of 50%. Where color rendition is not criticalcolor rendition is not critical, high, high

pressure sodium lamps offer energy savings of 50 to 60% compared to mercury lamps.pressure sodium lamps offer energy savings of 50 to 60% compared to mercury lamps.


4. Replace metal halide (HID) with High-intensity fluorescent lights4. Replace metal halide (HID) with High-intensity fluorescent lights

Traditional HID lighting can be replaced with Traditional HID lighting can be replaced with high-intensity fluorescent (HIF) lightinghigh-intensity fluorescent (HIF) lighting ..


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These new systemsThese new systems

incorporateincorporate

high-efficiencyhigh-efficiency

fluorescent lamps,fluorescent lamps,

electronic ballasts andelectronic ballasts and

high-efficacy fixtures thathigh-efficacy fixtures that

maximize output to themaximize output to the

work place.work place.

Advantages to the newAdvantages to the new

system are:system are:

They have lower energyThey have lower energy

consumption,consumption,1.

Lower lumen depreciationLower lumen depreciation

over the lifetime of theover the lifetime of the

lamp,lamp,

2.

Better Better dimming optionsdimming options,,3.

Faster start-up,Faster start-up,4.

Better color rendition,Better color rendition,5.

Higher pupil lumens ratings and less glare.Higher pupil lumens ratings and less glare.6.

High-intensity fluorescent systems yield High-intensity fluorescent systems yield 50% electricity savings50% electricity savings over standard over standard

HIDs. Dimming controls that are impractical in the HIDs can also saveHIDs. Dimming controls that are impractical in the HIDs can also save

significant amounts of energy. Retrofitted systems cost about significant amounts of energy. Retrofitted systems cost about $185 per fixture,$185 per fixture,

including installation costsincluding installation costs..

In addition to energy savings and better lighting qualities, high-intensity fluorescents In addition to energy savings and better lighting qualities, high-intensity fluorescents cancan

help to reduce maintenance costshelp to reduce maintenance costs..


5. Replace magnetic ballasts with electronic ballasts5. Replace magnetic ballasts with electronic ballasts

A ballast is a mechanism that regulates A ballast is a mechanism that regulates the amount of electricity required to start athe amount of electricity required to start a

lighting fixturelighting fixture and maintain a steady output of light. and maintain a steady output of light.

Electronic ballasts save Electronic ballasts save 12 25% of electricity use12 25% of electricity use compared to magnetic compared to magnetic

ballast.ballast.


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Go back toGo back to

Optimisation List Optimisation List

6. Optimization of plant6. Optimization of plantlighting (Luxlighting (Luxoptimization)optimization)

In production andIn production and

non-production departmentsnon-production departments

In manyIn many

plants theplants the

lightinglighting

system issystem is

notnot

specificallyspecifically

designeddesigned

for thefor the

process.process.

There areThere are

luxlux

standardsstandards

for eachfor each

type oftype of

textiletextile

process.process.

For instance, the required lux for weaving is For instance, the required lux for weaving is usually higher than that ofusually higher than that of

wet-processingwet-processing. Even within just one production process, the required lux. Even within just one production process, the required lux

varies by the process step.varies by the process step.

For example, in a For example, in a cotton spinning processcotton spinning process, the required lux in the blow room should be, the required lux in the blow room should be

much lower than that of ring frame section. If the lighting provided is higher than themuch lower than that of ring frame section. If the lighting provided is higher than the

standard (required lux) for any part of the production, this results in a waste of electricity.standard (required lux) for any part of the production, this results in a waste of electricity.


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Therefore, the plant engineers should optimize the lighting system Therefore, the plant engineers should optimize the lighting system based on thebased on the

standard lux specific for each process stepstandard lux specific for each process step..


7. Optimum use of natural sunlight7. Optimum use of natural sunlight

Many plants do not use Many plants do not use natural sunlight to an optimum levelnatural sunlight to an optimum level. In addition to optimizing. In addition to optimizing

the size of the windows, transparent sheets can be installed at the roof in order to allowthe size of the windows, transparent sheets can be installed at the roof in order to allow

more sunlight to penetrate into the production area.more sunlight to penetrate into the production area.

This can reduce the need for lighting during the day.This can reduce the need for lighting during the day.


Reference //Reference // Industrial Energy Audit Guidebook: Guidelines for Conducting an Energy Industrial Energy Audit Guidebook: Guidelines for Conducting an Energy

Audit in Industrial Facilities Ali Hasanbeigi, Lynn PriceAudit in Industrial Facilities Ali Hasanbeigi, Lynn Price

Recommended EE articles //Recommended EE articles //


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Share with engineers //Share with engineers //

About Author //About Author //

Edvard CsanyiEdvard Csanyi

EdvardEdvard - - Electrical engineer, programmer and founder of Electrical engineer, programmer and founder of EEPEEP..

Highly specialized for design of LV high power busbar trunkingHighly specialized for design of LV high power busbar trunking

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7 Energy-Efficiency Improvements in Lighting System _ EEP