Energy Efficient Industrial Lighting

Roy Hughes, PEng, LC

Energy Efficient Industrial Lighting

Energy Efficient Lighting Design

Dynamic Lighting Controls
New Technologies Efficient Lighting
Future Vision

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

Dynamic/Controlled Lighting
Manual zoned/ dimmed
Automatic - Occupancy
Infrared/ Ultrasonic/ Dual
sensors
Time clocks
Timers

Automatic - Light Levels

Photo cells (measured)
Load reactive (peak)
Time clock (predicted)

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 UIs determine the user experience
Distributed control of lighting From personal space to
enterprise control

Key value drivers of a

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

Reduced cost and complexity of system installation

Simplicity of Commissioning

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

Self Powered switches and sensors

Harvesting 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.

Motion

Vibration

Solar

Temperature

Differential

Switches & Sensors are Wireless

Wireless
Humidity

Wireless Light
Detection

Wireless Motion
Detection

Room Controller
Wireless Switch
Wireless Thermostat

Lights on/off - Dim up/down

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.

Adaptive Lighting

T
M

Prince 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.

Prince George Pilot Project

Energy Savings
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.
Annual Savings this Project
(170 Luminaries)
47,000 kWh ($3100)
Payback = 7 Years (worst case)
(Assuming $0.066 per kWh)

Dynamic Lighting Opportunities

No wired switches
Inspection tasks

Industry

Control/ call
Centers

Whats New in Lighting

Energy Efficient Lighting

Dynamic Lighting Controls
New Technologies - Efficient Lighting
Future Vision

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

T5

% of Initial Lumens

100
95

T8 (265 mA)

90

Incandescnt

85
T12 (430
mA)
HPS

80
75

20

40

60

80

Percent of Average Rated Life

100

Mercury
Vapor

Improvements to incandescent
Lamp Filament
Design
Including HIR
technology

Reflector Design
Shape and coatings

Bulb Coatings
Improved colour

Gas Fill
Krypton gas

Improvements in Incandescent
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

Halogen to LED replacements

4.8 Watts
150 Lumens
20W equivalent (120V)
Warm or cool white

11W R30 LED

500 Lumens
60W equivalent (120V)
Warm or cool white

4.5 W
150 Lumens
20W equivalent (12V - 24V)
Warm or cool white

Improvements to HID Lamps

Pulse Start Technology - matures
Ceramic Metal Halide more products
from 20 to 400 Watts
Colour control rivaling fluorescent
Various shapes - single ended to PAR

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

Relative Mean Light Output Relative Wattage
140%
120%
100%
80%
60%
40%

320W
POWERBALL
The Best of the Best

20%
0%

320W
POWERBALL

M400/U

MP400/PS BUONLY

MS400/PS BUONLY

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 10, 25, & 40
Easy upgrade and instant
retrofit for halogen PAR38

New generation Ceramic MH

White Light - less colour shift

Extreme high efficiency Universal burning position
Compact size 50% smaller
Improved efficacy 103 L/W
CRI - 66%
2730K CCT

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

150W HPS Type

CWA

Input

154 Watts

195 Watts

Losses

10%

30%

Dimmable

Yes

Limited

A New Age in
Urban Outdoor
Lighting.

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

E-Ballast

Lamps

Optics+Luminaires

System
Development

CosmoWhite

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 T8 / 80

70 lpw
92 lpw
62 CRI
85 CRI
flicker with magnetic
ballast
20,000 hr rated life
LLD: 60 to 70%

Imperceptible lamp
flicker with electronic
ballast
20,000 hr rated life
LLD: 80 to 90%
Better optical package

T-12
T-8

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
T-5

Do we have enough T8 lamps?

- 97 choices!
2700
F32T8/25/8xx
F32T8/28/8xx
F32T8/30/8xx
F32T8/30/8xx/long life
F32T8/7xx
F32T8/7xx/long life
F32T8/8xx
F32T8/8xx/long life
F32T8/8xx/extra long life
F32T8/8xx/HP
F32T8/9xx

3000
2
3
3
1
3
2
3
3
1
3

3500
2
3
3
1
3
2
3
3
1
3

4100
2
3
3
1
3
2
3
3
1
3

5000
2
2
2
1
2
1
3
3
2
1

6500

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

High Efficient Fluorescent

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

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

Lamp Lumen Depreciation

Metal Halide Pulse Start Vs T5HO Fluorescent
45,000
40,000

Lumens

35,000
30,000
25,000
20,000
15,000
10,000
5,000
0
0

2,000

4,000

6,000

8,000

10,000 12,000 14,000 16,000 18,000 20,000

Hours

Standard
400W
Pulse Start
Metal
Halide
Venture
320W
Pulse Start
Metal
Halide
T5 HO 3
Lamps per
Luminaire

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
CFLs 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 CFLs

Alternative
Low & High
Bay
Luminaires
Induction
Fluorescent

T8 or T5HO
Fluorescen
t
Compact
Fluorescent
Courtesy: 1st Source, Sportlight, Lightedge, Metalux, Day-Brite

High Wattage CFL

Courtesy: Sportlight

High

CRI
Instant start
Step Switched CFL
Low Bay luminaires
(8) 10,000 hr lamps
Hill Air Force Base

Plentiful

High Wattage CFL

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

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 - 40C
70% lumen maintenance at
60,000 hours
ICETRON

High

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

Induction Lamps
Courtesy: 1st Source,

 Principles of Energy Efficient Lighting

Design
Dynamic Lighting Design
Using Newer Technology for Efficient
Lighting
Case Studies in the Industrial Sector
Whats 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

2x4 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
HPS
Gym- -Before
After T5HO

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

Classroom - After T8 but lowered brighter- more uniform

Improvements to Ballast Technology

The Future is Electronic....Why?

Compact size
Performance:
Constant wattage
Energy efficiency & Economics
Controllability

High-Performance Electronic Ballasts

2 F32T8
Standard
ballasts
Optanium
Watts BF Watts BF
low
50
0.77
48
0.78
lpw
90
96
normal
58
0.88
55
0.88
lpw
89
94
high
77
1.16
73
1.18
lpw
89
95

Ultra
Max/Start
Watts BF
48
0.77
95
54
0.87
95
74
1.15
92

QHE / QTP
Watts BF
48
0.78
96
55
0.88
94
74
1.20
96

ULTim8
Watts BF
47
0.77
97
54
0.87
95
NA
-

Electronic Fluorescent ballasts

1 & 2 lamp High Ballast Factor
Electronic Ballasts deliver 36%
more light than standard T8
systems.

Features:
1 & 2 lamp ballasts now available
low harmonic distortion (<10% THD).
5 year warranty

2 - 32W lamps with 1.18BF ballast

provide the same light output as a
3-lamp standard T8 system
2 - 32W lamps with 0.77BF ballast
provide the same light output as a
2- 40W lamps, T12 system

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)

7 lbs

2.5 lbs

LIGHT OUTPUT (lumens)

400W MH Lumen Maintenance

45,000
40,000

Affect of Electronic
Ballast

35,000
30,000

Pulse Start MH

25,000
20,000
15,000
10,000
100

Standard MH
4K

8K 12K
HOURS

16K

20K

Improved LLD = More Light = Fewer Luminaires

HID Electronic ballasts

- 375 watts

- 400 watts

- 462 watts

HID Electronic Ballasts Lamp Life improving

Changes to LEDs

More products

more sizes and shapes

lower prices
higher efficiencies
better white LEDs

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

Accelerated R&D for White Light SSL

Efficacy (lumens per watt)

200
175

White Light SSL

Laboratory

150
White Light SSL
Commercial

125

Conventional Lighting
Technologies

100
T-12 ES

Potential Growth
for Conventional
Light Sources

Metal Halide
Pulse start

T-8 lamp

75
T-12 fluorescent

50

Mono
LED

25
0
1970

Mono
OLED

1980

1990

2000

2010

Year
SSL Laboratory and Commercial Curves, revised May 2006

2020

Energy Efficiency of White LEDs

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

What do White LEDs cost?

White LEDs 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.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 bulbshaped lamps
More delivered
illuminance for lower
total lumens and lower
energy consumption

Half of the light is lost in the fixture

PNNL

LRC

LED Roadway Light

Beta The EDGE

Hankey Asia Ltd.

More Outdoor LED Luminaires

Municipal Garage Project

www.ledcity.org

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

LED excels for low light applications

especially
where you
can use
colour

LED excels for specialty applications

Selection of promising nearterm commercial applications

(there are many others)

Winner Undercabinet

Linear by Lucere Lighting

18 watts
Available through sales reps

Winner Portable
desk/task

Halley by Lucesco
19 watts; dimmable

Downlights

Permlight

Prescolite

Progress Lighting

New on the market

LED Lighting Fixtures, Inc. (LLF)

Refrigerated Case Lights

Nualight

Lumination (GELcore)

Low Bay

City of Raleigh Municipal Parking

Deck Part of LED City Project

Before

Lighting Sciences
After

42 Watt LED replaces 175 Watt MH

42 Watt replaces 150 Watt HPS

LED Lighting

Outdoor Area/Streetlighting
Toronto Demonstration

Leotek Electronics

What changes are coming?

Higher current and temperature tolerances

Better color quality and metrics
Better luminaire design
New standards

Roadmap to Energy Efficiency

- what are our options!

Dynamic Lighting Controls

New Technologies for more Efficient
Lighting
Future Vision

UBC Solar Canopy Project

Inside Solar Canopy Project

Solar Canopy

White Light High Flux LED Sources

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.

iLED Surgery Lighting

The 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

Natural Light Collector and Fibre Optic Diffuser

Courtesy Parans

Skyport is a light collecting panel that sits on your rooftop

Gomez Paz
to transmit light Courtesy
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

Photonic LED Textiles Turn

Fabric into Intelligent
Displays
by integrating flexible arrays of
multicolored LEDs into fabrics,
lighting technologies will
revolutionize the very concept
of fabric and will open up a
wide range of applications in
the fields of
ambient lighting,
communication, and
personal health

Courtesy Philips

Thats Whats
New in Lighting
!

Roy Hughes, PEng, LC

&

Warehouse
ASHRAE 90.1 2004 space type models
Model
Building Type
Warehouse
Space Type description
Fine Material

42

Task
General
Wtd Avg FC

% Area
30
70
100

FC
30
30
30
30

% Area
30
70
100

FC
30
15
19.5
19.5

LPD =
1.4

Model
Building Type
Warehouse
Space Type description
Medium/Bulky Material

43

Task
General
Wtd Avg FC

LPD =
0.9

Alternative Low & High Bay Luminaires

Compact Fluorescent

Induction Fluorescent

Compact
Fluorescent

T8 or T5HO
Fluorescent

T5HO
Fluorescent

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

100

HPS (400 W)

4.3

MS350/PS

MS320/PS

60

MH400U

40

MV (400 W)

4.6

F54T5/HO/841

6.0

F28T5/841

4.5

T8 (HP)

4.2

F32T8/841

80

F32T8/741

Mean LPW

Lamp Efficacy

120

10.8

23.3
22.5

26.2

4.7

20

Design guide for Warehouse 400w Metal Halide