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For professionals wondering how to save energy in factories, retrofit LED solutions will deliver and perform better than legacy solutions. But choosing the best, well considered options and specifications depends on your exact scenario.
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LIGHTING BSEE LED lighting for factories – a facilities managers’ guide
ccording to The Carbon Trust, lighting typically consumes a fifth of the electricity used in commercial and
industrial buildings. In these times of high energy prices, finding cost-effective ways to reduce levels of electricity consumed by lighting can deliver appreciable long term reductions on business electricity bills.
But there is more to delivering sustainable solutions than picking the first LED that springs to mind.
Metal halide and industrial lighting
One Energys client, Parker Hannifin, has set a corporate objective of an annual 5% energy reduction. EHSE & Facilities Manager Tony Woodward realised that one of the best ways to achieve this goal would be to phase out old metal halide lamps in favour of next-generation LEDs.
An estimated energy saving of at least £36,423 per annum helped convince Mr Woodward’s superiors that LED replacements were the way to go. But the story wasn't that simple. “The fact is, I had looked at metal halide replacements in the past, but had not been able to find anything good enough,” he recalls. “But then I came across the Energys lamps, which offer the right colour temperature – an absolutely crucial
CASE STUDY
A Schneider Electric metering and monitoring project at the University of Oxford is helping the campus to reduce its carbon footprint and meet its sustainability targets. The partnership between Schneider Electric and the University goes back 20 years and has involved the installation of main meters and sub meters in all of its buildings.
Helping Oxford University understand energy consumption T
he University of Oxford is home to more than 22,000 students, with infrastructure over 600,000sq m, and 220 departments across more than 300 buildings.
The University has adopted an Environmental Sustainability Policy to enhance the positive environmental impact of current and future operations. It also has a Carbon Management Strategy, committing to reducing its carbon footprint by 33 per cent by 2020.
A key way in which it plans to reach its sustainability targets is by encouraging energy efficient practices and investing in its estate to reduce carbon emissions. Schneider Electric has been involved in a project for the past 20 years to install main meters and sub meters in all of the University’s buildings. There has also been a movement to upgrade from analogue to new digital meters, to futureproof the system.
The project extends to new buildings and retrofits in older University properties. These meters collect all electrical data from the various buildings – including laboratories, libraries and office blocks – and provide accurate time-stamped information about how the systems are working. The Energy Management and Environmental Sustainability teams use this data for system operation and tracking energy use.
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The University’s meters and sub- meters are a combination of ION7650, ION7550, ION7550RTUs and ION6200 meters. There are over 1,000 meters, of which more than 200 are main meters. These meters are designed for key distribution points and sensitive loads, and offer advanced power quality analysis coupled with billing accuracy. They improve power reliability across the University’s network by tracking real- time power quality, monitoring equipment status, trending loads, and logging events and alarms. Once a full and upgraded system was implemented it became easier for the Energy Management team to ensure that each department was being billed correctly for energy use. The upgraded metering system also allowed for automated billing. Schneider Electric’s Power Monitoring Expert (PME) software is used to collect and organise meter data. Prior to the implementation of PME, the meters had to be manually read in every building five times a year, taking two days each time – so the time savings are considerable. Information from the PME is used by Building and Facilities Managers to help make savings and increase energy efficiency. This has helped to reduce energy costs and increase power reliability/availability. David Baker, Electrical Engineer in the University’s Estates Services department, comments: “The
requirement and one lacking from previous products I’d seen. “An added benefit is that they also have in-built fans to keep them cool. A test involving eight products further underlined my opinion of their excellent light quality.”
Consistency of light quality was a particular preoccupation for Mr Woodward, who was keen to ensure the required illumination throughout the manufacturing shopfloor. The fixtures’ contribution to reducing radiant heat was another significant benefit; particularly given the firm's aim of enhancing its healthy working environments by minimising staff fatigue.
The details prove an important point; LEDs are good, but you still need to do your homework. Picking a reputable supplier, like Energys, will deliver bespoke solutions that fit your precise needs.
Additional benefits of LED versus sodium SONs
Every factory is different, so every facilities manager must seek the right LED technology to suit the legacy replacements needed.
In the example of facilities using sodium SONs, Energys LEDs ranging from 20W to 100W will effectively replace SONs ranging from 70W up to 400W. Because of the high efficacy and directional nature of these LED lamps, together with the sharp white light and high colour
uEvery factory is different, so every facilities manager must seek the right LED technology.
rendering index, it is possible to reduce the power consumption of light fittings by between 50% and 75% with no discernible reduction in effective light levels.
In this example, the new LED lamps would have a life expectancy of over 50,000 hours, and can maintain lumen levels at over 90% for the full warranty period of five years in normal use; 10 hours/day. Energys MD Kevin Cox comments: “Upgrading SON or metal halide lighting to energy efficient alternatives demands understanding of those technologies, and how to achieve the best retrofit improvements.
“Our message to facilities managers is, if you don't hear detail and precision from your supplier, question their expertise and the benefits they can offer.”
The truth is simple; when it comes to retrofitting light in factories, only the best will do. Expertise, attention to detail and high performance products are your watchword. Ask for evidence on benefits. Don't take the first LED solution you're offered at face value. Challenge your supplier's wisdom; let them prove their credentials.
www.energysgroup.com
upgraded metering and monitoring system provided by Schneider Electric, has given us more information on the University’s energy use than ever before, allowing us to make more informed decisions and save costs across the board. The University has over 300 buildings, so having all of the important information at our fingertips means we know what’s going on anywhere, at any given time. I consider the system to be my ‘fifth engineer’.” The aim of the metering system was to help improve operational efficiency and encourage further energy efficiency. The original
metering system was 10-15 years old and was initially built on a single building basis. One of its key benefits is disturbance monitoring, so that potential problems can be spotted early and fixed before they cause any issues.
Poonam Walid, Category Marketing Manager, EcoBuildings at Schneider Electric, said: “Regular upgrades to the metering network at the University mean that the team there has all the information necessary to be able to draw actionable insights and make decisions to keep reducing energy costs.”
http://www.schneider-electric.co.uk/en/ BUILDING SERVICES & ENVIRONMENTAL ENGINEER DECEMBER 2016 27
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