Upgrading T8 Fluorescent Lighting in Factory Production Environments. An Economic Comparison of T5 Fluorescent and LED Lighting Options

Transcription

1 Upgrading T8 Fluorescent Lighting in Factory Production Environments An Economic Comparison of T5 Fluorescent and LED Lighting Options In compliance with SLL & CIBSE Guidelines Powered by

2 Introduction The following test report has been compiled in compliance with the lighting industry s code of practice for minimum illumination levels in factory production environments (500 Lux). Through Relux lighting design software, illuminance simulation has been used to provide detailed light output comparisons between LED and Fluorescent lighting using manufacturers Lumen Data Files. The output data is then transposed into calculating energy savings, payback periods and real cost of ownership comparing both technologies. This report can be used as a useful tool for assisting Engineering Managers, Technical Managers and Financial Directors when considering a new lighting installation. The simulation in this report is based upon a typical factory production room as follows: Dimensions: 25m x 30m Height: 2.8m Design: White Ceiling & Walls Material Reflectance: Ceiling = 70% ǀ Walls = 50% ǀ Floor = 20% Average Light Level: 500 Lux Below is a guide to Lux Levels for various environments Illuminance (Lux) Activity Area 150 Some perception of detail Loading bays, switch rooms, plant rooms Continuously occupied with little perception of detail. Continuously occupied areas with perception of detail. Visual tasks with perception of detail Difficult visual tasks with higher level perception of detail. Very difficult visual tasks with high level perception of detail Extremely difficult visual tasks with extreme level of perception detail. Foyers & entrance halls Storage, warehousing, canteens & kitchens Factory production, kitchens, laboratories Quality control, visual inspection, grading Precise assembly Fine work inspection, precision assembly The Society of Light & Lighting (SLL), which is part of the Chartered Institution of Building Services Engineers (CIBSE), publishes a useful range of lighting handbooks and guides which provide detailed guidance and recommendations on lighting for a wide range of applications. To find out more about these publications go to Page 2

3 EXISTING INSTALLATION LUMINAIRE DATA 58w T8 Twin IP65 - Leading European Brand IP65 dust and moisture resistant luminaire for 2 x 58W T8 lamp(s) with magnetic circuit. Class I electrical. Canopy: light grey polycarbonate. Diffuser: polycarbonate with internal prisms. Toggles: polycarbonate. For surface or suspended mounting. Quick-fix installation brackets are supplied with each luminaire for surface mounting and optional accessory kits are available to assist with other mounting options. Complete with colour 840 lamp(s). Dimensions: 1600 x 143 x 111 mm Total power: 134 W Weight: 4.64 kg Luminaire data Equipped with Luminaires efficiency : 65.5% (B31) Number of lamps : % 17.8 % Designation : T8 CIE Flux Codes : Power : 58 W Control gear : Colour : System power : 134 W Luminous flux : 5200 lm Length : 1600 mm Width : 143 mm Height : 111 mm Page 3

4 EXISTING INSTALLATION ILLUMINANCE (LUX) LEVELS 58w T8 Twin IP65 - Leading European Brand [m] 25.0 N Fixtures Average Illuminance 511 Lux 25 m [m] 30 m Illuminance [lx] General Calculation algorithm used Average indirect fraction Height of evaluation surface 0.75 m Height of luminaire plane 2.80 m Maintenance factor 0.80 Total luminous flux of all lamps Total power Total power per area ( m²) lm 9648 W W/m² (2.52 W/m²/100lx) Illuminance Average illuminance Eav 511 lux Minimum illuminance Emin 419 lux Maximum illuminance Emax 597 lux Uniformity g1 Emin/Em 1:1.22 (0.82) Uniformity g2 Emin/Emax 1:1.42 (0.7) Page 4

5 NEW LED INSTALLATION LUMINAIRE DATA 35w LED IP65 - Leading European Brand Using Fortimo Gen 2 LEDs Luminaire data Equipped with Luminaires efficiency : 99.9% (A31) 91.9% 8.1% Designation : LED CIE Flux Codes : Power : 35 W Control gear : Colour : System power : 35 W Luminous flux : 3500 lm Length : 1573 mm Width : 101 mm Height : 101 mm Page 5

6 NEW LED INSTALLATION ILLUMINANCE (LUX) LEVELS 35w LED IP65 - Leading European Brand Using Fortimo Gen 2 LEDs [m] 25.0 N Fixtures Average Illuminance 521 Lux 25 m [m] 30 m Illuminance [lx] General Calculation algorithm used Average indirect fraction Height of evaluation surface 0.75 m Height of luminaire plane 2.80 m Maintenance factor 0.80 Total luminous flux of all lamps Total power Total power per area ( m²) lm 4620 W 6.16 W/m² (1.18 W/m²/100lx) Illuminance Average illuminance Minimum illuminance Eav Emin 521 lux 443 lux Maximum illuminance Emax 602 lux Uniformity g1 Emin/Em 1:1.18 (0.85) Uniformity g2 Emin/Emax 1:1.36 (0.74) Luminaire name : 35w LED IP65 - Leading European Brand Using Fortimo Gen 2 Equipment : 1 x LED 0 W / 3500 lm Page 6

7 NEW T5 FLUORESCENT INSTALLATION LUMINAIRE DATA 35w T5 Twin IP65 - Leading European Brand IP65 dust and moisture resistant luminaire for 2 x 35W T16 lamp(s) with electronic - fixed output circuit. Class I electrical. Canopy: light grey polycarbonate. Diffuser: polycarbonate with internal prisms. Toggles: polycarbonate. For surface or suspended mounting. Quick-fix installation brackets are supplied with each luminaire for surface mounting and optional accessory kits are available to assist with other mounting options. Complete with colour 840 lamp(s). Dimensions: 1600 x 143 x 111 mm Total power: 77 W Weight: 2.45 kg Luminaire data Equipped with Luminaires efficiency : 90.3% (B31) Number of lamps : % 19.7% Designation : T16 CIE Flux Codes : Power : 35 W Control gear : Colour : System power : 77 W Luminous flux : 3300 lm Length : 1600 mm Width : 143 mm Height : 111 mm Page 7

8 NEW T5 FLUORESCENT INSTALLATION ILLUMINANCE (LUX) LEVELS 35w T5 Twin IP65 - Leading European Brand [m] 25.0 N 25 m Fixtures Average Illuminance 510 Lux [m] 30 m Illuminance [lx] General Calculation algorithm used Average indirect fraction Height of evaluation surface 0.75 m Height of luminaire plane 2.80 m Maintenance factor 0.80 Total luminous flux of all lamps Total power Total power per area ( m²) lm 6237 W 8.32 W/m² (1.63 W/m²/100lx) Illuminance Average illuminance Eav 510 lux Minimum illuminance Emin 371 lux Maximum illuminance Emax 640 lux Uniformity g1 Emin/Em 1:1.38 (0.73) Uniformity g2 Emin/Emax 1:1.73 (0.58) Page 8

9 Energy Savings & Cost of Ownership Calculation Using 500 Lux for Production Environments Based upon 24 Hour Plant Operation Using 0.08 per kwh Rate Replacing T8 Fluorescent 1. Existing Installation 2. New Installation 3. Typical cost of Equipment 4. Payback Period 5. Mortality Factor 6. Lumen Depreciation over Life 7. Conclusion Page 9

10 1. Existing Installation 72 x T8 58W IP65 Std Non Corrosive Twin Fluorescent Average Illuminance 511 Lux 5ft 58W (72W*) T8 Twin Fluorescent with Magnetic Ballast *Overall Power Consumption = 72W per Lamp due to Losses in Circuit. Power Consumption per Fitting = 2 x 72W = 144W Annual Energy Consumption 8760 hrs x 144W = 1261 kwh x 72 = 90,792 kwh Annual Running Cost: 1261 kwh x 0.08 = per Year Total Annual Running Cost = 7, Page 10

11 2. New Installation 132 x 35W IP65 LED Fortimo Gen2 Leading European Brand Average Illuminance 521 Lux Power Consumption per Fitting 35W (No Losses in Circuit) Annual Energy Consumption 8760 hrs x 35W = 307 kwh x 132 = 40,524 kwh Annual Energy Saving = 50,268 kwh Annual Financial Saving 4, x 35W T5 Twin IP65 HF Fluorescent Leading European Brand Average Illuminance 510 Lux Power Consumption per Fitting 70W (No Losses in Circuit) Annual Energy Consumption 8760 hrs x 70W = 613 kwh per Fitting x 81 = 49,653 kwh Total Annual Energy Saving = 41,139 kwh Annual Financial Saving = 3,291 Page 11

12 3. Typical Cost of Equipment 35W IP65 LED Fortimo Gen2 Leading European Brand per Fitting x 132 = 14, W T5 Twin IP65 HF Fluorescent Leading European Brand per Fitting x 81 = 4, Page 12

13 4. Payback Period 35W IP65 LED Fortimo Gen2 Leading European Brand Equipment Cost Annual Saving Period 14, ,021 = 3.5 years 35W T5 Twin IP65 HF Fluorescent Leading European Brand Equipment Cost Annual Saving Period 4, ,291 = 1.5 years Saving over 5 years 35W IP65 LED Fortimo Gen2 Leading European Brand = 6,032 35W T5 Twin IP65 HF Fluorescent Leading European Brand = 11,518 Bulk lamp 20,000 hours (2.3 years) = 11,218 Page 13

14 5. Mortality Factor T5 Fluorescent Data for the survival factor and lumen maintenance of fluorescent lamps has been widely available by European lamp manufacturers for the last 20 years and is very reliable. The two graphs show lumen maintenance factor and survival rate over lifetime. It can be seen that T5 fluorescent lamps will only reduce by 10% in output over their rated life with a 50% survival factor at 20,000 hours. LED Currently there is no survival rate test data available for LEDs. The technology is still very new to the industry making it difficult to calculate. Therefore the survival factor at the 35,000 hours quoted by the luminaire manufacturer is unknown. Page 14

15 6. Lumen Depreciation over Life 35W IP65 LED Fortimo Gen2 Leading European Brand -30% = 365 Lux 35W T5 Twin IP65 HF Fluorescent Leading European Brand -10% = 459 Lux Over its lifetime, the lumen output of the 35W IP65 LED Fortimo Gen2 will depreciate by 30% compared to the lumen output of the 35W T5 Twin IP65 HF Fluorescent which will depreciate by only 10%. Towards the end of its lifetime, the 35W T5 Twin IP65 HF Fluorescent will be producing a lumen output of 459 lux, approximately 25% more than that of the 35W IP65 LED Fortimo Gen2. Page 15

16 7. Conclusion Although the LED option offers an additional 3,612Kw energy saving per year, economically T5 Fluorescent is the superior option, saving an additional 5,186 over the 5 year period. It can be seen that to achieve the recommended industry guideline of 500 Lux, the LED installation requires 40% additional fixtures when compared to the 35W T5 fluorescent lighting scheme. Consequently this extends the payback period of LED to over twice that of T5 Fluorescent. If the quantity of LED fixtures were reduced to the same level of T5 Fluorescent (81pcs) the average illuminance will fall to 290 Lux. With Lumen depreciation added (-30%) this will fall to just 203 Lux which is well below acceptable industry guidelines. Confusing Lumens per Watt with Illuminance Lumens per Watt is light energy output of a given source measured against energy consumed. The measurement is typically undertaken by the lamp or LED manufacturer in its bare source, providing reference information for luminaire designers. Luminaires incorporating a higher lumens per watt lamp or LED source do not automatically generate higher illuminance levels in a given environment. The level of Illuminance generated from a light source is the result of luminaire design and optical control. An important factor is how the energy light source and quantity is used in the luminaire design to distribute the light. This is referred to as Light Output Ratio (LOR). It is the ratio between input Lumens vs Output Lumens. For example, a luminaire with an LOR of 90 is losing 10% of its input Lumens. Typical examples of Lumens per Watt from different sources T8 Fluorescent T5 Fluorescent LED = 90 lm/w = 94 lm/w = 150 lm/w* *Typical maximum output value. However, when incorporated into IP65 designs with enclosed diffuser covers, LEDs are often under-driven to enable them to operate successfully across an ambient temperature range. The 35W fixture used in the example is rated at 3,500 lumens which equates to 100 lm/w (3500 lm 35W), meaning the LEDs are being under-driven by 33%. Page 16