Industrial Materials Preparation Area to Increase Light levels

Reducing Energy Consumption and Increasing Light levels by Implementing Induction Lighting, Induction Lamps, Induction Lighs  

The pre-production area of a composites manufacturer using Mercury Vapour Highbay lighting was upgraded to Induction Lighting Highbay and security lighting was also upgraded. Average lighting levels were increased by about 98% while electrical power consumption was reduced by about 22%.
Initial Measurements:
Lighting Renovation Design Objectives:
Lighting Renovations:
Final Measurements:
Comparison of Electrical Power Consumption:

     The pre-production area of a composites manufacturer using Mercury Vapour Highbay lighting was upgraded to Induction Lighting Highbay and security lighting was also upgraded.  Average lighting levels were increased by about 98% while electrical power consumption was reduced by about 22%.

    A composite materials and structures fabrication company was located in an older industrial warehouse, with high ceilings.  The pre-production area, where materials are measured and cut, was poorly lit by mercury vapour Highbay fixtures.  Staff had great difficulty seeing measurements and cut-line marks, particularly on the black carbon-fibre material.  The company specializes in high quality, close tolerance, composite structures made from fibreglass or carbon fibre materials. These structures include large and complex flight simulator shells, and wind turbine blades with complex topology all of which must be made with very high precision.

    The composites company’s manufacturing facilities occupy a total space of 2,972 square meters (32,000 square feet). Only the lighting in the pre-production area, where materials to be assembled and laminated are measured and cut to size, was renovated.
    The pre-production area has white painted cinder brick walls and a white painted ceiling with unpainted steel beams covered in a reddish primer coat. The height of the space from the floor to the bottom of the steel beamtrusses is 5.5 meters (18 feet).
    The area was lit by eight, poorly placed, 400 watt, Mercury Vapour highbay lighting fixtures (see initial measurements diagram). In addition to the highbays, there were two surface mount, 250 Watt, incandescent security lights attached to the steel ceiling and connected to the power supply by means of plugs and sockets. These lights were on a breaker and were operated 24/7.
    There are also four large glass skylights located in the ceiling over part of the pre-production area (see diagram below) which allows some natural lighting into the pre-production area.

The pre-production area where materials to be laminated are cut and measured (work tables and benches have been removed to facilitate a lift to reach the lights). Five of the Highbay lights that were replaced can be seen in this photo. Note the greenish cast to the lighting which is characteristic of Mercury vapour lighting - 

Initial Measurements:
   The initial average lighting level was determined by taking measurements using a “Cooke Cal-Light 400 calibrated precision light-meter”. Due to the skylights, all light measurements were performed after dark so that light from the skylights would not affect the illumination measurements.
   Light levels were measured, at floor level, in six locations spaced evenly between the existing Mercury Vapour highbay fixtures (see diagram below). The measurement locations were marked with tape on the floor so they could be used again for the “after” measurements.
  The initial light readings of 157, 140.1, 124, 118, 135.5 and 107.7 Lux were added and then divided by 6 to givean average light measurement of 130.3 Lux (see diagram).

Light level measurements in the pre-production area before the installation of Induction Lamps [blue numbers] in Lux (Lx) - 

Lighting Renovation Design Objectives:

    The primary objective was to raise the lighting levels in the area significantly, while improving colour rendering.  Colour rendering was especially important as the carbon fibre material used in some of the fabrication is black and thus details of measurement marks needed for cutting were difficult to see under the existing mercury vapour lighting.
    Reduction of electrical power consumption in the pre-production area was a secondary objective.

Lighting Renovations:
    The lighting renovations were performed over a weekend, with initial light measurements made on Friday night, electrical work performed on Saturday and Sunday during the day, and final light measurements made Sunday night after dark. This schedule, while more costly for electrical contracting work, was chosen so as minimally disrupt the company's production schedule.
    All eight of the existing MV highbay fixtures, installed as 2 rows of 4 fixtures located approximately 5.5 meters (18 feet) above the floor, were removed and recycled.  It was determined that the new strategies magnetic Induction lamp  Highbay fixtures would be installed such that the bottoms of the fixtures would not protrude below the steel beams. Thus preserved the the height in the manufacturing facility, while eliminating some shadows cast by the steel beams due to poor placement of the original mercury vapour highbay lighting fixtures (some were located slightly above the steel beams).
    Fifteen, 200W, 4,100K, magnetic induction lamp indoor highbay fixtures with open bottoms (no lens/diffuser)were to be installed in the same area in an evenly spaced five by three grid array.
    The two existing 250 watt incandescent bulbs (safety/security lighting) were removed and the electrical contractor then rearranged the locations of the surface mounted outlets, and installed an additional outlet such that the three outlets were relatively evenly spaced across the length of the area. Three, 40 watt, 4,100K induction lamp fixtures were installed adjacent to the sockets as replacement safety/security lights. Note that the security lights were placed non-symmetrically (see diagram) so that they would provide some light spill into the materials storage, and factory floor areas, located at either end of the pre-production area.

Final Measurements:
     Detailed light level measurements were taken after the new strategies induction light fixtures were installed - again at night so as to eliminate the effects of daylight from the skylights.  The measurements were taken at the same locations on the floor of the manufacturing area (previously marked with tape) as used before, with the sameCooke Cal-Light meter, and were again taken in Lux (Lx).
    The readings of 236, 268, 248, 282, 234 and 277 Lux were then added and divided by six to give an averagelight level reading of 257.5 Lux in the space (see diagram below).
    The Initial average measurement of 130.3 Lux was multiplied by the S/P Ratio of 0.80 for the mercury vapour lamps yielding an adjusted average light level of 104.2 VEL (Visually Effective Lux ) for the original lighting.
    The average of 257.7 Lux under the 4,100K induction lamps, was multiplied by an S/P Ratio of 1.62 to yield a reading of 417.4 VEL for the upgraded lighting.  Naturally, staff work on tables and benches, which are above the floor, thus they will experience even higher light levels on the working surfaces.
    This renovation of the pre-production area lighting represents an increase in average lighting levels of about 98% in meter Lux or about 300% in VEL (Visually Effective Lux/Lumens).
Light level measurements in the pre-production area after the installation of Magnetic Induction Lamps [blue numbers] in Lux (Lx) - CLICK IMAGE TO SEE LARGER VERSION

Comparison of Electrical Power Consumption:

    The initial lighting consisted of eight 400 watt mercury vapour Highbay fixtures, plus 50 watts each for “core & coil” ballast overhead, for a load of 450 watts per Highbay fixture; thus a total Highbay load 3,600 watts (3.6 kWh). In addition, there were two 250W incandescent security light fixtures adding 500 watts, for a grand total electrical load in the production area of 4,100 watts (4.1 kWh).
    The renovated induction lighting system consists of  fifteen 200 watt induction lamp Highbay fixtures with a Cos-Phi of .98, therefore each fixture consumes only 202 watts of power for a total of 3,060 watts for the highbays(3.06 kWh). The old incandescent security lights were replaced with three 40 watt induction fixtures with a ballast overhead of 2 watts each or 42 watts per fixture - total for the security lights 126 watts (.126 kWh). The grand total of the renovated induction lighting installation is 3,186 watts (3.19 kWh) - a savings of 914 watts (0.914 kWh).
    Based on local electrical energy costs of $0.12 per kWh, with an average usage of 50 hours per week and 50 weeks per year, the estimated energy cost savings is only $274.20 per year.
    However, the design objectives were met, with a dramatic increase in lighting levels, which is expected to save much more money than the power consumption reduction, by reducing material cutting and measurement errors as well as increasing employee productivity and reducing eye strain and absenteeism (see photo below).
The composites pre-production area where materials are cut and measured shown after installation of the magnetic induction lamps. Nine of the induction lamp indoor Highbay light fixtures can be seen in this photo - CLICK IMAGE TO SEE LARGER VERSION
    The original Mercury Vapour Highbay lights and the incandescent security lights, which consumed a total of 4,100 watts (including ballast overhead), were replaced with a mix of magnetic induction lamp 40 watt fixtures and200 watt induction lamp Highbay fixtures.
    The average lighting levels in the pre-production area were increased from 130.3 Lux to 257.5 Lux – an increase of about 98%.  When corrected for S/P Ratio, the increase was from 104.2 VEL to 417.4 VEL.  In addition, the company will realise additional dollar savings through a reduction in operational and maintenance costs provided by the induction lamps.
  • Electrical load was reduced from 4,100W to 3,168W - about a 22% energy savings!
  • Average light levels were improved from 130.3 to 257.5 Lux - an increase of about 98% brighter!
  • When corrected for S/P Ratio, the new strategies lighting produced 417.4 VEL - about a 300% increase in VEL!
    Most importantly, this facility has created a more productive work environment for their entire staff where errors in measurements, material cutting, and re-works will be significantly reduced due to the increased light levels.

Industrial Materials Preparation Area to Increase Light levels
Industrial Materials Preparation Area to Increase Light levels

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