Greening The Balance Sheet Lehigh Valley Energy And Environmental Conference 2010

Greening the Balance Sheet:
Refitting Industrial Lighting
Lehigh Valley Energy and Environmental Conference 2010
Sept 16th, 2010
Kevin I. Baker and Brian P. Roy

©Sitka Enterprises Inc, 2010

•The Opportunity
•Energy Trends and De-regulation
•The Role of Lighting in Running Buildings
•Lighting Technology Partial S-Curve
•Upgrading to more Sustainable Lighting Solutions
•Return on Investment

OUTLINE


THE OPPORTUNITY
Changing energy sources,
electricity de-regulation, higher © Anne Elizabeth Schlegel 2009

power pricing, federal and state
energy policy, rapid technology
developments, cost and
environmental consciousness
create a ‘perfect storm’ for new
and retrofit lighting solutions


Electricity is ~40% of Energy

U.S. Primary Energy Consumption by Source and Sector, 2007 (Quadrillion 1015 Btu)
Energy Information Administration, Annual Energy Review 2007

Making Electricity is Very Inefficient!


Energy Pricing and De-Regulation


More site electricity is consumed for
lighting than for any other end use.

~40 % of electrical use

Energy Information Administration, 2003 Commercial Buildings Energy Consumption Survey

Types of Lighting
• Standard fluorescent
– Mixture of low pressure mercury vapor and inert gas (such as argon) in tube. Phosphor powder
coating on tube fluoresces excited by UV emitted by mercury vapor when current applied. Current
controlled by a ballast.

• Compact fluorescent
– Same technology as above

• Incandescent
– Nitrogen and or argon filled, ~5-10% of power converted to light

• High intensity discharge (HID)
– Mercury vapor, metal halide, and high pressure sodium lamps

• Halogen
– Halogen gas-filled (iodine or bromine) quartz capsule operated at high temperature

• Light Emitting Diode (LED)
– Semiconductor diode that emits light when electrical current passes through it, solid state device.


Lighting Technology Revolution 2008
2006
2005 High Power
2002 LED
Question: White LED
When are Incandescent
2001
T5 Fluorescents
light bulbs phased out? 1981
LED efficiency>incandescent

1974 CFL efficiency>incandescent
Energy savingT8 Fluorescents
T8 Fluorescents
1962 First CFL
first introduced in US

1959 Energy saving fluorescent
1938
Practical LED’s
1934
First quartz halogen lamp
1879 First Fluorescent Lamp

First HID Mercury Lamp

1) GE Lighting
2) Revolution in Lamps, Raymond Kane, Heinz Sell, NetLibrary, Inc
First Incandescent lamp 3) Wikepedia


Nearly All Floorspace in Commercial Buildings is
Illuminated and Fluorescent Lighting Dominates

Energy Information Administration, 2003 Commercial Buildings Energy Consumption Survey

Increasing energy cost outlook
Energy independence and stimulus legislation
Improved lighting technology performance ©2009 Anne Schlegel
Product proliferation and innovation
Green goes mainstream

WHY NOW?
=> Today Offers the Opportunity to Economically Retrofit Older
Buildings, Improve Lighting and Enhance the People Environment

Process to Economically Retrofit Older Buildings
• Identify facilities with older lighting installations – T12 or T8 fluorescent and halogen or
incandescent spot based

• Carefully audit the facility
– Listen to occupant and review lighting and lighting control design
– Measure light levels vs. recommended and statutory requirements
– Collect operational cost and building use information
– Identify opportunity!

• Model and develop an improved overall lighting strategy
– GOAL: Deliver the highest quality people environment while optimizing operational costs

• Propose a new lighting solution, conducting a trial if appropriate
– Identify key benefits and ROI

• Help Customers secure federal, state and other rebate funding to make improvements
even more affordable.

• Manage effective turnkey installation and commissioning.

• Verify Savings and Benefits
– Sometimes needed to secure rebates

• Manage recycle of old lamps.

Typical Building $$$ Opportunities

• Lighting upgrades
– Upgraded Retrofit or New Technology
– New Controls
• Building management
– Daylight harvesting
– HVAC integration
• Motor replacements
• Utility systems
– Compressed air
• Power factor improvements


Core Retrofit Strategies
• Replace T12 with T8 or even better go to T5
– ~50% of the power consumption for same lumen output
– Longer useful light output (lumen maintenance)
– Reduced phosphor, mercury (< 3 mg) and recycle content
• Replace T8 with T5
– ~13-17% energy saving with same lumen output
– Reduced phosphor, mercury (< 3 mg) and recycle content
– Small lamp uses fewer resources and energy in manufacture
• Retrofit MIH with HO T5 (typical 465 W MIH fixtures retrofit with 234W HO T5)
– ~50% energy savings with similar lumen output
– Long lamp life (20,000 hours) minimizes maintenance cost
– Reduced warm-up time
• Retrofit Incandescent, Halogen and CFL Spot with LED and dimmable LED
– ~50-80% energy savings
– Light Quality
– Reduced halogen and other gas, heavy metal and recycle content
• Deploy occupancy sensors in low traffic areas
– Warehouses, Storage
• Consider “Daylight Harvesting” techniques in suitable buildings
– Shade control, intelligent dimmers


Typical Warehouse and Processing Area
Retrofit Fixture

Key Benefits

Fixture Features


High Bay Lighting Retrofit Example

400 watt 4 Lamp
Fixture Metal Halide T-5 High Bay

Electric Cost per kWh $0.10 $0.10
Hours per year 3600 3600
# of Fixtures 100 100
Watts per Fixture 460 220
kW 46 22
Annual kWh 165,000 79,000
Annual Electric Power Cost $16,500 $7,900

=> Pays back in ~ <2-years with rebates


Unique Solution for T12/8 Retrofit to T5

Fixture Features Key Benefits
• Refit existing fixtures with
minimal disruption
• Reduced energy up to 50%
• Improved environment
– No high frequency flicker
• Quality light
– Enhanced color rendition
– Minimal lumen loss
• Low future maintenance cost
– Lamp’s lifetime 20,000 hrs
– Low installation cost
• Short payback period


Office Lighting Retrofit Example

T12 x 4 lamp T5 x 2 lamp
Fixture Electromagnetic Ballast Electronic Ballast

Electric Cost per kWh $0.08 $0.08
Hours per year 3600 3600
# of Fixtures 100 100
Watts per Fixture 144 56
kW 14.4 5.6
Annual kWh 51,840 20,060
Annual Electric Power Cost $4,147 $1,612

=> Pays back in ~ <2-years with rebates


Pharmaceutical Packaging Example
• Reduced total power consumption:
– From 595 MWh/yr to and estimated 132 MWh/yr, saving approximately $32,000/yr in operating costs
from lighting and a further $4,000/yr from HVAC.
– Reduce facility Carbon footprint by ~300 tons CO2 equivalent/year
• Reduced maintenance expenditures (not estimated) due to:
– Longer lamp life
– Simpler stocking for entire facility
– Lower skill labor for tube replacement
• Comparable to today lighting levels in all key areas with lighting output sustained at a higher
output for the life of the bulb when compared to existing MH units
• Occupancy sensors for maximum efficiency (selected areas)
• Improved employee satisfaction due to enhanced workplace light levels
• Proposed implementation plan for minimal disruption of operations
• Annual power savings alone implementing the Sitka solution of: ~$32,000/year

 Simple payback for this project is <24 months based on 2010 power rates


©Sitka Enterprises Inc, 2010 www.sitkaenterprises.com

Summary
Changing sources in
energy production,
electricity de-regulation,
power pricing, federal and
state energy policy,
available lighting
technology and business
and public cost
consciousness create a
‘perfect storm’ for
economically introducing
enhanced lighting
solutions

Acknowledgements


Thank You
Contact Sitka at:
• Tel - 484 433 0052 or 610-393-6708

• Web - www.sitkaenterprises.com

• Facebook - Planet Saving Lighting

• Follow us on Twitter - @TheOnlySitka


Sitka
Enterprises
Inc.
Saving energy with sustainable lighting solutions

Backup Slide


Characteristics of Lighting

• Efficacy
• Efficacy is the amount of light produced per unit of energy consumed, expressed in lumens per
• watt (lm/W). Lamps with a higher efficacy value are more energy efficient.

• Average Rated Life
• The average rated life of a particular type of lamp is defined by the number of hours when 50
• percent of a large sample of that type of lamp has failed.

• Color Rendering Index (CRI)
• The CRI is a measurement of a light source’s accuracy in rendering different colors when
• compared to a reference light source. The highest attainable CRI is 100. Lamps with CRIs above
• 70 are typically used in office and living environments.

• Correlated Color Temperature (CCT)
• The CCT is an indicator of the “warmth” or “coolness” of the color appearance of the lamp’s light.
• The CCT is given in the Kelvin (K) temperature scale, and the higher the color temperature, the
• cooler the appearance of the light. Below 3,200 K, the light has a “warm” appearance and above
• 4,000 K the light has a “cool” appearance.


T5 Fluorescent Technology
• High lamp efficacies up to 94 lm/W
– Energy savings of up to 52%
• Highly efficient 3- band fluorescent (tri-phosphor) coating in
combination with pre-coating technology
– Tri-phosphor coating gives good color rendering (Ra > 85) and provides natural
lighting color
• Long lamp life (15-20,000 hours) minimizes maintenance cost
– Relatively high efficacy, both initially and during lamp lifetime, with sustained high
lumen output
• Range of light outputs
– Available color designations create atmospheres from warm white to cool daylight
• Environmentally friendly
– Low mercury content does (< 3 mg)
– Small lamp uses fewer resources and energy in manufacture
• Competitive capital cost
– Energy benefits with attractive ROI


What are LED’s -Light Emitting Diodes
– A relatively new technological
innovation based on the
emissive properties of
materials like Gallium Nitride
and the color properties of
phosphers
– LEDs are different than
existing lighting technologies
– Work best when a systems
approach is used
– Maximize energy efficiency
– Light and lighting qualities are
different


HOW AN LED WORKS

Illustration courtesy of Phillips Lumileds lighting

•A semiconductor doped with impurities to create a diode
•Electrical current flows one way, releases energy and produces visible light
– p- side anode to n-side cathode
•Coating materials used, define the color of light produced

•Commercial systems typically use a blue diode and phosphor combination to
generate white light - there are no white LEDs

•An alternative is a combination of red, blue and green LEDs


Comparison
Incandescent bulbs are inefficient, fluorescents are better, but the future is
LEDs

Source: Kevin Dowling, Asilomar, August 18th, 2008
Definitions:

• Luminous Flux – the quantity of light emitted by a lamp, measured in Lumens (lm)
• Efficacy – the ratio between the lamp’s output in lumens and the power is uses in Watts – lm/W
• Color Temperature – Determines whether colors appear warm or cool (Kelvin)
• Color Rendering – the extent to which the colors of surfaces will appear the same as if it was lit by daylight – the color
rendering index (R) is a scale between 0 and 100.
• Illuminance – the amount of light reaching a surface – measured in lux (one lumen per sqm)


Environmental Concerns on CFL’s
Mercury and CFLs:

Mercury is a toxic metal (neurotoxin) easily ingested by inhalation
A CFL bulb generally contains an average of 5 mg of mercury (about one-fifth
of that found in the average watch battery)

EPA Recommended Procedure for Safe Handling and Disposal of CFLs:

If you break a CFL:

– Open window, leave room for 15 minutes or more
– Use a wet rag to clean up all pieces
– Place pieces and wet rag, in a plastic bag
– Place bag and all other materials in a second sealed plastic bag
– Call your local recycling center to accept this material, otherwise put in trash
– Wash your hands afterward

Feb 25th 2008: Compact Fluorescent Lamp Breakage Study Report


Greening The Balance Sheet Lehigh Valley Energy And Environmental Conference 2010

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