Union Mine High School LED Retrofit
In 2015, the El Derado School District approached 1st Source about retrofitting around 60 fixtures with LEDs for the Union Mine High School gym. The district was able to provide 1st Source with a sample fixture of it’s 40w TT5 bulbs that were installed in 1998, enabling our engineers to analyze, test, and make recommendations for the betterment of the installation.
With the new design complete, the order was fulfilled and delivered. Installation of the new kits began on August 7, 2015, with school starting on August 10 and a full assembly scheduled for mid-morning that same day, it was imperative that the installation be completed. The work finished two days later on August 9, 2015. As the power was turned on, the visual results were very apparent. The gym had a bright luminous quality and there were no “dead spots” visible on the floor.
Prior to the installation of the LED retro-kits, a light survey was conducted of the gym floor. Fifty-six points of reference were utilized for this survey, covering the extreme edges of the gym, to the primary playing surfaces for basketball and volleyball. Readings taken along the east side of the gym, close to the folded seating, showed an average reading of 20.13fc. At center court a reading of 23.43fc was recorded. Overall this facility was well lit.
Once the installation was complete new readings were taken. Immediate findings revealed a marked increase in the light levels. The east side of the gym showed an average of 25.75fc, an increase of 28%. The reading at center court was 31.43fc, showing an increase of 34%. Throughout the gym, all light level readings showed increased values. Complied information from all 56 metering locations revealed an overall increase of 31%
Actual power levels are currently unavailable, but in static tests, the (4) LED boards drew a total of 96 watts vs. the (5) 40w TT5 fluorescent lamps at 200 watts per fixture, a savings of 52%. An additional advantage of the West Gym lighting system is bi-level dual lamp switching. The lights may be dimmed by another 50% with a simple switch. Total power savings can be upwards of 70% over the original TT5 fluorescents.
New York / New Jersey Port Authority Bus Terminal
To provide new energy efficient fixtures and retrofit kits throughout, the Manhattan bus terminal tasked 1st Source in conjunction with the contractor Constellation Energy. These updates ranged across the indoor and outdoor parking, bus passages, and walkways, utilizing various custom engineered retrofit kits for each environment.
Almost 90% of the fixtures in question were high wattage high pressure sodium or metal halide units. In discussions with NY/NJPA and Constellation, it was determined that the use of induction systems would be the best course of action. Site surveys were conducted with all 3 stakeholders in attendance. 1st Source staff documented the fixtures tagged for retrofitting and forwarded all information to the engineering department for development of the individual retrofit systems.
The Sylvania Induction units ranged in wattage from the 40w QL retrofit kit for use on the underside of an escalator, to the 200w Induction fixtures on the outdoor parking structure; with all units providing an increase in light levels and dispersion over the original HPS/MH lighting systems. As fulfillment of the numerous layers of the production schedule were completed; 1st Source staff provided assistance and expertise to the electrical contractor (FSG) regarding the various retrofit systems developed and provided by 1st Source. These interactions were vital to the development and modification of kit designs for ease of installation.
Once the installations were complete, another site visit was administered with the stakeholders present. The walk-through was done in the evening of May 20, 2014. With all sources of daylight removed, the value of the Sylvania Induction lighting revealed itself in a display of clean, bright illumination in contrast to the outdated HPS/MH lighting. The public spaces were lit with a generous quantity and quality of light, both for aesthetics and safety. The roadways and gate parking spaces for the buses displayed a dramatic change from the dim orange light cast from the metal halide, to the brilliant near white light of the Sylvania Induction lamps.
On the 7th floor outdoor parking structure, an attendant who has worked at the terminal for many years commented on the new lighting installed. He noted that, prior the new fixtures being installed; the center aisle of the parking lot was so poorly illuminated that he could not see past the first few cars in the row. Now, with the new lighting installed, one can see the entire distance of the aisle. Thus, adding to the aesthetics and safety of the parking structure.
The Port Authority Bus Terminal management, Constellation Energy, and FSG were all very pleased with the quality and performance of the lighting systems, as well as the overall performance of 1st Source Lighting; from sales, production schedules and deliveries, to the superior customer service provided by ownership and 1st Source staff.
DOE Waste Isolation Pilot Plant
In 2002 the Department of Energy’s Waste Isolation Pilot Plant near Carlsbad, New Mexico replaced all the high-pressure sodium fixtures inside their water pump house with the latest technology induction lamps. Each fixture combines quality construction with the dependable long life the Sylvania Icetron Induction system rated at 100,000 hours.
The original application consisted of (18) 100-watt HPS fixtures kept in continuous operation due to the emergency related aspects of the building. Concerned with the warm up period associated with HPS lights, operations and emergency personnel were forced to compensate by maintaining a 24/7 operating schedule for the lights to ensure immediate building access would not be impeded. This also caused the lighting system to prematurely reach rated life early in the projected life of the building. Maintenance personnel were constantly required to troubleshoot intermittent outages to maintain required light levels. In addition, problems with elevated cooling requirements increased throughout the building from heat emitted from the light fixtures.
Existing fixtures were replaced on a one-for-one basis so that re-piping the system would not be required. This also minimized downtime for building access as well as the costs associated with piping. The new configuration allows for maintenance (if any) to be performed on a single fixture basis without any lockout or tag-out requirements. The toggle switches were then replaced with time-controls to allow for quick switching and permitting light operation to be adjusted to the individual user’s need.
Sylvania Icetron induction lamps yield an 80 CRI @ 4100 K equal to the quality of office lighting. resulting in a uniform level of light throughout the space and providing a new look to an old room. Enhanced color provides an additional level of safety as the previous yellow hue is now replaced with distinct color. Tags and labels are easier to read ensuring appropriate decisions are made under emergency conditions. Annual energy savings are a staggering 97% (701 kwh from 20442 kwh), with the connected load essentially removed. The new induction lighting system is predicted to last the remaining life of the building, which would suggest a 100% reduction in future maintenance for parts and labor.
DOE National Ignition Facility
The Department of Engery’s groundbreaking facility houses the largest laser system in the world under one roof. The NIF is a 10 story building that spans 3 football fields and includes wide open rooms with high ceilings. 1st Source was tasked with garnishing the space with the goals of infrequent maintenance and easy, building-wide control.
The NIF represents a scientific collaboration from a variety of other countries and universities. In their outreach efforts, NIF conducts dozens of high profile scheduled tours for visiting dignitaries, scientific partners, press and media, and the general public. Most of the facility is a working laboratory, and some of it is available to the public. There is a general need for good lighting and a specific need for media-quality lighting as required along the tour routes.
1st Source Lighting provided their Ultra Induction Modular high bay to provide the additional light needed for these tours. The quality of light delivered by these fixtures provides excellent ambiance and detail that allows visitors to see the intricacies of the engineering and construction. The quality of the fixture construction combined with the technology’s long-life components provide high quality fluorescent light without the maintenance concerns that High Intensity Discharge (HID) or traditional fluorescent lights.
High Bay Lighting
The large laser bays contain the bulk of NIF’s beam transportation apparatus. The light amplifiers, mirrors, and related hardware enhance, fine-tune, and transport the focused light in its nanosecond journey to the target chamber. The beam transport tubes are stacked tightly in a large clean-room with aisles along the perimeter of the room. The original (HID) lighting provides adequate light and has required nominal maintenance on a regular basis.
Considering the challenge and inconvenience of changing a light bulb in a cleanroom with 60-foot ceilings, the NIF site was considering a retrofit to long-life fluorescent. 1st Source Lighting provided their Ultra Induction Recessed fixture as a drop-in retrofit. A custom two-lamp recessed fixture will “plug and play”, and will fit neatly into the hole left by the HID Fixture. The 100,000 hour life of the electrodeless technology will provide a decade (or longer) between lamp changes. In addition to the substantial maintenance savings, the instant on-off switching allows the facility to turn the lights off when the laser bays are unoccupied.
The NIF consists of more than 60,000 elements throughout the system, including large banks of capacitors, mirrors, lenses, motors, sensors, cameras, amplifiers and diagnostics. Nearly every square foot of space is utilized in the area surrounding the target chamber. The dense clusters of instrumentation, diagnostics, and related components are so tightly arranged, that the light provided by the overhead fixtures is inadequate and does not penetrate the labyrinth of equipment.
Conventional task lighting using traditional luminaires suffered from the ambient pulse energy created by the laser shots, and failed prematurely. 1st Source Lighting provided their Ultra Induction Surface Flood to provide the additional light needed for the various tasks surrounding the target chamber. The fixtures are industrial-grade and house an electrodeless light source that is not susceptible to the damaging pulse energy. The additional light provides excellent color rendering and penetrates many of the spaces that the overhead lighting fails to illuminate.
William Land Park, Sacramento
While the Land Park area of Sacramento is known for the antique, old fashioned look, the street lights of the same charm presented serious safety and maintenance challenges. Having adopted high-pressure sodium lamps as a standard, the city prepared to replace the old mercury vapor lamps with such, leading to opposition from the residents to such a light.
“The QL-85 induction lamp appears to offer the solution to many issues incurred with residential street lighting. The light color is “white”, 100,000 hour lamp life, eliminates four to five relamp cycles, and saves energy. The latest research into light color quality at night also seems to make the QL-85 the ideal light source for residential roadway lighting.” – Wesley Hiratsuka, Traffic Control and Lighting Supervisor.
After investigating induction lighting, Wesley Hitratsuka, the City’s Traffic Control and Lighting Supervisor, worked closely with SMUD (Sacramento Municipal Utility District) and 1st Source Lighting to develop a prototype retrofit kit. The kit was based upon the Philips 85-Watt QL induction lighting system. The design included a heat sink for the HF generator and power coupling. 1st Source Lighting produced 183 retrofit units for field installation. The illumination levels improved dramatically and the residents are very satisfied with the retrofit. With a system life rated at 100,000 hours, maintenance costs have been dramatically reduced. The new system also saves an annual estimated 26,357 kWh equating to $1,755 in energy costs.
The Schwan Food Company
“For every watt of light, the cooling system has to pull out 3.414 BTU’s. When lights are on 24/7/365 as our freezer lights are, that really adds up,” said David Bero, senior project manager of the Schwan Food Company when they needed their freezer lights upgraded, involving Minnesota-based Municipal Utilities and a compressed air study form the MMU Energy Services.
Effiency is not a on-size-fits-all solution. There is more than one option for companies looking to save on lighting in cold storage areas, but none of them suited Schwan’s case. Light-Emitting Diode fixtures are now becoming popular for this application. However, at the time, LEDs were not widely available commercially. Occupancy sensors are a good energy-saving strategy for relatively small walk-in units, but Schwan’s freezer resembles a warehouse rather than a room, complete with warehouse-style traffic. The ballast on a high intensity discharge lamp takes time to cool before it can restart. “We tested the sensors in our dry warehouses,” Bero added. “The way lights pop on right in front of the occupant is hard on the eyes, and it creates safety issues for forklift drivers.”
Determined to find a solution that met Schwan’s needs, Antony turned to the Internet to do a little research. “Mark was very, very helpful throughout the project,” Bero commented. “He really stuck with it.” Antony finally came across 1st Source Lighting, a company in Auburn, Calif., that offered a product that seemed close to what Schwan was looking for. “They at least had fixtures that operated in freezer applications,” said MMU Energy Services Coordinator Mark Antony. “Unfortunately, the lowest recommended temperature for 1st Source’s T5 HO lamp was minus 18 degrees, not low enough for Schwan’s freezers.
The designers at 1st Source were not about to give up, however, so they applied the cold-resistant construction features used on UI fixtures to some four-lamp T5 fixtures. “We’ve been building freezer fixtures for some time, and we knew we could come up with a solution that worked for Schwan,” said 1st Source Sales Manager Greg Cooper.
A few of the modified T5 fixtures were sent to the plant to test. Bero tried out the lamps and recommended a few additional changes that resulted in a T5 lamp that worked flawlessly at temperatures down to 32 below zero. The new fixtures saved Schwan $113,000 on electricity last year. Lighting was about $66,000 of the savings, “And the rest came from reduced cooling demand, because the ballasts put out less heat than HID ballasts,” said Bero.
Unlike HIDs, the new lights can be turned off on the weekends when the plant is closed. “They turn right back on at full output, and they have a much lower fire rate, they don’t burn out as easily as HIDs do in freezer conditions,” Bero pointed out. “So the savings are better than we initially calculated.” The project also gave 1st Source a new product. “We now have a standard T5 fixture rated to minus18 degrees that is sufficient for most businesses,” said Cooper. “There is less demand for the VTF32 series Schwan uses, so we offer it as a custom fixture.” The Marshall plant replaced almost all its HID fixtures with the T5s, and Bero is encouraging other Schwan facilities around the country to install the technology. He estimates the payback on the Marshall plant retrofit to be between one and two years.
Article referenced from Western Energy Services Bulletin 2007
Del Campo High School Gym
1st Source Lighting’s Big Gym T5 HO High Bay utilizes a multiple reflector design that maximizes the additive potential of each adjacent lamp to collectively illuminate the space. The old lighting system used 400 watt metal halide lamps with a color rendering index of 65. The new high intensity flourescent system utilizes high output lamps with a color rendition index of 82.
The biggest advantage, besides saving 50-70% on the energy bill, is the desirable features of instant-on controllable lighting. The lighting system is dual switched, meaning it may be dimmed by 50% with a simple switch, eliminating the need for costly controls and dimming ballasts. The contractor ran a second power conductor to the fixtures, a low cost option that adds versatility and desirable switching options.
San Mateo City Parking Garage
Needing a replacement retrofit for the existing fixtures, The City of San Mateo incorporated the use of 1st Source Lighting’s innovative T8 Delta Fixture to capture the best combination of energy and maintenance savings in a recent lighting retrofit. Each Delta fixture utilizes (3) T8 lamps in a triangular configuration backed with a low-maintenance white reflector.
The project involved a large multi-story 24/7 garage facility requiring average design lumens of (5) footcandles to ensure a safe environment for it’s customers. The original design consisted of (239) 175 watt metal halide fixtures with the intent to provide safe pedestrian and vehicular egress in a low-ceiling application. Comparatively inefficient, the light emitted from a single point source metal halide lamp combined with a low mounting height created a nuisance glare. Marginal light quality and poor O&M economics motivated the city to consider a major lighting retrofit project.
The existing fixtures were retrofit on a one-for-one basis with 1st Source Lighting’s 3-lamp high performance Delta T8. The high glare has now been replaced with higher quality, friendlier light, and improved color rendering. In addition, better maintenance characteristics, improved lumen depreciation, instant on/off with a 260% increase in lamp life have resulted in dramatically lower O&M costs. Lumen levels and overall light quality were improved to enhance customer safety with lamp life increased from 10,000 to 36,000 hours and ballast life from 40,000 to 60,000 hours. In addition, non PCB ballasts and low mercury lamps resulted in reduced disposal costs.
These attributes combined with solid economics, utility incentives, and a low simple payback, motivated the city to consider an alternative to the existing challenge. 1st Source Lighting’s custom solution consisting programmed-soft start ballasts and long life, low mercury T8 lamps have contributed to the overall improved O&M package for the city’s maintenance staff.