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Industrial Lighting
By Cletus Mullin, Rene Koltes, Mick Walton, and Jeff Krukowski
0 CAN$0
HPS LED HPS LED
(a) (b)
Figure 2. The (a) fixture counts and (b) costs of the preliminary designs.
Figure 3. (a) The HPS design: nine fixtures for an average lighting level of 32 lx. (b) The LED design: five fixtures for an average lighting level
of 41 lx.
by the high-mast lights and a comprehensive 3-D lighting made up of several parts that must be assembled on site,
design. This approach incorporated light contribution from whereas the LED fixtures come as complete units from the
fixtures on adjacent structures and equipment, along with factory. Typical material and installation rates for the fixture
the inherent advantages of LED technology. mountings in an industrial facility are shown in Table 3.
The directional light output of LED fixtures allows The holistic design for the six main processing plants in the
better control of light distribution when compared to refinery also included 24 high-mast lights. Table 4 details
conventional HPS light fixtures. Selecting appropriate the typical cost for high-mast light installation. Comparing
task-specific LED fixtures generally resulted in fewer the total installation costs of the traditional HPS lighting
required fixtures. An example of an LED design versus design with the LED design and the high-mast lights result
an HPS design for a typical pipe rack is shown in Figure 3, ed in a total reduction of CAN$1.9 million for the project
where the controlled optics of LED fixtures can provide when the holistic design approach was followed.
comparable or better lighting with fewer fixtures than
with HPS lighting. Energy Savings
The installation time for modern LED fixtures is also Reducing the number of fixtures compounded with the
shorter than traditional HPS fixtures because they are inherent reduction in fixture wattage resulted in sig
nificant energy savings when compared
to traditional HPS lighting designs with a
holistic LED philosophy. The lower energy
Table 3. The typical fixture installation cost in an industrial facility
consumption resulted in a lower carbon
(in CAN$) footprint for the facility. Figure 4 illustrates
HPS Fixtures LED Fixtures the reduction in energy consumption and
CO2 emissions [5] for the holistic design
Fixture Labor Fixture Labor approach with light fixtures operating, on
Mounting Cost Cost* Total Cost Cost* Total average, 12 h per day.
Stanchion 416 2,392 2,808 832 2,133 2,965 The total reduction in power for the
six main processing units was 714 kW,
Ceiling 399 906 1,305 649 827 1,476
resulting in total reductions of 3,128 MW/h
Wall 420 1,683 2,103 1,091 1,603 2,694 and 1,614 t of CO2 emissions per year.
*Labor costs include all material except the fixture. Using the refinery’s electricity rate of
CAN$0.08 kW/h, the resulting energy
savings per year is CAN$250,288, and
CO2 credits are not included in this value.
Table 4. The typical cost of a single high-mast light pole (in CAN$)
Distribution Requirements
Screw Pile Pole The traditional approach to lighting dis
Description Material Foundation Installation Total Cost tribution in an industrial plant is to place
dedicated transformers and associated
80 ft-high-mast 158,000 6,555 30,000 194,555 panel boards throughout the processing
pole with 22
LED fixtures plant using individual contactors in a mo
tor control center (MCC). The transformers
5.4 h, resulting in an average cost per repair of CAN$575, into neighboring properties, and provides the additional
excluding material. quality benefits of LED light sources, which include high
LED lighting technology provides an inherent reduc er color-rendering index, instant restrike, enhanced cold
tion in maintenance costs. HPS lamps typically have weather performance, and vibration resistance. If imple
a maximum life of 24,000 h (5.5 years at 12 h/day) [7]. mented on future industrial projects, the holistic lighting
LED light fixtures are covered under the manufacturer’s design approach is expected to provide similar results as
warranty for 94,949 h of maintenance-free operation (21.7 shown in this case study.
years at 12 h/day) [8]. With a lifetime of four times that of
HPS lamps, the fixture failure rate for LED is expected to Author Information
be only 25% of the annual HPS lamp failure rate. Cletus Mullin (cmullin@chemco.com) and Jeff Kru-
The expected annual fixture maintenance costs for kowski are with Chemco Engineering, Nisku, Alberta,
the refinery were determined using the total fixture Canada. Rene Koltes is with North West Redwater Part
counts in Table 2, and the costs are shown in Table 10. nership, Calgary, Alberta, Canada. Mick Walton is with
Therefore, the LED design philosophy is expected to ILS Products, Edmonton, Alberta, Canada. Mullin, Walton,
reduce light fixture maintenance costs annually by and Krukowski are Members of the IEEE. This article
CAN$313,375. first appeared as “Industrial Lighting—A Holistic
Approach Using L.E.D. Technology” at the 2016 IAS
Conclusions Petroleum and Chemical Industry Conference. This arti
When implemented early in the design stages of a proj cle was reviewed by the IAS Petroleum and Chemical
ect, a holistic lighting design philosophy that includes Industry Committee.
high-mast lights, detailed 3-D lighting analyses, and
task-specific LED fixtures can have a significant impact References
on overall project capital and maintenance cost. The [1] Illuminating Engineering Society & International Dark Sky Associa
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evaluation of the holistic lighting design approach on a http://darksky.org/our-work/public-policy/mlo
50,000-barrel/day oil refinery was conducted based on [2] International Dark Sky Association. Light pollution. [Online]. Available:
the following six criteria: http://darksky.org/light-pollution
[3] G. Brady, M. Throckmorton, M. Walton, and M. Cole, “Lighting and
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[4] R. Loiselle, J. Butler, G. Brady, and M. Walton, “LED lighting for oil and
4) emergency lighting requirements gas facilities,” IEEE Trans. Ind. Appl., vol. 51, no. 2, pp. 1369–1374, Mar./
5) construction lighting Apr. 2015.
6) maintenance costs. [5] United States Environmental Protection Agency. (2012). eGrid 2012
summary tables. [Online]. Available: http://www.epa.gov/energy/egrid-
The results of the holistic design approach were a 2012-summary-tables
reduction of 34% in task-lighting fixture quantities, 82% in [6] Government of Alberta OH&S, “Occupational health and safety code
annual lighting maintenance hours, and 55% in electrical 2009,” Government of Alberta, Edmonton, Canada, 2009.
[7] Phillips. (2015). Lamp specification guide. [Online]. Available: http://
energy consumed by lighting. Combining the total cost www.lighting.philips.ca/support/support/literature/catalogs-and-
impact for all the criteria evaluated resulted in a total capi brochures.html
tal cost reduction of CAN$31.2 million, an annual opera [8] Eaton Crouse-Hinds. (2015). Champ VMV LED brochure. [Online].
Available: http://www.cooperindustries.com/content/public/en/crouse-hinds/
tion and maintenance reduction of CAN$563,663, and an products/lighting/led_luminaires/champ_vmv_led_seriesluminaires0
annual reduction in CO2 emissions of 1,614 t. Additionally, .resources.html
the design is dark-sky compliant, eliminates light trespass