Electrical Power Utilization EE0.37-3.

5-2

Lighting Design for Semiconductor Fabrication Plant

22nd April, 2013

Praneet Choudhury TP021883|UC3F1208EEE

ASIA PACIFIC UNIVERSITY

Contents
Introduction ...................................................................................................................................... 1 Proposal Requirements and Limitations............................................................................................. 1 Factory Area A Manufacturing ........................................................................................................ 4 Factory Area B Inspection ............................................................................................................... 9 Factory Area C Packaging .............................................................................................................. 13 Canteen ........................................................................................................................................... 16 Corridor........................................................................................................................................... 18 Washroom ...................................................................................................................................... 19 Office .............................................................................................................................................. 20 Conclusion....................................................................................................................................... 21 References ...................................................................................................................................... 22

PRANEET CHOUDHURY TP021883|UC3F1208EEE LIGHTING DESIGN FOR SEMICONDUCTOR FABRICATION PLANT

Introduction
Lighting is one of the oldest necessities of mankind. The fundamental need for illumination is complemented by the aestheticism that is inherently incorporated in it. Thus any lighting design should appeal to the users in terms of visibility, comfort, aesthetic appearance, and psychological response. That being said, in the case where lighting is done for industrial purposes, more than visual appeal, it is important to design with objectivity, to design so that the task of the user is not only successfully illuminated, but that the overall productivity is enhanced because of the design. Notwithstanding this, responsibility towards the environment and responsiveness to the owners installation and maintenance costs is of utmost importance. IN these days of constant sustainability discussions, it seems only prudent to design lighting systems, keeping in mind energy effectiveness and efficient use of materials.

Proposal Requirements and Limitations

The given scenario requires the redesigning of the lighting system of a used warehouse, into a semiconductor fabrication plant. The layout of the new renovated warehouse/plant is as shown below.

Fig. 1 : Orginal layout of Factory

The designated Factory Areas are, A Manufacturing, B Inspection & C Packaging. These 3 areas form the backbone of the industry and are required to have 24/7 operation. Along with these, the Canteen, Corridor, Washroom and Office have to be duly relit to provide adequate support services. It can be realized here that if the Factory Areas are to be 25/7, of
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course the Canteen, Washroom and Corridor are to be lit 24/7 as well, since they provide critical services and will face constant human traffic throughout the whole duration of the production process. That leaves only the Office that is to be in service from 0900 to 1800 hrs each day for 5 days a week. The orientation of the building is important. Since the compass pointer is shown, it can be realized that the Corridor faces South, the Factory Area C faces East and Washroom and Office faces West. In view of cost savings for both installation and electricity consumption, the canteen is proposed to be relocated to the farther side of the building as shown below.

Fig. 2: Proposed alteration of Factory Layout

This is done for specific reasons and has advantages and drawbacks. Now the Canteen has an East facing, which means with the appropriate usage of glass panels on the walls and roof, a large amount of sunlight/daylight may be streamed into the area. Meal consumption is maximum during breakfast and lunch, which means a large portion of the light requirements are during the daytime. By making suitable structural modifications the Canteen can be almost electrical-lights-free during a large part of the day and any other time, dimmable light sensitive fixtures may be used to automatically control the light amount in the area. This also has a pleasing feeling to employees, who can consume meals under natural lighting and have a sense of the day passing through the glass paneling. It is to be remembered that these employees in all probability have shift duties due to 24/7 operation and are likely to be in the highly-restricted Manufacturing and Inspection Areas most of their duty periods, since semiconductor chip fabrication requires areas of complete isolation from daylight. It is advisable to design the Canteen in the lines of the wall and roof paneling shown below.
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Fig. 3 : Proposed style of Canteen Roof

As can be realized that this will provide the large amount of natural light heretofore described. The implications of this extra natural light will be discussed later. With reference to Fig. 2, an obvious problem presents itself. The Canteen is now located at a substantial distance from the Washroom, which means that there will be an increased traffic along the corridor at certain times of the day. This may be an inconvenience, no doubt, but it should be offset by an enormous amount of light savings for the Canteen Area. Again, a point to be noted is that the Canteen is, by specified design, the largest Area in the building, so the savings can matter. Each Area, namely Manufacturing, Inspection, Packaging, Canteen, Corridor, Washroom and Office will be dealt with separately in the upcoming chapters. As a choice of lights and fixture manufacturer, for reference purposes, Royal Philips Electronics is chosen, wherever possible, due to suitable availability of a wide range of products and ease of acquiring resources like data-sheets.

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Factory Area A Manufacturing

This area is light sensitive and mission critical in nature. Chip fabrication areas are generally classified by cleanliness which translated to the amount of dust particles present per cubic meter of air in the room. Thus the designation of the term Cleanroom to such areas. Furthermore light sensitive processes such as photolithography are carried out inside these Cleanrooms, further complicating the choice of lighting. It is understandable that the sensitivity and mission-critical nature of the area suggests more importance to accurate lighting, rather than cost savings. Nevertheless, there may be some energy-saving alternatives to explore. The light requirements and characteristics of a Cleanroom has been described most excellently in a web-article published by Brian Rener of Solid State Technologies, themselves manufacturers of semiconductor chips (Rener, 2011). Most of the specifications of a Cleanroom are referenced from here. The requirements of most Class 5 or Medium Grade Cleanrooms are around a 100 Foot-Candle. Also a Color Temperature of 3500K and a Color Rendering Index of 85 are suitable as these are universally considered neutral and accurate. Finally the author mentions that Fluorescent lamps are nearly always used in cleanroom environments due to their energy efficiency, low maintenance and long life (Rener, 2011). Philips has a choice of Cleanroom lighting with different specifications as shown here. Out of these the Claria will be considered in great detail due to the presence of Compact
Fig. 4 : Philips Cleanroom Range

Fluorescent Lights in the luminaires. As a cost saving alternative, Cleanroom LED will be analyzed to see if it provides any benefits. The advantages of these fixtures are that they provide perfect seal-ability and cleaning options for cleanroom purposes and are specially fitted to provide lighting for the semiconductor industry (Philips, 2013).
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Fig. 5 : Philips Claria Cleanroom Fluorescent

The CFLs inside the CLARIA, as documented by Philips should be of type PHILIPS MASTER PL-L 4PIN. These are available in 3 variants as shown below with pertinent ratings and values.

Fig. 6 : Comparison of CFLs for Claria

Whichever one is chosen, 3 of each will fit into each CLARIA luminaire. Since the Luminous Efficacy of the first type is high compared to the Lamp Wattage, an analysis is done to find the number of luminaires required with the first type.

Room Index = (W x L)/[H x (W + L)] = 35*40/(9*75)=2.07 2 where W, L and H, are room width, length and height from working surface respectively. Height from working surface is assumed to be 9m, since the luminaires are flush/recessed with the ceiling and machine/table height should be around 1m above the ground.
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The utilization factor corresponding to this Room Index can be acquired from the table published by the CIBSE (Chartered Institution of Building Services Engineers) which is shown below,

Fig. 7 : CIBSE tables for Utilization Factor based on Room Index

Conforming to the highest possible reflectances of the (C)eiling=0.7, (W)alls=0.5 and (F)loor=0.2, the corresponding Utilization Factor (UF) for the RI of 2.00 is seen to be 0.65. Reflectance depends largely on the material used in for the particular surface. It is advisable to use white PVC paneling on the ceiling and walls to increase their respective reflectance values, which would lead to a slightly better room index. White PVC has a reflectance value of 0.87. (CARLISLE SYNTEC INCORPORATED, 2013). For the purposes here, UF will be assumed to be 0.65. For calculation of Maintenance Factor, values of LLMF (Lamp Lumen Maintenance Factor) and LMF (Luminaire Maintenance Factor) can be obtained from the spec sheet of PLL 4pin in Fig. 6. LSF or Lamp Survival Factor will be assumed to be 1 if dead lamps are replaced immediately and RSMF (Room Surface Maintenance Factor) for Cleanrooms is around 0.98 (ERCO, 2013). Maintenance Factor (MF) = LLMF x LSF x LMF x RSMF = 0.9 x 1 x 0.94 x 0.98 = 0.829 1 Foot-Candle = 10.764 Lm/sq.m Required 100 Foot-Candle = 1076.4 Lm/sq.m
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For a room of dimensions 35m x 40m, required lumens, 1076.4 Lm/sq.m x 35m x 40m =1506996 Lm For the 18W PL-L model, since there are 3 CFLs in each luminaire, Nominal No. of Luminaires = Total Lumens / (3 x Watts x Lumens/Watt) =1506996/(3x18x67) = 417 Again due to MF and UF, actual number of luminaries required are 417/(MF x UF), since the effect of MF and UF are to increase the number of required luminaries to compensate for the decrease in lumens due to maintenance and utilization. 417/(0.65 x 0.829)=773 luminaires are too many for a 1400 sq. m area. Therefore the higher wattage model (55W) should be considered since it gives maximum lumens per luminary as seen from Fig. 6. Again, Nominal No. of Luminaires = Total Lumens / (3 x Watts x Lumens/Watt) =1506996/(3x55x87) = 105 Again, Actual Luminaries required = 105/(MF x UF) = 105/(0.65*0.829) = 195. This is a more acceptable number, and it can be factorized into 195 = 13 x 15 Thus the arrangement in the 35m x 40m room will be as shown on the next page. It is observable that the spacing between the lights and between the lights and walls are the same all throughout the room. This is aesthetically pleasing, practically feasible and most importantly, will provide uniform distribution of luminance. The space height ratio (SHR) can also be calculated as Spacing between lamps / Height from working plane = 2.5m / 9m = 0.3 which is very much within acceptable values. Actually the space height ratio is very low due to the mounting height which is same as the ceiling height. In reality a Cleanroom should have a much lesser ceiling height from working plane. This can be easily achieved by

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installing white PVC ceiling at a lower height and increasing the SHR to a more normal value. In any case the requirements are suitably met in the given situation already. Another type of fixture offered by Philips for the same Cleanroom purposes, houses LEDs and shows the characteristics as shown in the table below.

Fig. 8 : Arrangement of 195 luminaires for Factory Area A

In this case, Nominal No. of Luminaires = Total Lumens / (Watts x Lumens/Watt) =1506996/(150*75) = 134 and Actual Luminaries = 134/(0.65x1) = 206. Maintenance Factor is assumed to be 1 often for LED lamps, due to high MTBF (Mean Time Between Failures), as shown in the graph on the left and also 70% lifetime value of 50000hrs in the specs above. It can be realized that the previous no.
Fig. 9 : Philips Cleanroom LED product specs

of Pl-L luminaire was 195, and the LED is calculated as 206, which is not a great

difference. In order to keep the arrangement as shown in Fig. 8, if the CLARIA luminaires are replaced with Cleanroom LEDs and certain amount of back-calculation is done, it can be

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shown that using 195 instead of 206 no. of LED luminaires will reduce the 100FC requirement to 95FC, which is still acceptable. Cost savings of LED luminaires are major. While they are expensive to install, the lifetime is 50000hrs, compared to the 20000hr average of the PL-L luminaires. Also for a 24/7 facility, 20000hrs service time translates to roughly 2.3yrs before lamp replacement, compared to 50000hrs for the LEDs meaning 5.7yrs replacement periods. Power consumptions are not that different, since each LED luminaire is 150W compared to the CLARIA with 3 PL-L, each at 55W = 55x3=165W. Total savings with LEDs will be (165-150) x 195=2.25kW. So the LEDs have a lifetime advantage over the PL-L CLARIA luminaires. But it should be mentioned to the client that LEDs are notorious for unevenness of color. Even though the color temperature chosen is 3000K (recommended 3500K) and CRI above 80%, variations in these values are not uncommon among the same production batch of individual LEDs. If the client feels that cost savings in the context of Lamp Replacement is more attractive than slight unevenness in lighting at a later period, then the Cleanroom LEDs should be chosen as the luminaire. On the other hand, if easy availability, easy replacement, price and constant color-temperature advantages of the PL-Ls are considered more mission critical for cleanroom purposes, the CLARIA should be preferred. In both cases the arrangement of Fig.8 will be maintained with 195 luminaires.

Factory Area B Inspection

The second factory area B has inspection as its major function. While not missioncritical, inspection plays a major role in the production process due to the factor it mainly affects quality control. Since problems in quality or production errors will affect the processes that take place in Manufacturing, this area may be considered the second in importance, compared to Area A, when it comes to lighting. Inspection lighting has some specific requirements as well. Generally, there are at least 3 kinds of lighting involved, Main Lighting, Transverse Lighting and Foil Lighting (Bergin, 2010). The latter is used typically for shiny surfaces, and so may be disregarded here. Main Lighting is simply the lighting from the

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top that illuminates the products plan view. Transverse Lighting involves projecting the light perpendicular to the surface being examined to offer a view of unevenness and scratches that might throw a shadow, as shown here (IDEC Corporation , 2011). Thus it is important for the purposes of inspection to install lights on both on the ceiling and
Fig. 10: Transverse lighting for surface inspection

walls of the room. Overall values of lux and color temperature for inspection purposes varies over the product being inspected. 1000 lux seems to be the general recommendation in most cases (CIBSE, 2013) for minute inspection, which is the situation here. This value seems acceptable as well when compared with the lux value used for production cleanroom. Color temperature nearing daylight of 6700K-8500K is advised as well (Rener, 2011). Modern inspection equipment, like high speed cameras, photometers etc. will require specific kinds of spot lighting, sometimes in the range of 400,000 lux. But for simplicity, human inspection of semiconductor chips is assumed here. Due to the less stringent nature of activities in the inspection room, cleanroom type light fixtures are not necessary for the Factory Area B. Keeping in mind the special requirements mentioned above, IDEC Corporation, Australia have come up with a set of products specifically for vision inspection. Their Lumifa series, LF1F line of luminaires, are designed for both wall and ceiling mounting. Here Philips loses out due to unsuitability of mounts. The LF1F series are LED based luminaires with low wattage and active-cooled longlife and no-flicker design. This is important for inspection purposes, since even a slight flicker can cause distraction during visual inspection. Glare has also been taken into account while designing these, since they are specifically meant for wall mounting. The thin profile and even lighting over the 300mm square area of the luminaire are added advantages (IDEC Corporation, 2011).

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Flux required = 1000lm/sq.m For a room of dimensions 35m x 40m, required lumens, 1000 Lm/sq.m x 35m x 40m = 1400000 Lm Maintenance Factor (MF) is not specified by the manufacturer, and therefore will be assumed to be 1, since the light elements are highly durable 40,000hrlife LEDs. Utilization Factor (UF) will be the same as the Factory Area A since the room dimensions (and therefore Room Index) are exactly same. Therefore UF = 0.65. Now each luminary provides 8900 lumens. Therefore nominal number of luminaries = 1400000/8900 = 157. Therefore actual number of luminaries required = 157/(MF x UF) = 157/(1 x 0.65) = 241.5 240
Fig. 11: Lumifa LF1F LED-based inspection lighting specs

Since lights have to be mounted on

both the ceiling and walls, 75% of the light is generally assumed to be provided perpendicular and 25% lateral to the surface being inspected (Bergin, 2010). Therefore 0.75 x 240 = 180 luminaries have to be ceiling mounted and 60 have to be wall mounted. Ceiling mounted luminaries can be easily factorized into 180 = 12 x 15 and they may be arranged as shown on the next page. The wall luminaries may be distributed as 12 luminaries on each of the 35m walls and 18 luminaries each on the 45m walls. The arrangements are shown on the next page.

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As shown here, a distance of 2.5m is maintained horizontally and 2.7 m vertically between lights in the plan view. This is almost square and therefore acceptable. In the figure below, 2.5m distance is kept between each wall luminary and 1.25m between the corner luminary and the wall corner. A height of 2m above the floor is maintained for the wall luminaires to prevent direct glare at
Fig. 13 : Arrangement of 180 luminaires for Factory Area B

eye level and projected shadows.

Fig. 12 : Arrangement of 60 luminaires for Factory Area B Wall Mounted

Total Wattage for 240 luminaires = 240 x 11 = 2640 Watts. Space Height Ratio = 2.5/9 = 0.3. Again, the Space Height Ratio is quite low. This is due to the high ceiling of the already existing construction. For a better SHR and Room Index, the ceiling should be lowered which will give a better utilization factor as well.

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Factory Area C Packaging

Packaging area requires various light levels depending on the industry. It can easily vary between 100 lux to 500 lux depending on the minuteness of the packaged items. Illuminating Engineers Society (IES) recommends 500 lux for packaging/loading areas in general (IES, 2011) and Philips recommend a minimum illumination value of 500 lux at any electronics manufacture/assembly plant (Philips, 2012). Since the given factory layout has no dedicated storage room, it may be safely assumed that the packaging area will be utilized for storage purposes as well. Therefore the high ceiling design of this room may be retained. Storage and packaging areas are usually lit by high-bay metal-halide fittings, which the factory in question already has in place. Depending on the illumination levels required, the existing metal halide fittings should be used until they reach end-of-life, upon which it will be suggested, that they replace them with Philips GentleSpace High-Bay LED solutions which have a much larger lifetime and can contribute to energy savings significantly. This will save some initial up-front cost for the client. Area C has the same room dimensions as the previous two areas and therefore the Room Index immediately becomes 2, as calculated before. Thus the Utilization factor can be measured to be 0.65 from Fig. 7, keeping in mind that the wall, floor and ceiling reflectance values should be met. Specification of the GentleSpace high bay LED series from Philips are shown here.

Fig. 14 : Philips GentleSpace High Bay LED solution specs

As before, the nominal number of luminaries may be calculated.

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Nominal Luminaries = (500lm/sq.m x 35m x 40m)/ 10000lm = 70 It should be noted here that the 10000lm product was chosen from the options in Fig. 14, due to its highest luminous efficacy, 10000lm per 108 watts = 92.59lm/W Assuming Maintenance Factor of 1 for air-tight sealed LED fittings, and Utilization Factor of 0.65, the actual number of luminaries required = 70/0.65 = 108 This may be factorized as 9 x 12 and the arrangement possible is shown below, This gives a maximum Space Height Ratio of 4m/9m = 0.45 which is within limits. To save cost, if the existing Metal Halide high bays are used till the end of life, then an arrangement may be made to fit them into this wiring assembly. Therefore a calculation must be done for the metal halides as well.

Fig. 15 : Arrangement of 108 luminaires for Factory Area C

The maintenance factor of Metal Halides can be calculated as (values provided by (ERCO, 2013)), Maintenance Factor (MF) = LLMF x LSF x LMF x RSMF = 0.83 x 1 x 0.81 x 0.85 = 0.57 The low value of lamp lumen maintenance factor or LLMF is taken assuming almost end of life of Metal halides around 10000 hrs. Required number of lumens = 500 lm/sq.m x 35m x 40m = 700000 lm Average luminous efficacy or lm/W of Metal Halides = 90 and since 400W metal halides were installed before, Nominal number of luminaries required are, 700000/(400W x 90lm/W) = 19

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Therefore actual number of luminaries = Nominal Number / (MF x UF) = 19 / (0.65x0.57)= 51 This almost appears to be half of the number of Led fittings calculated above, therefore, instead of 51, if 54 of the existing metal halides are used in the same LED-wiring layout in Fig. 15, they may be arranged as here, Here the green luminaires

represent points occupied by the metal halide fittings and the red are vacant points. Obviously this will not lead to a very uniform lighting, but since packaging is not mission-critical, such an arrangement of metal-halides using the LED based wiring, will prove to be cost effective. As soon as the metal-halides reach end of life, they may be taken out
Fig. 16 : Alternate arrangement of existing metal-halide fittings for Factory Area C

and replaced by the GentleSpace fittings straight away, as in Fig. 15. It may be

important to notice here, that Philips manufactures the GentleSpace series as replacements for Metal Halide High Bays and therefore have similar kind of electrical line fittings (Philips Industrial, 2013). So 54 nos. 400W Metal Halides get replaced by 108 nos. 108W LED solutions, the total energy savings being, 54 x400 108 x108 = 9936W 10kW. This demonstrates the energy saving nature of LEDs. Also it may be noted that the GentleSpace are available in 2 LED variants, L90 and L70 in Fig. 14. Whichever one is used, they have significantly higher lifetime than the Metal Halides, the latter having a maximum lifespan of 15000hrs. The L90 and L70 GentleSpace are rated for 40,000 and 75,000 hrs, which means a replacement period of around 4.5 and 9 yrs respectively, at 24/7 operation.

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Canteen
As mentioned in Proposal Requirements and Limitations, the Canteen area will be relocated and reconstructed with glass/metal roof and skylights, to allow maximum daylight during the majority of the meal-consumption times of the day, taking advantage of its East facing orientation. This allows for major energy savings. In any case, sufficient lighting has to be installed since the cafeteria will go through 24 hour operation. Therefore, a dimmable or auto-dimming lighting system should be installed. Also, taking into consideration the highceiling design, it seems logical to recommend light fittings with suspended adjustable heights so that the lights can be localized over specific areas with tables or widened over more general parts of the canteen. There is only one product in the Philips catalog that offers dimmability with suspension type, the Philips SmartForm LED W22L124 LIN-PC SMT1. This particular variant has specs as shown below. Color temperature nearing daylight and long lifetime play significant roles as well in this recommendation. Room Canteen = (W x L)/[H x (W + L)] = 35*50/(9*85)=2.28 2.3 In the absence of CIBSE values for RI of 2.3 in Fig. 7, the nearest value 2 is taken as reference, which gives a UF of 0.65. If the lamps are suspended to a distance of 6m from the ceiling so that they are 3m above the
Fig. 17 : Philips suspendable SmartForm LED W22L124 specs

Index

for

the

canteen tables (1m height), the effective height becomes 4m and

the RI becomes 35*50/(4*85) = 5.14 5. This gives a utilization factor of 0.69, keeping in mind the reflectance requirements of the walls, ceiling and floor. This is done with an objective to
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make use of as minimal lighting as possible in the cafeteria. The maintenance factor of sealed LED fittings is taken as 1. CIBSE guidelines for indoor lighting state a requirement for 200 lux in cafeterias, canteens and dining rooms. Therefore, total lumens = 200 lm/sq.m x 35m x50m = 350000lm Nominal luminaires required = 350000/4300 = 81 Actual Luminaires required = 81/ 0.69 = 125 By assuming 126 luminaires, this can be factorized to 9 x 14 and the arrangement can be made as shown below, The slightly skewed distances from the wall to the end luminaries leads to the formation of square distances between every other luminary, so the arrangement can be assumed regular. With the height of the luminaries 4m above the canteen tables, the SHR becomes 3.5/4 = 0.875 which is well within maximum value of 1.5. The number of luminaries may be
Fig. 18 : Arrangement of 126 luminaires for Canteen

further reduced by realizing that not

every part of the canteen is occupied by employees. Instead of symmetrical arrangement, the luminaires should be concentrated in the regions of high eating activities and near the food counters. In any case, the roof glass paneling will provide constant light throughout the canteen, from around 7am till 4pm. The automatically dimmable Smartform LED luminaires will do the job for the rest of the day, thru the night till 7am. Power savings = 125 x 58W x 9hr = 65.25kWh

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Corridor
Here, again, as in the previous section, the Room Index may be improved by reducing the mounting height of the lamps. Since no movement of tall equipment is expected in the corridor, the same suspended Smartform LED luminaires may be used as before. It can be realized that, even though not explicitly mentioned, the corridor also has a 24/7 service and therefore any savings in luminaires will lead to some power and cost savings. This 24/7 nature is what leads to the suggestion of long life LED fixtures. A method of reducing the number of luminaires can be justified as follows. The side of the corridor with sensitive activity in the vicinity of the Factory Area A, B & C can be better lit than the side which adjoins the cafeteria. CIBSE recommends levels of 100-200lux for corridors, walkways and stairways (Elite Renewables Service Limited, 2013), therefore the lighting levels may be distributed as below, with no great loss in functionality.

Fig. 19 : Proposed illuminance values at two different parts of the Corridor

This will lead to an uneven lighting at the end of the corridor, but it can be justified by the cost savings. Total lumens required by the right side = 200lm/sq. m x 120m x 5m = 120000lm. Actual number of luminaires = 120000lm / (4300lm x 0.69 x 1) = 40. Here the values have been assumed as in the previous section, with UF = 0.69 because the lamps will be hung 5-6m from the ceiling, making the effective mounting height around 4m. MF for sealed LED fittings = 1. Similarly for the left end of the corridor, Actual number of luminaires required = (100lm/sq.m x 5m x 50m)/(4300lm x 0.69) = 8 Arrangement for the luminaires is shown here,

Fig. 20 : Arrangement of 40 and 8 luminaires for two different areas of Corridor

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The savings can be easily calculated if the whole corridor is given 200lux. Then Actual number of luminaires = (200lx x 5m x 170m) / (4300lm x 0.69 x1) = 57 nos. Since each luminaire consumes 58W, total power savings = (57-48) x 58W x 24hr = 12.53kWh per day. In addition the corridor may benefit from installation of glass wall paneling on the South side, so as to let in maximum daylight throughout the day. This should be implemented to take full advantage of the auto-dimming capabilities of the Smartform LED luminaires.

Washroom
Following CIBSE specification of a 100 lux in washrooms (Elite Renewables Service Limited, 2013), the number and arrangement of luminaires may be estimated in the usual manner, using specifications from Smartform LED luminaires from Philips. The only difference from the previous cases being that Smartform BCS 460 will be used instead of Smartform BPS 460. The former is the ceiling mounted/non-suspended version of the latter. The reason for extensive use of this luminaire in non-critical areas of a factory is its relative low cost, long life (50000hr), good color temperature (4000K) and acceptable CRI (>75). Washroom dimensions = 10m x 30m Height must be lowered, with white colored false ceiling for good Room Index as well as aesthetic reasons. So Utilization factor may be assumed to be 0.69 as before. Nominal number of luminaires = (100lx x 10m x 30m)/4300 = 7 Actual number of luminaires = 7/ (0.69 x1) = 10. These may be arranged as shown. In addition glass paneling may also be provided on the South facing wall of the washroom to provide light additional

Fig. 21 : Philips SmartForm LED BCS460 ceiling-mounted

Fig. 22 : Arrangement of 10 luminaires for Washroom

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Office
Around 300 500 lux is recommended by CIBSE for Executive Office rooms (Elite Renewables Service Limited, 2013). In view of cost savings, the lower 300 lux value will be chosen. The Room Index has to be improved by reducing mounting height to 4m, in which case, as calculated above, the RI will be 2.28 and the utilization factor will be 0.69 Since the facility has no meeting area, it will be expected that the office may be used for small meetings with both clients and employees. Therefore a nice ambience should be created with color temperatures around 3000K which are considered warm white. Philips has stylish and energy-saving, office-purpose, led-based lighting which meet the requirements. They are wall recess mounted and the main reason for recommendation directional adjustment. An office may have many staff desks at random positions which generally dont follow the lighting scheme on the ceiling. Instead of organizing office space by lighting, if the lights used have directional rotatability, then the office space may be organized at ease and not be dependent on lighting schemes. The LuxSpace luminaire is shown here. Total office area = 30m x 30m Total lumens = 300lx x 30m x 30m = 270000lm Using total luminous flux value from Fig. 23, Nominal number of fixtures = 270000/3332=81 Actual number of fixtures = 81/0.69=117 This cannot be factorized suitably, but assuming 121 fixtures, they may be
Fig. 23 : Philips LuxSpace specs

arranged as 11 x 11, giving a perfectly square pg. 20

distribution as shown next.

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These lights may be focused whichever direction is required to get slightly more light, in the region of a desk for example. Definitely, for these type of fittings, the ceiling has to be lowered to around 4m or lower, to provide good Space Height Ratio of around 0.65 and the reflectance values of the ceiling should be kept in mind during
Fig. 24 : Arrangement of 121 luminaires for Office

false-ceiling

construction.

Windows will be provided, but they cannot be applied as a source of light, since the office is mainly facing west and north.

Conclusion
The importance of LEDs in currently prevalent lighting designs cannot be overstressed. Luminous Efficacy values may not be very high compared to fluorescent or metal-halide fittings, as was seen in Factory Area A & B discussions, but the total lumens produced by each luminary housing a group of LEDs is much higher than almost all other fixtures, leading to less number of fittings. This saves cost, makes installation/replacement easy. LEDs also have a very large lifetime and thus it means peace of mind for 6 years or more of continuous 24/7 operation (assuming 50000hr lifetime).Suitable location of factory areas are important, as was realized in Canteen area discussion, where it is clear that daylight can be used to our advantage to save electricity using dimmable fixtures. Finally it should be noted that all the products suggested here are from Philips. There are certainly other brands on the market with competitive solutions, but due to range and availability, Philips is chosen as the all-in-one brand.

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References
Bergin, T., 2010. Advantages of LED Lighting in Vision Inspection Systems, s.l.: Quadtech Inc.. CARLISLE SYNTEC INCORPORATED, 2013. CARLISLE SURE-FLEX REINFORCED PVC MEMBRANE, s.l.: CARLISLE SYNTEC INCORPORATED. CIBSE, 2013. Chartered Institution of Building Services Engineers. [Online] Available at: http://www.cibse.org/index.cfm?go=discuss.viewthread&item=1|42 [Accessed 6 4 2013]. Elite Renewables Service Limited, 2013. Lighting Illuminance Guidance | LED Lighting | Elite Renewables. [Online] Available at: http://www.eliterenewables.com/led-lighting/lux-lighting-values.php [Accessed 5 April 2013]. ERCO, 2013. ERCO Light Scout - Guide - Maintenance Factor. [Online] Available at: http://www.erco.com/guide/simulation-and-calculation-95/maintenance-factor2713/en/intro-1.php [Accessed 1 04 2013]. IDEC Corporation , 2011. LF1F_Datasheet. [Online] Available at: http://www.IDEC.com/usa [Accessed 27 03 2011]. IDEC Corporation, 2011. LFIF Datasheet, Sunnyvale: IDEC Corporation. IES, 2011. IES Footcandle Recommendations, s.l.: Illuminating Engineers Society. Philips Industrial, 2013. Philips - International Highbay Brochure, s.l.: Royal Philips Electronics. Philips, 2012. Philips - Industrial Lighting Presentation, s.l.: Royal Philips Electronics. Philips, K., 2013. Cleanroom - Philips. [Online] Available at: http://www.ecat.lighting.philips.com/l/indoor-luminaires/waterproof-andcleanroom/cleanroom/20883/cat/ [Accessed 1 April 2013]. Rener, B., 2011. Understanding cleanroom lighting - ElectroIQ. [Online] Available at: http://www.electroiq.com/articles/cr/print/volume-15/issue5/features/features/understanding-cleanroom-lighting.html [Accessed 5th April 2013].

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