Harlan Labs- Hillcrest Lighting Audit

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Harlan Labs- Hillcrest Lighting Audit
NAME: Mir Ali
Date: July 2012
Project No. 12027
Rev R1

Harlan Labs- Hillcrest Lighting Audit

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1 Contents
1.1 Executive Summary .................................................................................................................... 3
1.2 Current Situation ......................................................................................................................... 4
1.3 LED Proposal ................................................................................................................................. 4
1.4 Office / Admin areas (Buildings 4, 20A, 22) ..................................................................... 5
1.5 Barrier / Production areas and Labs ................................................................................... 7
Intelligent Lighting Controls ............................................................................................................... 9
1.6 Maintenance Savings .............................................................................................................. 10
1.7 Conclusions: ............................................................................................................................... 10


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1.1 Executive Summary

Harlan Labs, Hillcrest had advised EECO2 to review the existing lighting at site and come up with a
proposal for upgrading the existing T5/ T8 Fluorescent light fittings to new energy efficient fittings in
recognition of increased policy compliance legislation, operational cost optimisation and a continuing
business driver to deliver improved building operational performance.

This Follows the European ban of certain types of incandescent light bulbs; fluorescent tube lighting has
now come under review. Standard T8 fluorescent tubes are being phased out, with production being
halted and the importation of them being banned as part of the EUs Energy-Related Product (ErP)
Directive designed to reduce CO2 emissions across Europe.

Harlan Labs, Hillcrest have initiated this study in order to review the efficacy of the existing lighting
system with a view to make a strategic investment to comply with current / future legislation and also to
reduce energy consumption at site.

The entire site was surveyed in order to review the lighting installation at site, access to the barriers was
made available and have been included in the assessment. It was noted that the site had been proactively
changing the existing T8 light fittings to T5 light fittings in order to conserve energy. Access was not made
available in the clean area Buildings 20, 27, 32 due to cross contamination issues and has not been
included in this assessment.

Lighting at site have been divided into two areas namely the production areas where lighting is on 18
hours (tracks kept on during night) and the Office / Admin areas which follow an 8-6 working 7 days a
week to ensure production. As drawings for the site were unavailable, we have not been able to carry out
a dialux calculation of the areas, we have looked at carrying out a retrofit by replacing the existing 5ft T5
and T8 twins and other assortment of light fittings at site to be replaced with energy efficient LED light
fittings, while this might provide a rudimentary assessment, it is recommended that a detailed lighting
design be carried out in order to evaluate the best light fitting suitable for the area, it is likely to result in
additional energy savings.

Based on the calculations it would appear that there is an energy reduction figure of a 60 % reduction in
lighting energy due to conversion from fluorescent / down lighters light fittings to LED lighting, this when
coupled with intelligent PIR and daylight dimming controls would result in energy savings in excess of 70-
75% from the current consumption with a payback about 2.5 years.

While reviewing the lighting for the barriers, which are primarily switched on to ensure adequacy of
lighting for animal welfare. There is an energy reduction figure of a 60 % reduction in lighting energy due
to conversion from fluorescent light fittings to LED lighting, this when coupled with intelligent PIR and
daylight dimming controls would result in energy savings in excess of 70-75% from the current
consumption with a payback of less than 1.5 years.

Energy Efficient lighting also reduce the amount of internal gains thereby reducing cooling energy at site.
The site is looking at adding cooling in order to meet regulatory compliance, this lighting upgrade would
Harlan Labs- Hillcrest Lighting Audit

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result in reducing the size of the proposed new cooling plant, thereby reducing initial CAPEX needed
including reduced operational costs.

Lighting energy accounts for a large part of the electrical energy at site, hence any savings made would
have a bearing on the site electrical consumption. Lighting at site accounts for approximately, 542, 000
KWHr / year which accounts for about 20% of the site electricity consumption, savings of 70% can be
achieved using low energy LED lighting along with daylight dimming and PIR controls.

The assessment is based on a retrofit due to lack of drawings at site, we would recommend that a proper
Dialux calculation be carried out in order to properly design the lighting system at site which would
require lesser light fittings than assessed resulting in increased energy savings and improved payback
periods.


1.2 Current Situation

The client had advised us to carry out a lighting survey for the site, during the survey it was noted that the
Light fittings at site consists of predominantly T5 Lighting for the barriers and 4X18 W for the isolator
areas, while the Office and Admin areas had a combination of T5 light fittings and 4X18 Watt 600X 600
light fittings in the corridors and offices with a manual light switching system providing lighting to the
Offices and barriers.
A Lux measurement at site showed that lighting in some offices meets the CIBSE minimum recommended
Lux levels in Offices is 300-550 Lux. Some offices had Lux levels in excess of 700 Lux resulting in excessive
glare, it was noted that natural day lighting is not being managed properly with no means of saving
energy due to beneficial day lighting. Lux measurements were carried out in the barrier offices, stores and
barriers which were between 450-700 Lux.

1.3 LED Proposal

Due to the recent change in legislation following the European ban of certain types of incandescent light
bulbs. Standard T8 fluorescent tubes are being phased out, with production being halted and the
importation of them being banned as part of the EUs Energy-Related Product (ErP) Directive designed to
reduce CO2 emissions across Europe.

A desktop exercise was carried out to carry out a retrofit to replace the T5 light fittings with Ultra low
energy LED light fittings (30w). A Dialux program could not be carried out due to lack of scaled site
drawings. LED lighting are increasing being used in animal care facilities, cleanroom environment with
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good results, and are in fact desirable due to reduced mean time between failure (MTBF) and reduced
maintenance requirement.
The site has been divided into the Office areas and the production areas based on hours of working.
Office areas have been calculated based on an 8-6 PM operation while the barriers have been calculated
at 18 hours.
1.4 Office / Admin areas (Buildings 4, 20A, 22)

We have conservatively estimated that the T5 lighting at site are the High Efficiency Lighting, the
higher output range have in some cases an energy consumption of more than double of the High
efficiency range.
Energy consumed by current lights
Individual Lights Quantity Watts Total W Per Hour
600x600 panels 27 86 2322
T5 5ft 99 35 3465


Total 5787

Energy Consumed by new Efficient LED Lights
Light Type Quantity Watts Total W Per Hour
LED Panels 27 30 810
LED T5 5ft 99 15 1485


Total

2295

Reduction in Lighting Energy: 60%
Lighting Energy savings
Day Monday Tuesday Wednesday Thursday Friday Saturday Sunday Total
Hours 10 10 10 10 10 10 10 70
Hours
Per
Annum 3,650

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Electricity prices based on 12.5p / KWHr

Year Year 1 Year 2 Year 3 Year 4 Year 5
Percentage Change 0.03% 0.03% 0.03% 0.03%
Price per KWh 0.125 0.1287 0.1326 0.1367 0.1406

Electricity prices based on 12.5p / KWHr, with a year on inflation of 3% have been used in the assessment.
Cash Flow Analysis:
Cash Flow (annual) Year 1 Year 2 Year 3 Year 4 Year 5
Initial Investment (Minus) 8,235.00 -3,748.85 -1,024.22 1,752.10 4,581.66
Cooling Savings (Add) 796.56 796.56 796.56 796.56 796.56
Energy Savings (Add) 1,593.23 1,641.02 1,690.25 1,740.96 1,793.19
Maintenance Savings
(Add)
205.00 205.00 205.00 205.00 205.00
Sensor Saving 79.66 82.05 84.51 87.04 89.65
*ECA Saving (Add) 1,811.70 - - - -
Cash Flow Analysis 3,748.85 -1,024.22 1,752.10 4,581.66 7,466.06

* Enhanced Capital Allowance is a cash flow benefit

1 2 3 4 5
Cash Flow Analysis -3,748.85 -1,024.22 1,752.10 4,581.66 7,466.06
-6,000.00
-4,000.00
-2,000.00
0.00
2,000.00
4,000.00
6,000.00
8,000.00
10,000.00
Cash Flow Analysis
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Return on Investment / Payback period: Payback period of 2.5 years. By incorporating
intelligent lighting controls with PIR sensors and daylight dimming, this could be reduced to 2 year period.
1.5 Barrier / Production areas and Labs

We have conservatively estimated that the T5 lighting at site are the High Efficiency Lighting, the higher
output range have in some cases an energy consumption of more than double of the High efficiency
range. Access to clean area buildings 20,27,32 was not made available and has not been included in this
assessment.
Energy consumed by current lights
Individual Lights Quantity Watts Total W Per Hour
T8 5ft 160 58 9280
T8 6ft 36 70 2520
T5 2ft 4 14 56
T5 4ft 8 28 224
T5 5ft 699 35 24465
T5 6ft 421 42 17682
600x600 Panel 231 86 19866
CFL down lights 147 36 5292


Total 79385

Energy Consumed by new Efficient LED Lights
Light Type Quantity Watts Total W Per Hour
Pebble LED T8 5ft 160 20 3200
Pebble LED T8 6ft 36 25 900
Pebble LED T5 2ft 4 7 28
Pebble LED T5 4ft 8 13 104
Pebble LED T5 5ft 699 15 10485
Pebble LED T5 6ft 421 18 7578
Pebble 600x600 LED Panel 231 30 6930
Pebble LED round Panel 147 15 2205

Total

31430
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Reduction in Lighting Energy = 60%
Lighting Energy savings
Day Monday Tuesday Wednesday Thursday Friday Saturday Sunday Total
Hours 18 18 18 18 18 18 18 126
Hours Per Annum 6,552

Electricity prices based on 12.5p / KWHr
Year Year 1 Year 2 Year 3 Year 4 Year 5
Percentage Change 0.03% 0.03% 0.03% 0.03%
Price per KWh 0.125 0.1287 0.1326 0.1367 0.1406

Electricity prices based on 12.5p / KWHr, with a year on inflation of 3% have been used in the assessment.

Cash Flow Analysis:
Cash Flow (annual) Year 1 Year 2 Year 3 Year 4 Year 5
Initial Investment (Minus) 105,475.00 -18,974.81 45,561.45 111,375.49 178,505.65
Cooling Savings (Add) 19,691.50 19,691.50 19,691.50 19,691.50 19,691.50
Energy Savings (Add) 39,383.04 40,564.54 41,781.47 43,034.92 44,325.97
Maintenance Savings
(Add)
2,252.00 2,252.00 2,252.00 2,252.00 2,252.00
Sensor Saving 1,969.15 2,028.22 2,089.07 2,151.74 2,216.29
*ECA Saving (Add) 23,204.50 - - - -
Cash Flow -18,974.81 45,561.45 111,375.49 178,505.65 246,991.41

* Enhanced Capital Allowance is a cash flow benefit

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Return on Investment / Payback period: Payback period of 1.5 years. By incorporating
intelligent lighting controls with PIR sensors and daylight dimming, this could be reduced to about 1 year.
Note: This assessment is based on a like for like retrofit; we have not been able to procure any site
drawings to allow us to carry out a dialux calculation. We would advise that a full design be carried out as
part of the lighting upgrade project in order to fully evaluate the best light fitting to suit the application,
which could result in fewer light fittings and lesser energy consumption. Access to buildings 20,27,32 was
not made available due to cross contamination issues, these have not been included in the assessment.
Intelligent Lighting Controls

Energy Efficient Lighting can provide up to 60% reduction in lighting energy consumption, incorporating
energy efficient lighting controls can improve it further to up to 40-45% reduction in electrical lighting
energy consumption. This also has an added effect of reducing internal gains of the building thereby
reducing the demand for cooling. As these areas have cooling, they can benefit from reduced cooling
demands.
It has been noted that traditionally heating systems have always been over designed, sensible gains
through lighting have traditionally been ignored whereas cooling has always been considered at a
premium. Heating loss due to energy efficient lighting has thus not been considered in our assessment.
it is beneficial to reduce internal gains as it helps provide spare cooling capacity for future proofing where
additional equipment can be added hence have been considered in the assessment.
1 2 3 4 5
Cash Flow Analysis -18,974.81 45,561.45 111,375.49 178,505.65 246,991.41
-50,000.00
0.00
50,000.00
100,000.00
150,000.00
200,000.00
250,000.00
300,000.00
Cash Flow Analysis
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1.6 Maintenance Savings

The maintenance savings are based upon the MTBF of the existing lights versus the new LED lights. Our
calculations show a maintenance saving of 2,457 per annum for the whole site although it is believed to
be a pessimistic view.

1.7 Conclusions:

The current lighting system meets the CIBSE LG 7 criteria of 300-500 Lux for office based tasks. In order to
keep up with upcoming legislation, it is recommended that the existing T8/ T5 light fittings be replaced
with LED light fittings, this would result in a substantial reduction in energy consumption with added
benefits in reduced maintenance due to higher lives of these light fittings and reduction in cooling
demand due to lower sensible gains due to lighting. As the site is currently looking at adding cooling to
meet regulatory compliance, incorporating LED lighting would assist in lowering the cooling capacity
needed at site, hence reducing initial CAPEX required for the cooling plant.
This would result in an energy reduction figure of a 60 % reduction in lighting energy due to conversion
from fluorescent lighting to LED lighting, when coupled with intelligent PIR and daylight dimming controls
would result in energy savings in excess of 70-75% from the current consumption.