Induction Lighting

[jdsmith]

I have a project coming up to replace all of the lighting in a couple refinery process units. Most of the fixtures are mercury vapor with a few high pressure sodium thrown in where the mercury vapor have failed already. I'm almost certain we can justify going with induction fixtures based on the 75% reduction in maintenance costs - 100,000 hour life with induction vs. 24,000 hour with HPS.

The replacement for a 100W HPS or mercury vapor fixture is supposed to be an 85W induction according to the Crouse-Hinds catalog. The light output from the induction fixture diminishes to 70% of max over the 11 year life. Since there's no maintenance over that period, we're wondering if that decay combined with globes not being cleaned for 11 years will result in insufficient light output towards the end of their lifespan. On the other hand, since the CRI of induction is higher than HPS, does this counter that effect?

I counted the fixtures in one unit tonight and it had 140, so we're probably looking at 450 or so all together. I'd like to hear any other experience or wisdom anyone has with these induction fixtures too since they're new to me.

 

[gar]

080424-0838 EST

I looked at the following site to find out what an "induction fixture" was, although I had guessed what it was. Just after WWII when the 2 meter ham band became available I demonstrated the characteristic of a beam antenna by moving a fluorescent lamp in its path and showing the intensity variation.

http://inductionlighting.blogspot.com/

You have a number of good questions and I can not give you any specific information.

In reading the blogspot I noticed that the "induction lamp" efficiency was not quite as good as T5.

While induction lamps can generate more lumens per watt compared to metal halides (80 v. 70), it is not as efficient as T5?s that powers 100+ lumens per watt.

The cleaning (dirt accumulation) problem would seem to be a major consideration. What is its cost? Next after this the value of the 100 vs 80 limens/watt. It appears the T5 would consume 20% less energy.

I know that Dana Corp. is looking at replacing all current lights in the production areas with T5s to reduce energy consumption. This is probably several million square feet.

.

 

[Az Streetlights]

Induction lighting thoughts

Induction lighting thoughts

jdsmith
In AZ , in Mesa specifically we are testing some induction lighting as well as LED's. As for Roadway purposes, neither can match HPS. We installed one induction light in the middle of some 100 W HPS full cut-off luminaires (full cut -off are required in our state due to the night sky bill passed in 1989 for the astronomers) and while the CRI index is higher, overall luminence is less, and there is a definite dark spot in the roadway.
Witht that being said, I believe induction lighting is a great light source for hard to reach areas due to the long life of the the lamps. However, in a refinery setting you will probebly have a huge Light Loss Factor (LLF) due to contaminents, causing Luminare Dirt Depreciation (LLD). Regular cleaning will be necessary. LLD would aslo be a problem for an HPS luminare as well.
I still believe, and it has been my experience, that HPS luminaires are still hard to beat/match at this time for overall costs, longevity, and lumens per watt.
my $.02 worth
AZ Streetlights

 

[weressl]

I have a project coming up to replace all of the lighting in a couple refinery process units. Most of the fixtures are mercury vapor with a few high pressure sodium thrown in where the mercury vapor have failed already. I'm almost certain we can justify going with induction fixtures based on the 75% reduction in maintenance costs - 100,000 hour life with induction vs. 24,000 hour with HPS.

The replacement for a 100W HPS or mercury vapor fixture is supposed to be an 85W induction according to the Crouse-Hinds catalog. The light output from the induction fixture diminishes to 70% of max over the 11 year life. Since there's no maintenance over that period, we're wondering if that decay combined with globes not being cleaned for 11 years will result in insufficient light output towards the end of their lifespan. On the other hand, since the CRI of induction is higher than HPS, does this counter that effect?

I counted the fixtures in one unit tonight and it had 140, so we're probably looking at 450 or so all together. I'd like to hear any other experience or wisdom anyone has with these induction fixtures too since they're new to me.

We have installed replacement induction lights in place of HPS and old incandescent units. The primary justification was reduced maintenance cost.

Couple of points in addition to your already thoughful consdierations.

Induction lights have a much lower T rating that other units with the same light output, with the possible exception of fluorescent units.
There are now several manufacturers of induction light fixtures listed for hazardous locations, so you can make them fight for it.

There are now 160W units available so you can perhaps replace one fixture for two if your spacing and mounting elevation of the existing fixtures allow it. (Often low wattage HPS's were specified because the T rating, not because the light output.)

Buy GLASS optic hardware instead of plastic, it will hold up better on the long run against dirt. Consider periodic pressure wash cleaning, perhaps one in the lifecycle of the fixtures.

General consideration for all lighting jobs:

Group relamping and changing/cleaning the glassware is the most cost effective way of maintaining your lighting fixtures.

If your fixtures are controlled by a photocell consider installing a simple 6 digit elapsed hour-counter on it and do group replacement at 85-90% of life.

Remember that ballast have a finite life also, I am not certain but I have seen number in the 50000hr. range. That would mean, in the case of HPS for example, that at every second or third lamp change you need to change your ballast too.

 

[jatrottpe]

Be careful when looking at different manufacturers T-ratings, as some utilize Restricted Breathing options to achieve the lower T-ratings. (Crouse-Hinds). I know some facilities do not allow restricted breathing fitttings. Crouse-Hinds and Appleton make similar induction fixtures. The 55W Induction replaces the 70W HPS, The 85W Induction replaces the 100W HPS.

 

[weressl]

Be careful when looking at different manufacturers T-ratings, as some utilize Restricted Breathing options to achieve the lower T-ratings. (Crouse-Hinds). I know some facilities do not allow restricted breathing fitttings. Crouse-Hinds and Appleton make similar induction fixtures. The 55W Induction replaces the 70W HPS, The 85W Induction replaces the 100W HPS.

True, but the restricted breathing application provides a lower rating than the normal rating of the fixture. To be more specific; the fixture has two temperature ratings, one for ordinary installation and another where the restricted breathing provision is added. I think that the induction lighting is a great leap for the industries where area classifications limit the temperature.

The restricted breathing should also aid in limiting the entry of dirt, therefore preserving the inside clarity of their optics so you can hose the fixture down from the outside to restore large amount of the light output when they get dirty.

Also note that there is a now 165W induction unit available.

 

[jatrottpe]

Weressl
I do not disagree with your assesment of the induction lights and restricted breathing.

On Crouse HPS fixtures (Champ), if you order them with restricted breathing, they are only labeled for Zone 2. I have been asking them for documentation stating it is labeled for Division 2 and they have only provided me with copies of the tests. All documentation provided by them state the fixture is labeled for Zone 2. (For clarification their induction light is labeled for Division 2 with restricted breathing.) I have come across a few sites who do not yet accept restricted breathing. Therfore I was pointing out that in a refinery application where you typically need T3 ratings due to Heptane, the Crouse fixture without restricted breathing does not meet this temperature classification.

 

[bobgorno]

Weressl
....they are only labeled for Zone 2.

501.5 Zone Equipment. Equipment listed and marked in
accordance with 505.9(C)(2) for use in Class I, Zone 0, 1,
or 2 locations shall be permitted in Class I, Division 2
locations for the same gas and with a suitable temperature
class. Equipment listed and marked in accordance with
505.9(C)(2) for use in Class I, Zone 0 locations shall be
permitted in Class I, Division 1 or Division 2 locations for
the same gas and with a suitable temperature class.

 

[jdsmith]

Just a quick update on the status of my lighting project and what I've found out so far. I ended up with a total of 1800 lights all together! It's hard to believe there are really that many when you look out into the plant at night, but that's how many I found.

Looking at the light output, both the 85W and 165W induction light outputs diminish by the same number of lumens throughout their life. The 165W starts at 12,000 lumens and after 100,000 hours it's down to 8,000 lumens. The 85W fixture starts at 6,000 lumens and diminishes to 2,000 lumens after 100,000 hours. This doesn't make much sense to me, but that's what the manufacturer provided. 100W high pressure sodium lamps start at about 9,500 lumens and diminish to 8,000 after 24,000 hours. I checked on how ofter HPS ballasts are changed and I found out that almost every time a lamp is changed the ballast is changed as well, primarily because the lamp failed a month before the electrician came to change it and by that time the ballast had burnt up. I'm not sure if process isn't reporting lamp failures very quickly or the electricians don't get them changed quickly, but I'm assuming both of these are a factor. Either way it increases the total cost of ownership of the HPS fixture.

One thing I still need to figure out is what OSHA or other regulations govern lighting levels in the process units. I found a specification from when the unit was built on how many foot-candles should illuminate different areas and surfaces, but it doesn't indicate that it was taken from a regulatory standard or if it is just good design practice. I imagine somebody will tell me to buy an IES handbook, but I need to budget for that for a while:smile:.

Where I've ended up is that 85W induction will not be as much light output as the 100W mercury vapor originally installed, which means I won't meet the lighting level specs I found even when the fixtures are initially installed. I would meet the specs for the entire life of the HPS fixture or the entire life of the 165W induction fixture. We bid the fixtures a couple weeks ago and got a price of just under $200 each for 100W HPS fixtures. The 85W induction is around $450, and the 165W induction just above $500.

We're waiting on bids from contractors now for changing out the fixtures. At this point it looks like 165W induction is the way to go even though we'll have to rewire some 20A circuits into 30A or split them up if we have the panel space. Part of the contractors scope is to take load measurements of each circuit and panel to figure out how much we'll have to rewire.

I should probably mention the T-ratings as well:
85W induction Crouse-Hinds is T2D, can add restricted breathing option at no cost to get T6.
165W induction Crouse-Hinds is T3.
100W HPS Crouse-Hinds is T2A, can add restricted breathing at no cost to get to T3.
85W Appleton induction is T3A.
165W Appleton induction is T2B.
100W Appleton HPS is T2D.

I did verify that we have three or four substances that put us into the T3 range. I haven't heard back from Appleton on whether they can provide an independent T3 rating on their fixtures. Whoever we buy fixtures from will need to provide a UL or other independent evaluation of the temperature rating because I keep hearing stories or manufacturers being less than honest on their temp ratings. I also heard that a unnamed refinery recently got an OSHA writeup for having metal halide fixtures installed that aren't T3 rated. Considering OSHA will be in our plant in the next 6 months we clearly need to worry about it.

 

[Induction Junction]

Induction Lighting

Induction lighting is a great light source. We are currently working on a project where we are retrofitting existing hazardous location rated fixtures to 120 watt induction fixtures. I have pictures if anyone is interested. We also jus completed a outside car dealership retrofitting 1,000 watt flood fixture to become 340 watt induction fixtures. The light output is great and the customer is happy. The customer is saving about $14,000 dollars per year with 50 fixtures. This doesnt include the saving generated from not having to change lamps. Induction lamps outlast Metal Halide 5 to 1. I would keep an eye on Induction i think its the best technology out there right now.

 

[Induction Junction]

Unappreciated

Unappreciated

Moderators note;
This was a reply to a post that was removed and therefor made no sense.

 

[tom baker]

Couple of more comments
Pro-Induction lighting is instant to 80% of initial lumens. Great for power outages or security lighting.
Very high CRI, studies show, but not in lighting standards yet, that the with the white light you don't need as high a lumens as HPS.
Con- Lamps are not standard, are wired in and not screwed in.
Fixture availability is limited.

The lamp may outlast the ballast!

But for a tought to lamp location they are perfect. And go with glass.

Tom
IES member, on IES Roadway Lighting Committee

 

[jdsmith]

Induction lighting is a great light source. We are currently working on a project where we are retrofitting existing hazardous location rated fixtures to 120 watt induction fixtures. I have pictures if anyone is interested. We also just completed an outside car dealership retrofitting 1,000 watt flood fixture to become 340 watt induction fixtures. The light output is great and the customer is happy. The customer is saving about $14,000 dollars per year with 50 fixtures. This doesnt include the saving generated from not having to change lamps. Induction lamps outlast Metal Halide 5 to 1. I would keep an eye on Induction i think its the best technology out there right now.

What are these 120W and 340W fixtures? Are those size generators made by Phillips or do you have your own? Feel free to PM me your product information if you like since you shouldn't post it here. I would be interested in hearing about induction fixtures larger than 165W and other manufacturers of hazardous location fixtures that can meet T3 without restricted breathing. I've already talked with Appleton and Crouse-Hinds.

 

[jdsmith]

Couple of more comments
Pro-Induction lighting is instant to 80% of initial lumens. Great for power outages or security lighting.
Very high CRI, studies show, but not in lighting standards yet, that the with the white light you don't need as high a lumens as HPS.
Con- Lamps are not standard, are wired in and not screwed in.
Fixture availability is limited.

The lamp may outlast the ballast!

But for a tought to lamp location they are perfect. And go with glass.

Tom
IES member, on IES Roadway Lighting Committee

Could you elaborate on the comment about non-standard lamps that are wired in? I have a couple 85W demo units and the glass globe part is bayonet mounted. Are you referring to the post inside the globe? Do the post and globe both get changed on relamping?