Lighting Retrofit Project Case StudyOctober 2012, Sumner Distribution Center

Case Study Series

Executive Summary

The Mission Produce Lighting Retrofit Project was designed to implement all qualified LED solutions while realizing maximum financial savings for the client. 93% of the project was retrofitted with LED products while the 7% was replaced with better performing fluorescent technology. Rather than a high cost central control system, localized controls were implemented to maximize the energy savings. This project created 79% energy savings from the previous lighting design & achieved a superior lighting environment for all worker activities. Simple payback based on electricity alone is 1.4 years and if the additional savings from maintenance, tax deduction benefit & cooling load reduction are considered, the actual payback is expected to be within one year from the date of project completion.

Project IntroductionThere are three main parts to this project:

PART I: ! Refrigerated Warehouse - 48 units of 400W Metal Halide High Bays were ! ! ! ! replaced with 160W LED High Bay with localized controls.

PART II:! Office Area - Task Ambient Lighting Strategy was implemented to create energy saving while ! ! improving worker productivity in the office areas while restrooms and storage rooms ! ! were retrofitted with LED low bay fixtures with motion sensor. All fixtures were controlled with ! ! daylight harvesting, dimming, timers and/or occupancy sensors.

PART III:! Due to high humidity, the current T5HO vapor tight fixtures were left in place and relamped ! with low watt T5HO’s, maintaining light levels and increasing efficiency by approximately 10%.

! ! This case study doesn’t cover the T5HO installation.! !

Sumner Distribution Center

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PART II:Office Area

PART I:Refrigerated Warehouse

PART IIIRipe Rooms

1.0 Refrigerated Warehouse

Model 400W MH

Power Usage

*Refrigerated Space Interaction Factor(Where Applicable)

Total Power Per Unit

Number of Units

Color Rendering Index

455W

1.2

546W

48

65

Model LUNA 160

Power Usage

Controls Savings

Total Power Per Unit

Savings Per Unit

Number of Units

Color Rendering Index

160W

Average of 46%

86W

Up to 460W(84% Maximum)

48

83

Much of the light is lost before reaching the task area and lacks uniformity.

400W MH LUNA 160

Impressive uniformity with maximum illumination of work areas with minimal glare.

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1.1 Visual Observations After Retrofit

Quadrupled Light-level on Task Areas

Better Vertical Uniformity & Less Contrast

Glare-Free Optical Design

No-glass breakage concerns & no Mercury

Improved Color Rendering Index

Utility Rebate Eligibility Design Lights Consortium Qualified Product for maximum eligibility

IES Footcandle Recommendation Before retrofit light level was at 20 FC(Meets IES Recommendation for medium active application). After retrofit light levels are measured between 90 - 120 FC.

Productivity Improvement Higher efficiency is expected in all applications with superior lighting environment. Old lights had the restrike time of 15 minutes for employees to turn the lights on.

O&M Saving Controlled LED in a refrigerated environment is expected to last longer. For this application, 70,000+ hours/L70 expectation is projected.

EPACT 2005 Tax Benefit Eligible to receive commercial lighting tax deduction benefit.

No More 1000W Halogen Work Lights

Uniform Distribution on the Ground Level

Superior Heat Sink DesignMinimal heat creation to achieve dramatic cooling load reduction

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Every Lighting Fixture was integrated into a controls strategy for the Mission

LED Retrofit Project

1.2 Controls Integration

Zone based occupancy control was designed into the project by Rick Allen, who is the principal of Energywise. Since LUNA 160 was able to deliver twice as many footcandles than before with just half of the units turned on, Rick limited the auto-on feature to only 50% of the installed high bays in areas where coverage was appropriate. This strategy was applied to 46% of the fixtures and saved an additional 24% annual kWh. This still met the most aggressive IES recommendation for warehouse activities. However, since Mission Produce requires higher light level for certain activities, he wired the remaining units to a timer switch so the maximum usage of the lighting will be limited to applicable activities only.

“The significance of the Mission project is that all areas and all fixtures are effectively controlled using a variety of technologies and strategies to insure maximum energy efficiency without compromising employee safety and productivity” ! ! Rick Allen, Energywise

“Definitely better lighting for productivity, safety, cleaning & inspection.”

Zura Goodpaster, Distribution Center Manager

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Ambient Model GP300TK45W

Power Usage

Controls Savings

Actual Usage Per Unit

45W

30%

31.5W

Task Lighting Model TL-4300

Task Lighting Usage

Total Usage

Saving %

New LPD

Ambient Light Level

Task Lighting Level

8.5

40W

85%

0.23W/SF

Average of 25 FC

50 - 100FC

Model 3-F32T8

Power Per Unit

Number of Units

LPD

Total Usage Per Office

Controls

Task Lighting

Lighting Design Strategy

Glare Control

Ambient Light Level

90W

2

1.2 W/SF

180W

None

N/A

None

None

40 - 50 FC on Task Level across the whole area

180 WattsSerious Glare Issue

40 WattsErgonomic Lighting

2.0 OfficeAwarded by NGL 2012(www.ngldc.org), the first CCT tunable LED troffer, GP300TK45W and Commercial Energy Star Certified Prism TL-4300 implements the Task Ambient Lighting Strategy.

3-F32T8Prismatic Troffer

25FC60FC

50FC 50FC

*Each of the office area has different level of demand savings. Above comparison was made based on the task ambient lighting model that was implemented for the private office application.

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2.1 Visual Observations After Retrofit

Two 3L-F32T8 Troffers Replaced with One LED 2x2 Troffer

Photosensor controlled Ambient Lighting for Lobby with Daylight

50-100FC Task Lighting is Provided by TL-4300

Utility Rebate Eligibility Energy Star & DLC Qualified Product for maximum eligibility

IES Footcandle Recommendation Meets the code with superior user experience

Productivity Improvement Higher efficiency is expected in all applications with superior lighting quality

O&M Saving No maintenance is expected over next 10 years(5 Year Warranty).

EPACT 2005 Tax Benefit Eligible to receive commercial lighting tax deduction benefit.

3000K 4000K 5000K

Multiple Custom Mood Settings for Conference Rooms

25FC Ambience at Task Level Minimizes Glare on Monitor Screens

User friendly touch control panel for CCT tuning & dimming

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3.0 Restroom3 restrooms were retrofitted with A2W4-0445 and wall mounted occupancy control unit.

Utility Rebate Eligibility Energy Star & DLC Qualified Product for maximum eligibility on LED solutions.

IES Footcandle Recommendation Meets the code with superior user experience

O&M Saving No maintenance is expected over next 15+years on LED applications(5 Year Warranty).

EPACT 2005 Tax Benefit Qualified under the building area method.

Model 2-F32T8

Power Usage

Controls

Total Power Per Unit

Number of Units

Color Rendering Index

CCT

59W

None

59W

3

80

3500K

Model A2W4-0445

Power Usage

Controls Savings

Total Power Per Unit

Savings Per Unit

Number of Units

Color Rendering Index

CCT

46W

30%

32W

27W

3

86

4500K

2-F32T8 1x4 Wraparound A2W4-0445

Surface mounted A2W4-0445 brings crisp illumination with instant on feature

Chain or pendant mounting options are also available for utility lighting applications.

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Project Analysis

Simple Payback Based on Energy Savings

Overall Energy Savings

Estimated Annual Energy Savings

Applied Rebate Program

EPACT 2005 Commercial Lighting Tax Deduction

Lighting Design Strategy

Product Qualification Standard

Ergonomic Lighting Improvement

1.4 Years(After Utility Rebate)

79% Energy Saving

147,982 kWh/yr

PSE Enhanced Lighting Program

Eligible to receive commercial lighting tax deduction benefit

Task Ambient Lighting Strategy, Zone Based Occupancy Controls Strategy

Energy Star, Design Lights Consortium & Lighting Facts

Greater efficiency and visual comfort have been reported by the employees

Special Thanks to:

Project Management Team:

Project Manager

Strategic Solutions Manager

Mission Distribution Center Manager

Partner Relationship Manager

PSE Engineer

Rick Allen, Energywise

Ryan Kim, PLANLED

Zura Goodpaster, Mission Produce

David Kim, PLANLED

Corey Corbett, PSE

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