meea industrial webinar: industrial load reduction: the role of intelligent leds in an energy...
DESCRIPTION
C&I customers represent a substantial opportunity for load reduction, but the key is to incentivize projects with excellent performance, economics, and impact. Intelligent LED systems are redefining the lighting category and displacing legacy technologies with proven results. The webinar, presented by Michael Feinstein from Digital Lumens, will cover the following topics: • Industrial lighting technology review • Intelligent LED System overview • 90% energy reduction – the economics of intelligent LEDs • Large C&I lighting customers – retrofit & new construction case studies • Future of intelligent LED lighting Mike Feinstein is responsible for leading the Digital Lumens sales and marketing teams and has had extensive experience in the entrepreneurial and investment worlds, most recently as Managing Director of Sempre Management. Previously, he was a General Partner at Venrock Associates and Atlas Venture, where he served on the boards of start-ups including Boston-Power, Ciclon Semiconductor (acquired by Texas Instruments), CircleLending, WaveSmith Networks (acquired by CIENA Corp.) and Quantum Bridge Communications (acquired by Motorola). Michael holds a B.S. in Electrical Engineering and Computer Science from MIT. This presentation is part of the Midwest Energy Efficiency Alliance Industrial Webinar Series. Find out more at http://www.midwestindustrial.org.TRANSCRIPT
MEEA’s Midwest Industrial Initiative
Webinar:
Industrial Load Reduction: The
Role of Intelligent LEDs in an
Energy Efficiency Portfolio
February 28, 2013
11:00AM-12:00PM CST
MEEA’s Role in the Midwest • Non-profit serving 13 Midwest states
• 10+ years serving state energy offices, utilities, ESCOs, state and local government, manufacturers
• 150+ Members
• Staff of 25 in Chicago
• Actions – Advancing Energy Efficiency Policy
– Promoting Best Practices
– Delivering Training & Workshops
– Coordinating Multi-Utility Program Efforts
– Designing & Administering Energy Efficiency Programs
– Evaluating & Promoting Emerging Technologies
– Regional Voice for DOE/EPA & ENERGY STAR
Midwest Industrial Initiative (MI2)
In Fall 2010, MEEA has created the MI2 in order to: • Promote adoption of energy efficiency in the industrial sector
• Provide information on electric and natural gas utility energy
efficiency rebates and programs
• List national and local energy efficiency best practices and
technology information
• Offer catalog of case studies of successful energy efficiency
implementation
www.midwestindustrial.org
www.midwestindustrial.org
• Dedicated website on Industrial Efficiency
in the Midwest
– Utility, state and local case studies
– Catalogue of utility industrial contacts
– Utility programs
– Industrial opt out and self direct policies
– EIA data by state and fuel
• Social media presence
– www.twitter.com/industrialEE
MI2 Activities
• Quarterly regional utility calls
• Midwest presence for SEEAction Industrial working
group and CHP group
• Developing Midwest CHP working group
• MI2 to be conduit of efficiency information to
industrial companies and industrial associations
• Promote successful efficiency programs,
technologies and financing mechanisms
MI2 Upcoming Webinars
• Mitsubishi – review of manufacturing
facility improvements
• Baltimore Gas & Electric – CHP as part of
cost effective efficiency program
• Schneider Electric – Energy reduction
efforts
• Dates Forthcoming…
Reminders for Today’s Webinar
• Submit questions in the chat box in the
right panel
• Q&A will take place after the presentation
is complete
• Presentation will be available on
http://www.midwestindustrial.org/resources
/webinars
MEEA Staff Contacts
• Jay Wrobel, Executive Director
• Stacey Paradis, Deputy Director
• Chelsea Lamar, Senior Program Associate
• Rick Holmes, Senior Advisor, Industrial Initiatives,
Industrial Load Reduction The Role of Intelligent LEDs in an Energy Efficiency Program
Midwest Energy Efficiency Alliance | Midwest Industrial Initiative
© 2013 Digital Lumens
Agenda
• Industrial lighting technology review
• Intelligent LED System overview
• 90% energy reduction – the economics of intelligent LEDs
• Large C&I customers
• Retrofit & new construction case studies
• Future of intelligent LED lighting
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Legacy Industrial Lighting
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HID (MH & HPS)
• Highest operating cost
• Significant heat output increases HVAC load
• 2-year relamping
• Contains mercury and lead – difficult/costly disposal
• No ON/OFF cycling capability
Fluorescent T12
• Does not fully illuminate when first turned on
• Re-lamping/reballasting
• Minimal ON/OFF cycling
• Contains mercury – difficult/costly disposal
Current Industrial Lighting
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Fluorescent T8 & T5HO
• More efficient than T12 predecessor, however many issues
remain:
• Poor initial illumination, re-lamping/reballasting, minimal
ON/OFF cycling, contains mercury – difficult/costly disposal
• T5HO poor performance in cold temperatures
Plain LEDs
• More efficient than fluorescent alternatives
Intelligent LED System
• Most efficient
• Includes fully integrated features that maximize efficiency
Legacy Fixtures Current Options
HID T12 6LT8 6LT5HO
LEDs
w/sensor
s
Intelligent
LEDs
Wattage 450 250 300 350 155 155
Annual
energy cost $39,420 $21,900 $26,280 $30,660 $6,789 $2,716
Annual
maintenance $10,000 $6,500 $6,000 $6,000 $0 $0
Upfront
project cost N/A N/A $$ $$$ $$$$ $$$$
10 yr energy
consumption
(kWh)
394,200 219,000 262,800 306,600 67,890 27,156
10 yr TCO $494,200 $284,000 $336,800 $380,600 $137,890 $106,656 Table assumptions
• $0.10/kWh
• 100 fixtures
• 8,760 hours/year operation
Energy Consumption Comparison
• Includes wattage for ballasts for HID, T12, T8 & T5
• 10 year TCO figures for Retrofit Options include upfront project costs
• 10 year TCO figures for Current Fixtures HID & T12 do not include upfront project costs
• Strong LED lighting, networking, and software experience
• Award-winning company and technology
• Integrates LED-based luminaires with built-in controls & intelligence
• Reduces lighting energy use by up to 90%
• Optimized for rugged industrial environments
• Lowest total cost of ownership (TCO)
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Leading the Way in Intelligent Lighting
Intelligent Lighting Drives Maximum Savings
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Networked Together Centrally Managed Smart Lights
The Complete Solution
100% of the light for 10% of the energy
• Reduced wattage
• Fully integrated:
• Sensing
• Dimming
• Daylight harvesting
• Local intelligence
• Central control
• Great light quality
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Intelligent fixtures to address each facility’s unique
needs
ILE-3-18
• 18,000 lumens
• 215W
• 26,000 lumens
• 325W
ILE-3-26
• Up to 50’ mounting height
• Three independently rotatable LED
light bars
• Integrated occupancy sensors
• Integrated daylight harvesting
• Wide or narrow optics options
• Onboard intelligence to manage fixture
behavior
• Wirelessly connected to LightRulesTM
management software
• 107,000 hour lifetime rating
• 5 year warranty
ALL
FIXTURES
FEATURE:
ILE-3-13
• 13,000 lumens
• 155W
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• Occupancy sensors designed
and manufactured by Digital
Lumens
• Fully integrated into each fixture
• Each sensing package features
three infrared sensors
• Higher ceiling heights
• Improved performance
• Dimming, also integrated into
each fixture, can be
programmed from 0-100%
High Performance Occupancy Sensing & Dimming
Facility occupancy map
Average Industrial Occupancy Rates
Data pulled from 40 Digital Lumens customer sites:
• Cold storage 15%
• Dock 40%
• Dry storage 30%
• Manufacturing 35%
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Effect of Occupancy Sensor Settings on Energy
Consumption
Occupancy Sensor Log Data
4:30pm 5:30pm
Sensor
Delay
% “Active” ILE Energy
Cost*
(155W)
HIF Energy Cost*
@ 15 mins (220W)
30 sec 25.2 % $35 / yr $190
60 sec 40.8 % $57 $190
90 sec 52.4 % $73 $190
3 min 72.5 % $102 $190
5 min 89.3 % $125 $190
10 min 98.6 % $138 $190
* 10¢ /kWh
Based on 25% occupancy
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• Automatically assesses available ambient and adjusts light output
accordingly to illuminate area with target light level
• Photo sensors fully integrated into each fixture
• Depending on available ambient light, reduces lighting use by an
additional 25-50%
• Consistent light quality throughout the space
Daylight Harvesting
• Active levels
• Inactive levels
• Occupancy sensor
timeouts
LightRulesTM Control Software
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• Energy consumption
• Energy costs
• Energy savings
• Facility occupancy
• Daylight harvesting
• What-if analysis
Control Report
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Control, Edit & Report
Dashboard Scheduling
Occupancy Map Facility Map Energy Reports
Profile Management
• Customize lighting profiles by zone,
e.g.:
• Loading docks
• Frozen storage
• Ambient storage
• Minimize lighting energy costs while
maximizing operator efficiency & safety
• Automated or manual control
• Full system flexibility
• Interoperability & API
• Managed lighting = managed costs
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Customized Lighting
Intelligent Lighting System Savings Summary
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Intelligence
LED power
reduction
(watts)
Incentives
Fine-tuning
HVAC & chiller
load reduction
Maintenance
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Tested & Proven
• Robust design
• Rugged and integrated technology
• Tested, certified, listed, and labeled
• UL, CE/CB, DOE, Lighting Facts, DLC, NEMA IP Rating, LM79, LM80
• Outstanding support
• 5-year warranty
• Backed by world-class lighting professionals
• 107,000-hour lifetime rating
DesignLights Consortium
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• Deployed in the world’s leading industrial facilities
• More than 500 large-scale deployments
• Saving customers $25 million and 250 million kWh per year
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500+ Installations
New Orleans Cold Storage
Installation Snapshot: MEEA Region
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• 85+ installations
• 8.5 million+ total
square feet
In a Variety of Industries and Environments
Customer Environment Industry State
Pepsico Ambient Food manufacturer IL
Kellogg Cold/freezer Food manufacturer OH
Millard Cold/freezer Warehousing/distribution IA, NE, KY, IL
ConAgra Cold/freezer Food manufacturer MO, IA
Domino's Cold/freezer Food manufacturer & retailer MO, MI
Nestle Cold/freezer Food manufacturer IL
Sara Lee Cold/freezer Food manufacturer IA, IL
United Dairy Farmers Cold/freezer Food manufacturer IA
Reinhart Food Service Ambient Food manufacturer OH
Interstate Warehousing Cold/freezer Warehousing/distribution IN, IL, MI, OH
MEEA Energy Consumption -– Industrial Lighting
State Industrial Energy
Consumption (M kWh)
Lighting Energy
Consumption (M kWh)
IA 18,865 5,471
IL 44,180 12,812
IN 46,552 13,500
KS 10,651 3,089
KY 45,022 13,056
MI 30,841 8,944
MN 22,798 6,611
MO 17,330 5,026
ND 3,850 1,117
NE 10,210 2,961
OH 53,109 15,402
SD 2,360 684
WI 10,069 2,920
Totals 315,837 91,593
MEEA Industrial Lighting Consumption
• 91,593 million kWh per year in MEEA territory
• Most current lighting fixtures stay on 95% of the time regardless
of:
• Occupancy
• Ambient light
• Opportunity for massive energy savings
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Make Lighting Upgrades a Priority
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• Lighting accounts for 29% of
industrial electricity use
• Lighting upgrades are a fast & easy
way to reduce energy consumption
• Have far-reaching energy-saving
potential
Source: U.S. EPA Energy Star Building Upgrade Manual http://www.energystar.gov/ia/business/EPA_BUM_Full.pdf
More Energy Savings with Less Work
• The average Digital Lumens industrial lighting
retrofit = savings of 105,891 kWh
• 1,084 residential retrofits, or
• 46 commercial retrofits
• Do more with less
• Focus on key large industrial energy users
• Far fewer points of contact and less work for the
utility
• Quickly achieve energy reduction goals
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Source: EPA Fast Facts on Energy Use http://www.energystar.gov/ia/business/challenge/learn_more/FastFacts.pdf
Source: Canaccord Genuity The Third Cycle version 4.1, Quantifying the Unknown
• Facility size: 460,000 ft2
• Project type: retrofit
• Environment: Ambient, cold, and
refrigerated spaces
• Temperature range: -20°F to 70°F
• 7 x 24 x 365 operation
• Previous lighting solution: High
intensity discharge (HID)
• Annual lighting energy savings: 87%
• Payback: <1 year
Before and After
9 ft-cd 20 ft-cd
Case Study: Maines Paper & Food
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Case Study: Associated Grocers of New England
Before and After
• Facility size: 380,000 ft2 with 56,000
ft2 cold storage lighting upgrade
• Project type: retrofit
• Operational Schedule: 24 x 6
• Environment: refrigerator
• Temperature: -15°F
• Previous lighting solution: T5 HO
Fluorescent
• Annual lighting energy savings:
$52,000
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Case Study: New Orleans Cold Storage
• Facility size: 142,000 ft2
• Project type: new construction
• Environment: cold storage
• Temperature: -15° to 35°F
• Alternative lighting solution
considered: T5 fluorescent
• Annual lighting energy savings:
245,764 kWh
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Case Study: Ben E. Keith
• Facility size: 475,000 ft2
• Project type: new construction
• Environment: cold & ambient
storage
• Temperature: to 40°F
• Part of major sustainability
initiative
• Prompted when EE Manager
heard about utility incentives from
a peer
Case Study Deep Dive: Silver Beauty
Location Chicago, IL
Business Builds and leases warehouses in Chicago area
Facility type: Dry warehouse
Facility Size 177,413 square feet
Operating Hours 24x7
Previous Lighting 1,000 Watt Metal Halide
Issues • Energy and maintenance expenses
• Light levels
• Noise levels (humming)
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Silver Beauty: Requirements & Alternatives
Requirements
• High light levels in both racked aisles and open spaces
• Instant on/off – no warm-up time required
• Daylight harvesting
• Ability to fine tune/re-program lighting settings as facility setup
changes – without touching each fixture
• Noise-free
• Sound investment
• No maintenance or re-lamping expenses
• Rapid payback
• Long lifetime
Lighting Alternatives Considered
• None
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Silver Beauty Results
• 92% lighting energy savings
• From $78,335 to $4,078/year
• 1,237,626 kWh savings per year
• Excellent light levels across the facility
• Today in Warehouse #5, LightRules reports
occupancy of 30% in well-traveled aisles and
10-15% elsewhere
• Facility manager discovered in his other
facility, Warehouse #6, that his T5 fixtures
(with occupancy sensors) were experiencing
quick lamp life degradation due to frequent
cycling – even with cold weather ballasts
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An Inside Look at Silver Beauty’s Incentive
• Presenting: Mark Allen, Energy Engineer, ComEd
• ComEd’s Smart Ideas for your Business Program
• Prescriptive vs. custom incentives
• Custom incentive requirements
• LightRules vs. the ComEd meter
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The Future of Intelligent LED Lighting
• Further customization
• Integration with other key technologies
• Cloud management
• Automated demand response
• Expansion into all commercial and industrial applications
43
From the Industrial Perspective
• Not a lot of time to assess lots of products and technologies
• See energy provider as trustworthy source of information
• Some have EE/sustainability managers but most don’t
• Many need a project payback of 2 years or less – incentives
may make or break it
• May be trying to comply with corporate EE/sustainability
directives
• May be on tight deadlines
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What Can Utilities Do?
1. Grant custom incentives that bring projects to ≤2 year payback
2. Sponsor a test trial to monitor energy reduction
3. Train energy efficiency team and trade allies in new technology
4. Next step – installation site visit coordinated by MEEA
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Efficiency Flexibility Reliability Savings
Intelligence Doesn’t Cost More
It Gives You More
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Mike Feinstein
Vice President, Sales & Marketing
(339) 545-1663