LED Lighting · 2020-04-12 · Lighting is omnidirectional LED is directional with focused lighting...
Transcript of LED Lighting · 2020-04-12 · Lighting is omnidirectional LED is directional with focused lighting...
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LED Lighting WMEA Conference
November 22, 2013
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What Does LED Stand For Light
Emitting
Diode
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LED vs. Traditional Lighting Overview
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• Lighting consumes 19% of all electricity in the world
• Approximately 67% of all lighting currently installed is based on older, less energy
efficient technology developed before 1970
• The mercury from one fluorescent bulb can pollute 6,000 gallons of water beyond
safe drinking levels & contaminate a 20 acre lake forever
• ~ 500,000 injuries & accidents are a result of people falling from ladders
• Value of LEDs becomes exponentially important in mining environments
Key Issues
• Safety
• Maintenance expenses
• Rising energy prices
• Lifecycle costs
• Environmental pollution
• Harsh environments
Lighting Facts
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LED Compared To Traditional Sources
• No filaments like incandescent lamps
• No electrodes like gas discharge lamps (HPS, MH, and fluorescent)
• Devices are robust, vibration & impact proof; very rugged and
durable
• Instant on, full color, 100% light; cold start capable
• No mercury in the light source
• Long life – reduced maintenance costs
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Difference With LED Lighting Benefits
• Efficiency Up to 150 lumens/watt
• Directional No wasted light, any
pattern possible
• Long Lifetime >60,000 hours to
70% Lumen Maintenance (L70)
• Start Instantly Nanoseconds vs. >
10 min re-strike (HID)
• Environmentally Friendly No Hg,
Pb, heavy metals
• Infinitely Dimmable, Controllable
Increased power savings & lifetime
• Love Cold Temperatures Cold start
capable
• Low Temperature – Run cooler than
HID/HPS
Visible Light
Heat
Lens
LED Chip or Die
with Phosphor
coating
Thermal
Heatsink
Bond Wire
Outer
Package
Cathode
Lead Silicon
Submount
Solid State Lighting –
P-N junction semiconductor device
with a die & phosphor coating.
• No Ballasts
• No Glass bulbs
• No Filaments
• No Pressurized gases
• No toxic chemicals
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Newmont Carlin – Elko, NV
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Newmont Carlin – Elko, NV
Control Panel for Stacker
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LED Environmental, Operational and Safety
Design Features
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Lumens vs. Footcandles Explained
HID, Incandescent, fluorescent
Lighting is omnidirectional
LED is directional with focused
lighting in a target workspace
• Foot-candles/lux is the true measure of a light fixture’s ability to effectively
illuminate a targeted area NOT raw lumens
• Directional nature of LEDs makes them suitable for use with custom optics
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Rio Tinto Kennecott Copper - Salt Lake City, UT
Kennecott Smelter
Tank Area
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Kennecott Area Lighting
& Smelter
Rio Tinto Kennecott Copper - Salt Lake City, UT
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• No filaments like incandescent lamps
• No electrodes like gas discharge lamps
(HPS, MH, and fluorescent)
• No mercury in the light source
• Negligible UV or infrared radiation in visible
light distribution spectrum
• Zero disposal costs
• Reduction in carbon footprint
• No light pollution – Dark Sky compliant
design
• Visible spectrum is wildlife friendly
supporting sea turtles, etc…
Environmental Benefits
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Economic Value $$$
Direct Energy
Savings($/yr HVAC
Savings $/yr
Labor Savings
$/yr
Lamp & Ballast
Savings $/yr
Fixed Costs*
$/yr
Downtime Reduction
$/yr
One Time Material
Reduction ($) **
One Time Utility
Rebate ($)
One Time Tax Rebate
($)
Economic Impact to Replace
One 250w MH fixture with LED
Annual Recurring Savings $$
• Energy
• Labor
• HVAC
• Lamp/Ballast
• Fixed costs*
• Downtime opportunity cost
* Rental Equipment, Lifts, Scaffolding
One Time Benefit $$
• Utility Rebate
• Material Reduction Costs **
• One Time Tax Savings ** Circuit Size, wiring, panel boards
Operational Benefits
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Colowyo Mine – Dragline Boom Lighting
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Safety Benefits
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Safety Benefit Maintenance-Free
The best way to prevent a maintenance
accident is to minimize the need for it
Maintenance-Free Operation
• LED fixtures offer longer
life vs. conventional light
sources
• LED technology alone is
not enough to drive long
life
• Key drivers to long life
include Driver life, LED
component selection,
thermal management, T-
codes and robust
design
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• Heat Sinking in a LED system is done @
• LED package substrate level
• LED printed circuit board level (Thermal pads)
• LED fixture body over PCB & drivers in form of
finned structure to increase heat transfer
surface
• Why is Heat Sinking Important?
• Reduction in lumen depreciation & color shift of
LED over time
• Obtain lower T codes for fixtures used in
explosive environments
Finned Heat Sink
Thermal Management - Longer LED Life, Color Stability & Lower T Codes
Junction Temperature (Tj) – within the LED die is
affected by drive current, thermal path & ambient
Safety Benefit Maintenance-Free: Thermal Management
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Robinson Copper - Ely, NV
Application: Shovel Lighting
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PVM9L 90° Stanchion on
cooling tower & landings
Rio Tinto Kennecott Copper - Salt Lake City, UT
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Newmont Leeville –Elko, NV
Application: Conveyor Stacker
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Newmont Carlin – Elko, NV
Application: Filter Press
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Safety Benefit Maintenance-Free: Economic Life
Crouse-Hinds New Champ LED Economic Life Example
Ambient
Temp
L70* LED
Life (Hrs)
Driver
Life (Hrs)
Fixture
Life (Hrs)
# of Yrs
@ 24 hrs
usage
# of yrs
@ 12 hrs
usage
25C 453,000 172,060 172,060 20 39
30C 469,000 143,383 143,383 16 33
40C 501,000 107,537 107,537 12 25
55C 417,000 60,000 60,000 7 13
* L70 – Time at which fixture has 70% of its initial output
0
40,000
80,000
120,000
160,000
200,000
25C 30C 35C 40C 45C 55C
Lif
e (
Ho
urs
Of
Op
era
tio
n)
Fixture Life (Economic vs Rated)
Fixture Life (Hrs)
Economic Life
Rated Life
Economic life can range
anywhere between 60K
to 170K hours or 7 to 20
years of maintenance
free safe operation
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Dust Marine Hose Vibration up to 3G
& 5G forces
Safety Benefit Reliability in Adverse Conditions
Fixtures Designed To Withstand The Harshest Conditions
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Safety & MSHA
SAFETY Beyond Economic
Impact $$
Maintenance Free
Operation
Lower Temperature
Codes
Vibration, Corrosion,
Dust & Water Resistance
Lighting Quality
Electrical Protection &
Reliability
Installation
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Safety Benefit Lighting Quality
Benefits • Bright crisp white lighting & natural color • Improved workplace illumination • Consistency in color • Minimize # of fixtures • Accident avoidance • Downtime avoidance • Instant ON/OFF & restrike • Instant start in cold -40C
Features • Higher foot candles delivered to work plane • More coverage • More uniformity • Consistency in color • Minimize light spill & max/min Fc ratio
Design Drivers • Custom optics – Type I, III & V
• Lens design & material
• Binning
• LED component selection
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Type 1
Type 3
Type 5
Applications • Mining conveyer belts
• Aisle way & Hallways
• Catwalks & walkways
• Ramps & loading docks
• Tunnels
• Narrow crosswalks or
passages with wall
fixtures
• Tunnels with wall mount
• Wall stanchion mount
with 180° forward throw
• Pendant, ceiling or
stanchion mount
overhead building
• Processing mills,
industrial plants, large
buildings, warehouses
Custom Optics For Directional & More Uniform Light Distribution By Application
Safety Benefit Light Quality: Optics
Reduction in loss
behind by fixture
by 50%
Better uniformity
Higher avg FC
Longer coverage
by 5-7 ft
Better uniformity
175w MH vs VMV7L
TYPE I OPTICAL PATTERN
TYPE III OPTICAL PATTERN
TYPE V OPTICAL PATTERN
0.58 avg FC @ 18ft 0.49 avg FC @ 18ft
0.61 avg FC @ 18ft 0.59 avg FC @ 18ft
0.68 avg FC @ 18ft 0.47 avg FC @ 18ft
Higher avg FC
Better uniformity
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Transformers – “Transform” incoming power to a lower desired voltage proportional to input voltage
Power Supplies or Drivers
• Constant Voltage – produce a fixed output voltage regardless of input voltage & convert AC to DC
• Constant Current – regulate energy passing through LEDs by passing constant current through LED system
• Drivers result in loss of efficiency of LED system. Most drivers are 85%-90% efficient with a power factor of > 0.85
• Drivers contain electronic components which can raise temperature of LED system and need to have an effective heat sink
• Driver redundancy & field replaceability are key for a reliable LED system
Transformer 100V to 120V 10V to 12V
Power
Supply 100V to 120V Fixed 24V DC
Drivers isolate the LEDs from surges in incoming voltage or current
Drivers 24VDC Fixed 350mA
Power
Supply
Drivers
Led
Drivers
Electrical Protection: Drivers
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Rio Tinto Kennecott Copper - Salt Lake City, UT
Application: Roadway Relighting Project
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Roadway Lighting
Rio Tinto Kennecott Copper - Salt Lake City, UT
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Newmont Leeville – Elko, NV
Application: Bus Stop Lighting
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Summary
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LED System Selection Criteria For Harsh & Hazardous Applications
Total Cost Of Ownership – Safety, Lifetime, Efficiency, Light Quality & Installation
1. Safety (Certifications & Compliances) • Temperature rating
• NEC/IEC Hazardous location certifications
• Moisture/wet location protection
• Environmental conditions (Vapors, dusts, fibers etc.)
2. System Lifetime • LED case and junction temperature (Tj)
• Secondary system thermal management
• LED rated and economic life
3. Light Quality & Performance • Color temperature & CRI
• Lux or foot candles
• Light distribution and supporting optics
4. System Efficiency • LED package efficacy (lm/w)
• LED package lens (optics)
• Secondary system optics (reflectors)
• Driver and heat sink efficiency
5. Mounting And Installation Options
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