W The Environmental Protection Agency (EPA) began a program called “Green Lights” in January of 1991. It is a pro- gram designed to reduce pollution in the United States by encouraging companies] government facilities and other organiza- tions to use energy-efficient lighting.

The EPA estimates that lighting, and associated air-conditioning that removes the heat generated by lighting] accounts for about 25% of national electricity use. Yet more than half of this amount is wasted by inefficient lighting products or improper lighting system design. According to the EPA, every kilowatt-hour of electricity used requires the emission

of 1.5 pounds of carbon dioxide, 5.8 grams of sulfur dioxide and 2.5 grams of nitrogen oxides-all objectionable pollu- tants. Therefore] reducing lighting elec- tricity waste will benefit the environment.

The voluntary Green Lights program

Why is the government involved? During the last 10 years, a number of high-efficiency lighting systems have appeared that have the potential to sub- stantially cut energy use while providing equal or better illumination levels. The

Lighting has not been a high priority for U.S. businesses. I The EPA is seeking to change that fact.

shows companies how to illuminate their facilities using much less energy, thus achieving a profit while also reducing pollution. Surely this is a better way for our country to do business.

Electric Power Research Institute has estimated that if these systems were used to their full potential in this country, the electricity used for lighting could be reduced by as much as 50%. This reduc-

- ._ -. _ _ . _ _ _ _ _ _ _ _ _ _ ~

32 PLANT SERVICES / AUGUST 1992

tion also would reduce electrical bills by at least $1.8 billion and also markedly reduce pollutant emissions.

Despite these facts, and the fact that many of the energy-saving lighting prod- ucts have attractive financial returns, large-scale retrofits have not been com- mon. This is partly because lighting is not a high priority for the majority of American institutions. Falling within the area of facilities management, lighting usually is viewed as overhead. It is all too common for facilities to install the lowest first-cost (instead of lowest life-cycle cost) lighting systems. Described simply, the aim of the Green Lights program, according to the EPA, is “to catalyze a more rapid revolution in the market- place.”

What does the program involve? During its first year of existence, the vol- untary Green Lights program was joined by 402 institutions, which pledged that they would upgrade with energy-efficient lighting wherever profitable, while main- taining or improving the quality of light- ing. The volunteers are divided into two main cat eg o r i e s : “ Partners , ” which includes corporations and governments and “Allies,” which includes lighting manufacturers, lighting management companies and electric utilities. In addi- tion, the term “Endorser” is used to describe trade and professional organiza- tions that support the program.

The check-lists included show what is expected of a Partner or Ally, and what the EPA pledges to provide under the Green Lights agreement. As mentioned, this program is voluntary, and companies can withdraw at any time, with no notice or penalties.

Some of the notable Partner success stories cited by the EPA during the first year of the program include Warner- Lambert in Morris Plains, N.J., which installed almost 3,500 T8 fluorescent lamps, which will yield an annual savings of $190,000. Johnson &Johnson, active in energy-conservation for many years, already had energy-efficient lighting installed in about 50% of its facilities prior to the Green Lights program.

continued on page 35

Q Appoint an imple

Q Survey the lighting in all of its U.S. facilities.

Q Consider a full range of lighting options to reduce energy use.

Q Upgrade 90 percent of the square footage of its facilities with the options that maximize energy savings to the extent that the upgrade is profitable and does not compromise lighting quality. There are no technology prescriptions.

Q Complete upgrades within 5 years of signing the agreement.

Q Annually document the improvements it makes.

Q Design al l new facilities to meet most current building efficiency

Q Educate its employees about the benefits of energy-efficient lighting.

standards.

When companies sign the Green Lights Memorandum of Understanding, they agree to upgrade their facilities with energy-efficient lighting. In return, the EPA commits to provide a wide variety of products and services designed to make the job easier.

LIGHTIN(

An example of savings The illustrations shown here, from MagneTek Inc.'s helpful "Green Lights" brochure, highlight the dramatic energy sav- ings possible through lighting retrofits.

Atypical four-lamp fluorescent fixture contains two stan- dard magnetic ballasts powering four 40-watt lamps. The ballasts can be replaced by a singlelow wattage electronic ballast and the lamps by 32-watt T8 lamps.

49% reduction in energy consumption Light level is comparable to energy-saving lamps operated by a CBM-certified magnetic ballast. Lighting quality is improved because the T8 lamp is "high color rendering"- meaning it enhances colors. Energy savings total 94 watts- a 49% reduction in energy consumption. If you pay eight cents per kilowatt-hour of electricity, you would save $23.46 per year for this fixture alone.*

*Assumes lamps are lit 12 hours per day, 5 days per week.

Copies of the MagneTek "Green Lights" brochure are provided free on request.

To learn more, Circle 260

Before Upgrade: 192 watts

T12 Fluorescent Lamps

A typical four-lamp fixture containing two standard magnetic ballasts powering four 40-watt lamps

After Upgrade: 98 watts

T8 Fluorescent Lamps

Upgraded fixture with one Low Wattage electronic ballast and four 32-waft T8 lamps

lnpput watts &sed on American National Standards lnstitute (ANSI) data.

The importance of m These charts, provided by Philips Lighting Company from its "Industrial Lighting Guide" show the effects of dirt on luminaire lumen output and the effec equipment age on light output. Training courses and materials available as part of the Green Li program stress proper lighting maintenance and also group relamping. According to the Philip lication: "The cost of maintaining a lighting system can be reduced significantly through group r ing performed when lamps have reached be 60 to 80% of their average life. Group relam the replacement of lamps in an entire area preplanned schedule-uses labor more efficie and typically costs only 10% of spot relamping costs, that is, replacing lamps as they burn out.

Copies of the Philips Industrial Lighting Guid

To learn more, Circle 261 ble free on request.

Aging Wects oti L&b& O u t p ~ t

0 20 40 60 80 100 120 140 160

continued from page 33 Nevertheless, under the directorship ol Harry Kauffman, Corporate Energj Manager, during the first year. of thc Green Lights program 10 facilities werc upgraded, for a savings in 1991 0 1 $200,000 and 2.9 million kilowatt-hours of electricity.

Amoco Corporation's Naperville, Ill. 1.2-million-square-foo t complex replaced 6,000 light switches with 6,000 occupancy sensors, for an annual savings of $316,413, and a reduction of almosl 4.5 million kilowatt-hours. The Oliver Carr Company in Washington, D.C. has upgraded more than 1.3 miltion square feet through delamping, rebdasthg and reflector installation, for an estimated annual savings of $480,000.

Utility rebates and Green lights The Green Lights program has developec a registry of financing resources, whick provides detailed information on mort than 200 utility programs that offer light. ing rebates and free installations to their customers. It also provides a directory 01 more than 75 companies that can financc lighting efficiency upgrades using leasing shared savings, guaranteed savings, and

continued on page 3€

AUGUST 19921PLANT SERVICES 35

continued from page 35 other financing techniques. The registry is provided free of charge to all Green Lights participants.

The following actual scenario gives an example of a public utility with a rebate program that resulted in savings for an industrial plant. Two years ago, Massachusetts Electric entered into per- forinance contracting arrangements with several low-bidding energy service com- panies. The companies recommend and install energy efficiency improvements for Massachusetts Electric customers. Massachusetts Electric pays the perfor- mance contractor a fee based on the kilo- watts saved; the customers save on their utility bills; and the utility gets additional capacity at less than the cost of building new generating units.

One of these contractors, Green Lights Ally Puget Energy Services, based in

Ashland, Mass., coordinated a lighting retrofit for Sealy Mattress Company’s Randolph, Mass. plant, which is estimat- ed to have cut $40,000 per year from the plant’s electrical bill. The project involved

Sound Power and Light Company Boeing’s Kenton, Wash., Facilitie Organization received about $6j6,00( for the installation of new metal-halidl lighting fixtures in three buildings; thesi

Boeing’s Renton, Wash., Facilities Organization received a grant of about $656,000 from the local utility to replace fluorescent fixtures with metal-halide.

replacing fluorescent and metal-halide lamps and fixtures with high-pressure- sodium lamps and fixtures, and reduced Sealy’s electrical load by 214 kW. The project cost of $190,000 was paid for by Massachusetts Electric.

A larger-scale project involves Boeing, a Green Lights Partner. As part of the grant program of Green Lights Ally Puget

Green Lights training needs The decision to enter a company into the Green Lights program as a Partner

Free programs, scheduled nationwide, feature training on lighting fundamen-

or A l ly usually comes f rom t h e top. With the high-visibil i ty of e n v i r o n m e n t a l matters, CEO‘s a n d c o m p a n y presidents are viewing participa- tion in the Green Lights program as

tals, technology, project manage- ment and Green Lights reporting.

An example of the training pro- grams offered for Partners and Allies is the free two-day confer- ence held i n - .

good publicity. At the Nela Park conferences, attendees can cooperation with Perhaps they examine energy-saving lighting products. GE Lighting at the don‘t always con- GE l i g h t i n g sider when they sign the Green Lights Inst i tute at Nela Park i n Cleveland. agreement what it will mean to the facil- Scheduled several times during the year, ities manager who actually has to per- the conference begins with a review of form the lighting upgrade. Yet the fact is the Green Lights program and lighting that it is central to success of the pro- application fundamentals, with details on gram that the facilities staff has enough currently available energy-efficient light- knowledge of l ighting systems t o ing products. Attendees are told how to achieve energy savings. conduct a lighting system audit and,

The Environmental Protect ion using the results from this audit, how to Agency agrees to meet the need for formulate a relighting plan. Lighting cost training when it signs an agreement analysis and information on lighting sys- with a participating Partner company. tem maintenance also is included.

To learn more, Circle 262 _ . _ _ _ - ~ -

_ _ _ _ -

replace fluorescent fixtures. Since implementation of the project

lighting energy consumption i n thc upgraded buildings has dropped mor1 than 50%, while the amount of ligh reaching the work area has increased.

The Boeing Facilities Organization ir Auburn, Wash., received a similar gran of about $588,000 from the Puget Powe program.The case history that follows nvolving Knorr Brake, gives details 01

nother project, which involved a Greei ights AUy contracting company workin! n cooperation with the local utility to thc lenefit of an industrial plant.

iolophane, Newark, Ohio, which con- ributed information to this article, man rfactures a line of energy-efficient ighting products.

To learn more, Circle 263

The US. EPA in Washington D.C. has a Green Lights Hotline at

You can get questions answered, or request information to be sent to you. Or you can FAX your questions or requests for information to the EPA at (202) 775-6680. In addi- tion, al l state EPA offices also have information on the Green Lights program.

(202) 775-6650.

36 PLANT SERVICES / AUGUST 1992

Contractor is Green Lights Ally: Knorr Brake plant r

Sometimes opportunities for lighting upgrades seem out of reach to industri- a l facilities because of financial obsta- cles. Knorr Brake Inc. benefitted from [he knowledge of a contractor that is a Green Lights Ally, and achieved a light- ng upgrade with no initial expenditure required. Furthermore, 100% of the pro- ect's costs were funded by monthly mergy savings over a preestablished .ime period.

When Knorr Brake, a manufacturer i f braking systems for trains and sub- way cars, outgrew its existing facility, in extensive search located a com- i lex in Westminster, Md. Jnfortunately, the major renovation iudget allocated little money to ipgrade the existing lighting system.

The lighting system in the facility had keen set up to support a bench assem- ily type of manufacturing, and was not I good f i t for Knorr Brake's operations. h o r r Brake's management was lpproached by Primo Lighting Aanagement, a contracting firm and ireen Lights Ally, which proposed a enovation of the lighting system that tould save the plant a substantial mount of money on its electrical bill, i i th no initial expenditures required. norr Brake agreed to the project.

In the manufacturing area, plans /ere made to remove all existing fluo- ?scent industrial type fixtures and to istall 400-watt metal-halide high-bay xtures and lamps. Since fewer fixtures /ere required and fixture spacing need- d changing, new piping and wiring /ere installed. Also, a number of sup- lemental industrial type fluorescent fix- ires were installed at a lower level for isk lighting. These were ordered with lectronic ballasts and T8 fluorescent mps. In the office areas, the existing Jorescent fixtures were kept in place, [ith electronic ballasts added. The old 12fluorescents in the offices were ianged out and T8 types installed.

le overall lighting load a t the facility As a result of these improvements,

!aps benefits was reduced by 96 kilowatts, or more than 55%, equalling a savings of more than $28,000 a year. Early in the pro- ject, Primo Lighting Management had coordinated discussions with Baltimore Gas and Electric; as it turned out, the utility's load reduction incen- tive program paid for about 40% of the total lighting upgrade at Knorr Brake. The remaining 60% of the project cost is being repaid on a monthly basis out of the energy savings realized. Repayment is structured to create a positive cash flow on a monthly basis. After the preestablished repayment schedule is completed, 100% of the savings will go to Knorr Brake.

Primo Lighting Management is a con- sulting and contracting firm specializ- ing in lighting projects, located in Baltimore.

To learn more, Circle 264 High-bay metal-halide lighting fixtures we a product of GE Lighting Systems, Hendersonville, N.C.

To learn more, Circle 265 $00-watt metal-halide lamps are a Yroduct of GE Lighting, Cleveland.

%orescent fixtures for task lighting we a product of Lumax Industries, qltoona, f a .

To learn more, Circle 267 Flectronic ballasts used for task light- ng fixtures are a product of MagneTek, =aramus, N. J.

To learn more, Circle 268 r8 4100 Kelvin fluorescent lamps for ask lighting fixtures are manufactured iy GTE Sylvania, Danvers, Mass.

To learn more, Circle 269 Yectronic ballasts for office area fluo- escent fixtures are a product of \dvance Transformer Company, losemont, 111.

To learn more, Circle 270 T8 3500 Kelvin fluorescent lamps used 7 office area fixtures are products of ;TE Sylvania.

To learn more, Circle 271

To learn more, Circle 266

"The machine operators

immediately commented on

the improvement in comfort

and ease of communication." George Bange,Plant Engineer

CaMec Continental

George Bange hired us to help him create a safer, more comfortable, more productive workplace. We custom de- signed and fabricated a noise sontrol system that lowered noise levels and echoing in Cablec's production facility.

George says that our noise &sorbing system had a "sig- iificant impact" even before the nstallation was complete! And, mause the system was nstalled on the facility's walls & :eilings, production & mainte- lance routines continued JnChanged.

We have over twenty years ?xperience designing, fabricat- ng and installing custom noise xmtrol systems that protect (our workers' hearing and your ?mployers' pocketbook.

:all us to receive a free noise :ontrol plan for your facility!

spec(a1,sts m noise control products and Services

industrial noise control, inc. 1411 Jeffrey Drive . Addison, IL 60101

708-620-1 998

To learn more, Circle 123 AUGUST 1992/ PLANTSERVICES 37

T H E H O W - T O M A G A Z I N E F O R 1 0 0 + E M P L O Y E E P L A N T S