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CATEGORY: Projects » Industrial
By Craig DiLouie, on May 16, 2012
Adapted from an article originally published in the July issue of Illuminate Magazine. Used with permission.
Project: Sears Distribution Center
Owner: ProLogis
Tenant: Sears Holdings Corporation
Location: Stockton, CA
Architect: Ware Malcomb
Lighting Design: Exposure Illumination Architects, Inc.
Electrical Engineer: ACIES
General Contractor: Big-D Pacific
Photography: Exposure Illumination Architects, Inc., Cooper Lighting
In 2006, Sears Holdings Corporation concluded a year-long study to produce an outline of the ideal built-to-suit facility to support its distribution network, and decided to replace five of its older facilities with new state-of-the-art centers.
In 2007, the company engaged ProLogis, a leading global provider of distribution facilities, to build a LEED-certified 780,400-sq.ft. distribution center in Stockton, CA, the last of the five. The new distribution center would be used to store and distribute big items such as washers, dryers and refrigerators. ProLogis, in turn, engaged Ware Malcomb, an architecture and design firm.
“Sears wanted a reliable, low-maintenance facility that met its standards,” said Jim Terry, Director, Commercial for Ware Malcomb. “ProLogis wanted to provide an energy-efficient, comfortable, functional environment that was of higher quality than typical distribution buildings. Ware Malcomb utilized unique architectural elements, including a suspended trellis canopy, bold entry articulation and consistent architectural treatment—paint, panel massing, clerestory windows—across the entire façade to bring a level of quality not typically seen in a large distribution facility.”
For the lighting, ProLogis and Ware Malcomb collaborated with Scottsdale, AZ-based Exposure Illumination Architects, Inc. In the RFP for the built-to-suit facility, Sears specified a maintained 30-footcandle light level, which it believed would support an environment conducive to safe and productive work among the 28-ft.-high product storage bins. ProLogis wanted these needs satisfied by a highly energy-efficient lighting system consistent with the company’s leadership in sustainable warehouse design.
The result was one of the most energy-efficient warehouse buildings in the country, with an effective lighting power density of 0.18W/sq.ft.—78% less than the maximum prescribed by California’s Title 24 energy code.
“For lighting designers focused on energy conservation, getting in early in the process is critical, allowing us to take responsibility not just for the lighting and controls, but also the total daylighting solution,” said Daniel S. Spiro, AIA, IES, president of Exposure Illumination Architects, Inc. “This involves educating the owner and design team at the front end of the design process about energy savings potential. Later in the process, once budgets are set, it’s very hard to make a change.”
In working on previous warehouse projects with ProLogis, Exposure Illumination Architects favored hi-bay fluorescent lighting as an alternative to more traditionally favored metal halide for a number of benefits, most notably high energy savings. For this project, Spiro envisioned integration of fluorescent lighting and daylighting using advanced lighting controls to dramatically maximize energy savings.
After receiving the product storage bin layout plan from Sears, which showed the fixed locations of the bins in the 600,000-sq.ft. storage space of the building, the lighting designers specified approximately 16,000 linear ft. of Cooper Lighting’s Metalux MB Series T5HO Micro-Bay luminaires in 360-ft. linear rows mounted 32 ft. off the floor. Select luminaires were specified with emergency battery backup, providing mandatory illumination throughout the warehouse in the event of a power outage without the need for a backup power generator.
“The Micro-Bay luminaire’s profile is extremely narrow, which increased design flexibility,” says Spiro. “The building code required obstructions wider than 2 ft. to be at least 2 ft. away from sprinkler heads. By being less than 1 ft. wide, we were able to place the luminaire within 1 ft. of the sprinkler heads. We gained valuable flexibility in placement. The luminaire could be as close as possible to the aisle center as a result.”
The luminaire’s narrow profile also enabled the electric lighting to integrate with the building’s daylighting strategy by minimizing blockage of daylight entering the space through a series of skylights also aligned over the center of each aisle. Except on cloudy days, these 4-ft. by 8-ft. double-dome skylights by manufacturer Bristolite, which are placed 40 ft. apart on center and cover 2% of the roof area, are able to meet target light levels without requiring any electric lighting during the daytime.
“Over 90% of the space has daylighting via skylights and clerestory windows,” Terry points out. “While not typical in industrial and distribution buildings, from past Ware Malcomb projects where we’ve employed extensive daylighting design, companies have noticed low employee turnover and increased productivity. Daylighting creates employee connection to the outside environment.”
One of the primary advantages of fluorescent over metal halide is its instant-ON operation, making automatic energy-saving switching strategies much easier to implement. This allowed the lighting designers to go beyond producing desired light levels for fewer watts, and look at what additional savings controls could bring to the table. By specifying luminaire sections adjoined in continuous runs, multiple circuits could be installed along the run, enabling granular zoning of sections in the row to support different control strategies such as daylighting control and occupancy sensing.
A Cooper Controls Greengate lighting automation system, which controls all of the building’s lighting at the lighting panels, turns the lights along critical pathways and aisle entrances ON before dawn. For example, in the bulk storage area, 16-ft. luminaire sections located at the head of each aisle are switched and kept ON all day for safety reasons. The rest of the lighting in each row is divided into 40-ft. sections, each controlled by its own integral occupancy sensor. In the late afternoon, as falling light levels are detected, the control system restores power to the lighting circuits; the lights remain OFF, however, unless occupancy is detected by the connected occupancy sensor, which turns the lights ON in the immediate area.
As daylight levels increase on the following morning, raising ambient light levels above a target threshold (as preset for local zone photosensors installed in select skylights), power to the non-critical lighting circuits is cut off. Multiple photosensors are used, dividing the lighting into nine daylight control zones, increasing sensitivity and flexibility based on an understanding that lighting conditions may vary in different parts of the building throughout the day.
“Stockton benefits from 310 days per year of clear skies, 55 days with semi-cloudy conditions, and only 16 with overcast conditions,” says Spiro. “On an average day, between 9 AM and 5 PM, most of the electric lighting is OFF in the building, saving energy.”
 As falling light levels are detected by a photosensor in the late afternoon, the Cooper Controls Greengate control system restores power to the lighting circuits feeding about 16,000 linear ft. of luminaires mounted 32 ft. off the floor. The lighting remains OFF, however, unless occupancy is detected by the connected occupancy sensor, which turns the lights ON in the immediate area. Meanwhile, in the other major space in the building, the 134,000-sq.ft. dock bay/staging area, 2×4 6-lamp T5HO luminaires provide general lighting, dual circuited so that two lamps provide 33% light levels for security purposes at all times. The circuit feeding the remaining four lamps is energized only if insufficient daylight is available, such as on cloudy days or at night, and then only if occupancy is detected.
Sears, which benefits directly from the operating cost savings based on their lease with ProLogis, is enjoying a projected 2.75 million kWh/year energy savings, which adds up to significant annual cost savings—$399,000—based on a local utility rate of $0.145/kWh (compared to a standard HID solution complying with Title 24’s requirement of 0.8W/sq.ft. maximum power allowance).
Monitoring to date [May 2009] has confirmed projected savings, measuring an average $0.0225/sq.ft./month electrical operating cost (lighting plus battery chargers) for the four winter months. Savings are expected to escalate during the summer—when the sun angle is higher, daylight hours are extended and utility rates typically increase—which are expected to reduce energy costs to as low as $0.0125/sq.ft./month, says Spiro. Annual energy costs are projected at $0.20-0.22/sq.ft. The next highest energy-performing building in all of Sears’ warehouses is $0.34/sq.ft./year (the worst is $0.58/sq.ft./year).
After an incentive provided by the local utility, PG&E, reduced the incremental labor, material and design costs, the energy savings is expected to recoup the net cost in less than eight months—a return on investment of 154%.
“A relatively small increase in initial construction costs for adding skylights and clerestory windows can quickly pay for itself in electricity costs and employee well-being,” says Terry.
“I would summarize this project with a simple statement,” says Spiro. “More costs less.”
By Lighting Controls Association, on April 30, 2012
The Lighting Control Innovation Award was created in 2011 as part of the Illuminating Engineering Society’s Illumination Awards program, which recognizes professionalism, ingenuity and originality in lighting design. LCA is proud to sponsor the Lighting Control Innovation Award, which recognizes projects that exemplify the effective use of lighting controls in nonresidential applications. In this award’s first year, eight projects were recognized with an Award of Merit, with one further recognized with a Special Citation Award.
This month, we will explore the role that sophisticated lighting controls play in minimizing energy costs for Groom Energy Solutions’ client Maines Food & Paper, which won an Award of Merit. Lighting design by Groom Energy Solutions. Photography by Bob Kirby. Control manufacturers/products: Digital Lumens ILE-HB-3 with Lighting Rules.
This project for Maines Food & Paper involved a lighting efficiency upgrade involving conversion from 400W HID to 160W intelligent LED lighting.
The above image shows the “before” condition. Requirements included improving light levels and reducing energy use fulfilled by introducing intelligent system with integrated sensors, computer and wireless networking.
The above image shows the “after” condition. The lighting management software provides reporting of fixture-based energy and occupancy data, as well as control of fixtures in zones with active and inactive full-range dimming and occupancy sensor time delays (as low as 30 seconds).
 Click on the image to see full size. The lighting management software provides communication with all fixtures in the facility via the wireless mesh network. The system operates according to zone-based settings given to it by the software, which can be adjusted at any time. Reporting of Occupancy and Energy data allows verification of energy savings as well as fine-tuning of the facilities lighting system over time to maximize energy system and manage the asset.
 Click the above image to see full size. Zone-based control of fixture settings with active and inactive levels and sensor delays. Fixtures programmed with these settings via wireless control, and operates independently of other fixtures according to these rules. Continuously able to maximize energy efficiency.
Row of lights operating in the same zone. Set with an inactive dimming level of 10%, so some light level is available even when the area is not occupied.
After an occupant has passed through the aisle triggering each fixture’s occupancy sensor and the active dimming level of 100%. Each fixture in this zone returns to inactive dimming level of 10% after only 90 seconds, providing light efficiently when needed.
100% output.
Each fixture in this zone returns to an inactive dimming level of 0% after only 60 seconds since last detecting occupancy.
 Click the above image to see full size. 94% reduction in lighting run hours and a 87% reduction in lighting energy
Energy Efficiency: 0.575W/sq.ft. lighting power density before, 0.24W/sq.ft. after. Budget: ROI was calculated at 210%.
By Lighting Controls Association, on May 23, 2010
 Kaiser Permanente installed WattStopper lighting controls as part of a warehouse renovation designed to improve lighting and reduced energy consumption. The upgrade resulted in better task lighting throughout the facility and energy savings of over 40%, as detailed in the following case study.
Managers of a 350,000 square foot Kaiser Permanente distribution warehouse in Northern California were dissatisfied with the facility’s lighting. Task illumination was ineffective, maintenance was difficult, and energy use was high. To improve the situation, they decided to completely retrofit the lighting and add energy saving controls.
Robert Ofsevit, vice president of Concord, California-based Alamo Lighting, coordinated a turnkey upgrade, including over 400 WattStopper occupancy sensors and time switches. More than a year after completion, Ofsevit’s design is exceeding expectations for performance and energy savings.
Warehouse lighting
Prior to the upgrade, much of the lighting remained on close to 24 hours a day from Sunday night through Friday afternoon. The space was lit with metal halide, high pressure sodium and older fluorescent sources. Light distribution was poor: illumination levels were insufficient for many tasks, but were far too high in some areas.
Before developing a lighting and control plan, Ofsevit assessed the safety requirements of the facility, as well as the tasks being performed. The new controls ensure that lights in many areas are not turned on until they are needed, and are turned off after they are no longer needed.
The new lighting uses just one lamp type – a 5000° Kelvin extra long life 4’ T8. Fixture types, reflectors and ballasts were carefully specified to deliver appropriate lighting levels for different areas and tasks. The overall connected load was reduced.
The upgraded fluorescent lighting provides better color rendition, less shadowing and less glare than the old lighting. Additionally, lumen maintenance is better and building maintenance is easier. Both the new lighting and the controls have been overwhelmingly embraced by employees, who now feel far more comfortable working in the space.
Integrating controls
WattStopper line voltage passive infrared (PIR) HB occupancy sensors control individual six-lamp high bay fixtures in the warehouse rack aisles. The PIR coverage, using aisleway lenses, ensures that lighting turns on in each section of the aisle as a worker approaches. Lighting in many rack aisles remains off for much of the day.
HB sensors also control approximately half of the fixtures in high-ceilinged packing areas and in the main aisles, which experience high levels of forklift traffic. The rest of the fixtures remain on during working hours. Keeping sufficient lighting on throughout the space helps workers feel secure and comfortable in the large warehouse space.
Previously overlit under-mezzanine spaces were efficiently retrofit, and a number of these spaces were rewired to create small zones of task lighting. Now, approximately half the fixtures remain on to provide illumination for workers walking through the areas. Workers can turn on the additional lighting in each zone as needed, using a conveniently located TS digital time switch. Lights turn off automatically following the user-selected time period.
 Bi-level lighting in private offices is controlled by DW dual technology, dual relay wall switch sensors. Dual technology was selected to best detect small motion. The first lighting level (66%) is switched on automatically upon occupancy. The second level (33%) may be switched manually. In practice the second level is seldom used, contributing to energy savings.
Controls in other areas were selected to suit the unique needs of each space. UT ultrasonic sensors, which can sense around partitions, control open office spaces, lunch and break rooms. A time clock controls energy-efficient lighting in a secure storage area, providing significant savings compared to previous 24/7 operation of older generation T8 fixtures. A low voltage digital time switch is available for after hours override.
Resulting energy savings
Kaiser Permanente’s Marvin Cave, Facility Manager, Regional Building Operations, NCAL, notes, “The lighting upgrade has improved the quality of lighting in both the office area and warehouse, and saved a significant amount of energy and utility costs.”
Analysis of utility records shows a reduction in energy use, measured in kilowatt hours, of over 40% for the 12 month period following installation. The energy savings will pay back the cost of the upgrade in three years, net of a $71,000 Pacific Gas and Electric rebate.
Selecting the controls
Kaiser Permanente managers selected the winning lineup of design, project management and lighting and control technology based on positive prior experience. The company in 2003 implemented a lighting upgrade with controls at another warehouse facility, using the same team, and that installation continues to perform successfully.
Kaiser Permanente is a leader in the health care industry when it comes to energy conservation. For over 20 years it has worked to reduce energy use and costs – from energy-efficient lighting upgrades, to harnessing renewable and sustainable energy to help power its hospitals, medical offices, and other buildings.
For more information about WattStopper, visit www.wattstopper.com.
By Lighting Controls Association, on January 23, 2010
 WearGuard-Crest, a division of ARAMARK, set an ambitious goal: to replace all the lighting fixtures throughout 280,000 square feet of office, manufacturing, and retail space at its headquarters in Norwell, Massachusetts, just south of Boston. Furthermore, the company wanted the project to pay for itself in energy savings.
J&R Wiring, Inc., took up the challenge. After researching the most advanced lighting control systems on the market today, J&R Wiring identified the one technology with the most powerful return on investment (ROI)—DCL® (Demand Control Lighting) from Universal Lighting Technologies.
Only DCL technology can reduce power to lighting ballasts as much as 50 percent without the need to install expensive control wiring. The DCL Control System can be operated manually or automated for “set it and forget it” simplicity. The control system communicates with the ballasts at the circuit level. Each lighting circuit can be controlled individually for zone programming. By eliminating the need for extra wiring, DCL technology is simple to install in retrofit projects or new construction.
After identifying DCL as the ideal solution, J&R Wiring worked with Universal Lighting Technologies to design an automated lighting control program that would optimize energy savings throughout the WearGuard-Crest facility. Lighting fixtures in the office, lobby, and hallway areas would be divided into eight zones with photocells for daylight harvesting between the hours of 7:00 a.m. and 6:00 p.m. In addition, the entire facility would be controlled by scheduling software so that lights would automatically adjust to 50-percent power at 6:00 p.m. for cleaning crews and then zero percent at 11:00 p.m. Under this plan, J&R Wiring projected an energy savings of 539,531 kilowatt-hours, which represents a 45 percent reduction in power being consumed by the facility’s lighting fixtures. Next, J&R Wiring approached the local electric utility, National Grid, to discuss possible incentives for WearGuard. Through its Energy Initiative program, National Grid provides incentives for energy efficient retrofits for its commercial and industrial customers. For this project, National Grid performed an independent review of DCL technology and its benefits for WearGuard-Crest and provided significant incentives. Another advantage to WearGuard-Crest was that DCL allowed them to participate in National Grid’s Demand Response Program. Although no longer offered, this program gave National Grid the ability to request that participating companies voluntarily slash their demand by a set percent when the local electrical grid is approaching capacity.
This is occasionally necessary during peak hours for energy use, which is—not coincidentally—when electricity rates are at their highest. Cutting energy use during peak hour rates is a significant source of financial savings for companies with high energy bills. These savings are simple to achieve with DCL technology whether or not the company is part of a Demand Response Program.
In Sept. 2008, the installation began. First, J&R Wiring replaced the facility’s outdated lighting equipment with DEMANDflex™ ballasts from Universal Lighting Technologies. These high-efficiency T8 ballasts can be individually “tuned” by the installer to the appropriate power level (ballast factor) in order to ensure just the right amount of light for the application. This helps eliminate overlighting and wasting energy.
According to J&R Wiring President Jim Killian, the DEMANDflex ballasts at WearGuard-Crest were tuned ten to 20 percent below full power during installation for immediate energy savings even before the DCL Control System was installed.
 “There was quite a bit of saving from tuning alone,” said Killian. “We were able to reduce power levels ten percent or more, and the ballasts are producing better light for less energy.”
Installation of the DCL Control System began in January 2009. The daylight harvesting zones and automated scheduling software have performed exactly as demanded.
“The installation went off without a hitch,” said Chris Hart, senior electrician for WearGuard-Crest. “This is a powerful front-end control system that is also extremely economical.”
Once WearGuard-Crest has recouped its investment in DCL technology, the energy savings will continue to compile month after month.
“Daylight harvesting is knocking down power consumption significantly,” said Killian. “And I’m impressed with the extremely subtle and extremely smooth changes in lighting.”
National Grid encourages its other customers to aggressively investigate the power of energy-saving lighting technologies, especially “whole-building” solutions such as DCL technology.
“Addressable lighting control systems like this one have a lot of potential for energy savings and carbon footprint reductions,” said Thomas Coughlin, commercial/industrial lighting program manager for National Grid. “We’ve had a very good experience,” said Killian. “I’m very happy with the product overall.”
ARAMARK is a leader in professional services, providing award-winning food services, facilities management, and uniform and career apparel to healthcare institutions, universities and school districts, stadiums and arenas, and businesses in 22 countries around the world.
With more than 500 employees at its facilities in Norwell, WearGuard-Crest has been America’s premier direct mail retailer of work clothes and personalized uniforms for almost 50 years.
For more information about Universal Lighting Technologies, visit www.unvlt.com.
By Lighting Controls Association, on May 13, 2008
 The cost of energy is skyrocketing. Supply cannot keep up with demand, and the electrical grid is dangerously overtaxed. Fortunately, there is a new energy management technology that can dramatically reduce electrical consumption in commercial buildings.
Universal Lighting Technologies developed DCL® to provide immediate, wireless control of every lighting fixture in a building or multiple buildings. DCL gives building owners and managers the power to slash energy use during peak hours. The first DCL customers in California have already reduced utility bills by 25 percent to 30 percent.
Founded in 1884, Ganahl Lumber Company is California’s oldest lumber retailer. Today, Ganahl operates eight stores in Orange County. Ganahl was selected by its utility provider as an ideal candidate for DCL technology in 2005.
Ganahl agreed to install a complete DCL system in its 20,000 sq. ft. retail and office facility in Costa Mesa, California. The installation was performed by Energy Controls & Concepts, Inc. (ECC), an industry leader in the analysis, development, and management of lighting efficiency projects.
DCL (or Demand Control Lighting) allows Ganahl to reduce lighting levels throughout the building with a single command. The DCL control unit communicates with the building’s lighting ballasts at the circuit level in order to reduce power anywhere from 1 percent to 50 percent. The result is significant energy and financial savings.
“I am extremely pleased with the process, execution and results of our lighting conversion done by Energy Controls & Concepts and the products provided by Universal Lighting Technologies,” said Brad Satterfield, General Manager of Ganahl Lumber in Costa Mesa.
 DCL Systems use DemandFlex™ ballasts from Universal Lighting Technologies. ECC installed 72 DemandFlex ballasts in two-lamp lighting fixtures on the first and second floors of the Ganahl facility. The DCL system at Ganahl communicates with DemandFlex ballasts on both 120V and 277V circuits. There is no need for additional two-wire low voltage control wiring, as required by other lighting control systems, making DCL a perfect fit for this retrofit project.
DCL technology allows Ganahl to participate in its local power provider’s demand response program. The utility is able to reduce power to the lighting fixtures at the Costa Mesa facility anywhere from 1 percent to 50 percent, depending on its needs during peak hours. Power levels can be reduced by a single command from a personal computer at the utility’s headquarters.
“We have a bright, vibrant store,” said Satterfield. “Any reductions made by the utility company go unnoticed, and the energy savings have more than exceeded my expectations.”
Ganahl Lumber Company can also manage its own lighting levels for energy savings during peak hours. DCL technology gives Ganahl the option of reducing power to its lighting fixtures on demand or by automated scheduling.
During daylight hours, a ten percent reduction in light levels generally goes completely unnoticed by a building’s occupants. Industry surveys reveal that most business owners are willing to accept a 35 percent reduction in lighting levels for short periods of time, generally up to four hours. This can significantly reduce the burden on a local utility during peak hours in addition to lowering energy bills. For this reason, utility companies may provide businesses with rebates and incentives for adopting DCL technology. Ganahl works closely with its power provider to ensure maximum energy savings—a win-win for both companies.
Thanks to DCL technology, Ganahl’s Costa Mesa retail facility reduced its overall power bill by more than 25 percent. The greatest savings were achieved during peak usage hours when the utility charges higher rates because of high demand. The energy savings achieved with DCL satisfied all expectations of the company and the power provider.
“We’re proud to be the first lighting manufacturer to offer business owners and building managers this level of remote power management,” said Chris Dimino, Senior Vice President of Marketing and Product Development for Universal Lighting Technologies. “Between incentives from utility companies and the financial rewards of reducing power consumption, DCL can provide forward-thinking companies with a rapid return on investment (ROI)—in addition to other practical and environmental benefits.”
For more information on Universal Lighting Technologies, DCL System Controls, and DemandFlex ballasts, call 1-800-BALLAST or visit www.unvlt.com.
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