Solid State Lighting

A Manufacturers Approach to Sustainable Operations

OYL Manufacturing Company Sdn Bhd & J&E Hall is one of the top manufacturers of HVAC (Heating, Ventilation and Air Conditioning) units in Malaysia. They are a member of the Daikin group which produces models under the Acson, York, American Air Filters, J&E Hull, McQuay HVAC kWh Consumption and Daikin product brands for use in residential, commercial and industrial applications. 1400 OYL/Daikin has a strong commitment to 1278 1200 environment performance of their products. The units themselves are large consumers of end use 1000 963 920 electrical power. The company has taken 863 800 numerous steps to minimize their products use 600 of energy including using inverter compressors, 400 more efficient heat exchanger and automatic filter cleaning. These product changes have 200 allowed OYL/Daikin to reduce the average 0 energy consumption of their units under JIS 1995 2000 2005 2010 conditions by 32% over the past 15 years.
2.8 kW residential air conditioner under JIS standards

Not content with only optimizing the energy consumption of their end products, OYL also places a strong focus on sustainable manufacturing. OYL has a sustainability team which continuously reviews their operations and identifies opportunity areas where the plants impact on the environment can be reduced. The site has executed many sustainable manufacturing projects at the plant with simple payback periods from 2.5 months to over 3 years including;

Project Description Installation of air curtains at doorways Inverter on air handling blower at canteen Inverter on cooling tower fans Utilities auto switch-off during non-operating periods Local air blowers to switch off main air compressor during low demand Rain water harvesting for process water and toilets High Bay metal halide to induction lamp retrofit and noncritical over lighting removal Fluorescent Tube T8 to T5 retrofit and noncritical over lighting removal

Payback Period 9.4 months 2.3 years 1.5 years 3.7 months 7 months 3.1 years 2.1 years 1.6 years

"Lighting retrofits are good candidates for energy saving projects because they are easy to implement, visible, and simple to calculate and verify the results.
Hj. Muhammad Razif Facility Manager OYL Manufacturing

Even though the plant changed a portion of their fluorescent T8 tubes to T5, they still had over 2,000 T8 x 1200mm fluorescent tubes in the plant. These remaining T8 fluorescent tubes were identified by the sustainability team as an opportunity to reduce energy consumption further. Most of the tubes were located in people centric areas such as in the offices, conference rooms, canteen, etc. Maintaining the lighting levels and lighting quality were identified as an important aspect during this retrofit project.

22-October-2012

This white paper is brought to you by Osprey Engineering Sdn. Bhd.

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Solid State Lighting

A Manufacturers Approach to Sustainable Operations

The sustainability and electrical team evaluated 2 options for the retrofit, changing to T5 fluorescent tubes (copy the previous fluorescent lighting retrofit project) and changing to T8 LED tubes. The team decided to implement the LED tubes for the following reasons; LED tubes have larger energy savings than corresponding T5 tubes. One of the reasons the previous T8 to T5 retrofit had such a short payback time is that many of the original T8 tubes were not replaced but removed for delamping. This was not possible with this retrofit. LED tubes have no harmful substances (RoHS certified) while T5 tubes contain mercury and are classified as a scheduled waste. LED tubes are of sturdy aluminum/polycarbonate construction while T5 tubes are made of glass and subject to breakage

OYL Manufacturing engaged Osprey Engineering to source the T8 LED tubes. A small set of LED tubes were initially tested. The samples had a clear cover so the tubes would be seen as an LED tube and easily identified as an energy saving project. However, feedback from the staff was that the brightness from the small, individual, LED chips were too strong when viewed directly. Based on this feedback, frosted covers were specified for the retrofit project. Full specifications of the LED Tubes are below. LED Specifications
Dimensions Material Specification LED Specification Number LED Chips LED Beam Angle Electrical Specification Cover Type Color Temperature Luminous Flux Installed LED Tube T8 x 1200mm Aluminum Frame, Polycarbonate Cover SMD 3528, High Bright 286 170 degrees AC 85-270 VAC, 19 Watts Frosted Cool White, 6000k 1,700 lm

To minimize project investment, OYL in-house technicians installed the LED tubes over a 3 month duration. During the installation, the ballast and starter were bypassed with the Line and Neutral wired directly to the bi-pin sockets. The old fluorescent tubes were sent to a managed disposal company.

Results
The main success criteria for this energy saving project are the delivery of equivalent or better lighting quality than the existing fluorescent tubes and realization of significant energy savings. Lighting Quality: A detailed lighting level study was done in the workshop office area of the plant. For this study, the lighting levels at the desk top height (1,800mm below the luminaire height) with the existing fluorescent tubes were compared with the new LED tubes. The measurements show that the lighting levels produced by the LED tubes averaged 27% higher than the fluorescent tubes.

22-October-2012

This white paper is brought to you by Osprey Engineering Sdn. Bhd.

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Solid State Lighting

A Manufacturers Approach to Sustainable Operations

Workshop Office Illuminance Diagram Fluorescent Tube vs. LED

28 '
96 vs. 98 35 vs. 44 174 vs. 170 45 vs. 60 224 vs. 323 179 vs. 110 47 vs. 34 118 vs. 96 31 vs. 35 96 vs. 58 240 vs. 261 100 vs. 172 256 vs. 296 245 vs. 278 190 vs. 275 109 vs. 182 270 vs. 273 250 vs. 318 150 vs. 283 230 vs. 273 200 vs. 272 224 vs. 295 257 vs. 327 147 vs. 286 265 vs. 303 164 vs. 182 193 vs. 298 140 vs. 310 279 vs. 323 105 vs. 174 210 vs. 367

18 '

XXX

2 Lamp Recessed Troffer Fixture for T8 x 1200mm lamp Illuminance at Desktop Level, lux. RED = Fluorescent Tube, GREEN = LED

During the retrofit execution, there were times when a room had a temporary mix of old fluorescent and new LED tubes at the same time. Some of the staff noted the color temperature difference between the 2 types of lamps. However, when the retrofit execution was complete, the OYL team was very satisfied with the increased lighting levels from the new LED tubes.

Project Savings: The energy consumption of a lighting circuit with 8 luminaires (16 tubes) was analyzed before and after the retrofit. It was found that the LED tubes used only half of the power as the existing fluorescent tubes, 18.3W vs. 35.3W. The project financials show an annual savings of over RM 53,000 due to energy savings and lower maintenance cost due to longer lamp life. This savings occurs with a higher delivered illuminance. Additional savings are expected when Malaysia rationalizes the current energy subsidies which will substantially increase the electric rates.

Annual Lighting Operating Cost, RM

Investment 2,200 Tubes including in-house installation Annual Electric Demand Savings (37.5 kW) Annual Electric kWh Savings (08:00 18:00, 6 days/week, 117 MWhr) Annual Maintenance Savings Total Annual Savings Simple Pay Back Period RM 255,000 RM 14,400 RM 36,100 RM 3,200 RM 53,700 4.7 years

120,000 100,000 80,000 60,000 40,000 20,000 0

Fluorescent LED

Mar

OYL Manufacturing Sdn Bhd & J&E Hall is the premier air-conditioning manufacturer in Malaysia producing a wide range of HVAC equipment for the Malaysian and global export markets from basic residential air-conditioners to high technology light commercial and commercial heat pump, air-cooled and water-cooled chillers with larger capacity of up to 75HP. ww w. o yl .c om .m y

Osprey Engineering provides engineering and consulting services to the process and manufacturing industries. Ospreys core areas of expertise are automation, control, real time performance monitoring and optimization. They have completed works for companies including Petronas, Shell, BASF, P&G and Kelloggs over the past 15 years. ww w. os p r e y- e ng i n eer i ng .c om

22-October-2012

This white paper is brought to you by Osprey Engineering Sdn. Bhd.

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