Getting Ideas for Energy Management Opportunities
Incandescent = 100
Fluorescent = 300
Metal halides = 400 - 600
High-pressure sodium = 450 - 700
Improving the energy efficiency of lighting is one of the “high visibility, good PR optics” projects in any industry: everyone can relate to it and see the results. The evaluation of lighting systems is mandated by the 1996 Energy Efficiency Act, which sets minimum requirements for lamp efficacy and lighting quality. The energy audit of your foundry should help in determining conformance to the regulations. Electric utilities, manufacturers of lighting products and consultants can also provide help.
Our drive to increase lighting energy efficiency should not diminish the requirements of adequate lighting of the workplaces. A 2000 report on the survey of Canadian foundries compared the range of existing lighting levels with the requirements set by the Illuminating Engineering Society of North America. There were sharp differences in lighting levels, increasing with worker’s age.
TABLE 5:
Lighting levels (in lumens/sq. ft.) throughout foundries
| Area | Typical level range (average) | Required for workers aged | ||
| under 40 | 40–55 | over 55 | ||
| Moulding | 3–300 (41) | 100 | 150 | 200 |
| Pouring | 6–450 (63) | 50 | 75 | 100 |
| Core making | 5–300 (49) | 75 | 100 | 150 |
| Grinding | 4–180 (56) | 100 | 150 | 200 |
| Inspection | 2–117 (49) | 100 | 150 | 200 |
After L.V. Whiting; Note: 1 foot-candle = 1 lumen/sq. ft.
It is worthwhile to consider this table for several reasons. Adequate lighting levels that correspond to the age of the workers have many tangible and intangible benefits that are often overlooked:
- Improves morale and reduces absenteeism;
- Positively influences quality (i.e., better workmanship and improved customer satisfaction);
- Allows for better control of costs by reducing defects and rejects;
- Provides inducement to experienced older workers to stay on rather than retire early;
- Improves housekeeping and safety records (i.e., cleaner, more orderly workplace and lower accident and insurance costs); and
- Positively influences the company’s image and personnel’s self-image.
In reducing lighting costs, focus therefore on improvements to housekeeping and the energy efficiency of lighting fixtures rather than on reducing the lighting intensity in workplaces.
Pay attention to selecting the right type of lighting fixture for the environment. Position the fixture to minimize light loss from dust accumulation (fluorescents are the worst in this respect), and position it so that there are no obstructions to lighting.
Where applicable, try to take advantage of natural daylight (skylights, windows). Think about ways to facilitate window/skylight cleaning, however.
Other EMOs
Housekeeping
- Assign responsibility for turning off lights at the end of the production day, and turning them on prior to the start of shift in each department and in general areas.
- Establish a regular cleaning schedule for lamps and shields of light fixtures – particularly in dusty environments.
- Implement a regular re-lamping program.
- When re-lamping, it is most economical to change all the lamps at the same time.
- Reduce or switch off unnecessary outside floodlights and signs.
- Reduce parking lot lighting when lot is not in use.
Low cost
- Use motion detector light switches where feasible, e.g., offices, storerooms, etc.
- Consider using motion detector light switches or photocells for outside floodlight control.
- Install automatic lighting control by time clock that will switch off lights at predetermined times (with overriding provision for local areas).
- Provide adequate task-focused rather than general space lighting.
- Where the environment permits, paint the walls and ceilings with lighter colours and use the light reflection to improve the brightness of the workplace.
Retrofit; high cost
- Replace lower-efficiency lighting with more efficient types (e.g., mercury lamps with high-pressure sodium lamps).