Case Study - Why LED lights should be used in place of HPSV & Tube-lights in any Plant / Industries which are running 24 x 7

Its an old article, but despite seeing so many HPSV light in industries, thought to post it again

Everywhere in India concentration is placed on use of effective & efficient energy systems.

My mail is regarding benefits of HPSV lights vs LED lights, saving that can be made when we replace HPSV or Fluorescent Tube lights with LED Lights.

 And if you are not using LED lights in plants than you should definitely start using it. We have seen plants which have completely opted for LED Lights

 A Quick look at that below, Which i have observed in my last plant

• A 70 Watt HPSV light should take current around 0.3-0.4 Amp but takes around 0.7-0.8 Amp due to presence of choke with Power Factor around 0.9-0.92 if capacitor is there.
• An Equivalent LED light for 70 W HPSV is 40 Watt and it takes around 0.18-0.22 Amp with PF 0.98 -0.99 and Lumens more than 70 Watt HPSV. Only difference is colour.

Both checked with same clamp meter, Energy meter and Lux Meter.

Same was the Case with 150 Watt, 250 Watt and 400 Watt, HPSV Light. You too can check Current of HPSV lights of 70, 150, 250 and 400 watt and you will know the difference

We changed 70 Watt HPSV lights and 40/36 Watt Fluorescent Tube-lights with 40 Watt LED lights and 20 Watt LED Tube. Our first target was to replace all those lights which are running 24 x 7 so to get faster Payback and savings

Now this is very much beneficial for those industries who are taking power from Grid and Paying Demand charges

Suppose you replace 100 Nos 70 W HPSV with 100 Nos 40 W LED lights and 200 Nos 36 W Tube-light with 20 W LED rod, which are running 24 x7.

So Direct saving is 30 Watt X 100 = 3 kW and 16 Watt x 200 Nos = 3.2 kW means reduction of 6.2 kW or say 6 KVA demand.

As the number of replacement increases demand comes down and so the savings, Suppose your demand come down by 5 KVA and per KVA demand is Rs 300 per KVA, means saving of around Rs 1500 Per month and around Rs 18000 per year.

Payback period calculation of LED lights against HPSV Lights and Fluorescent Tube-Lights is less than 2 years for lights that are running 24 x 7

I wish every Electrical Engineer got the idea how to save energy and reduce your electricity bill.

Locations where replacement with LED will benefit industries

1)      CCR, Admin Offices, Lubrication Room, Load Centres or Substations (Where in Florescent Tube-lights can be replaced with LED Tube light which almost runs for 24 X 7 Hour. 36 / 40 Watt can be easily replaced with 18/20 Watt)

2)      Cable Cellar and Transformer Room

3)      Enclosed Room like Compressor rooms, Electrical or Mechanical Workshop, or any enclosed room (Packing Plants, etc)

4)      Inside Silos (Silos is used for storing semi-finished or Finished material)

 Many Benefits of LED Lights apart from Load reduction are as below:

1)      Reduction of Lighting Load with same lumen (i.e 70 Watt HPSV = 35-40 Watt Led, 150 Watt HPSV = 70-80 Watt LED, 250 Watt HPSV = 120-150 Watt LED)

2)      Reduction of Current Due to less wattage and non use of Choke, Ignitor and Capacitor, hence reduction of Copper loss I(Sqr)X Resistance

3)      Reduction of KVA requirement of lighting transformers due to Point 1 &2

4)      Reduction of Maintenance cost due to non use of Choke, Ignitor and Capacitor which is mostly required to be changed after every 2 year. Also LED gives guarantee of 2-3 years depending on Manufacturer

5)      HPSV light is hot light if it is on for more than 10 - 20 minutes you will not be able to touch it as it produces heat, But LED is cool light. Hence saving Environment.

6)      Reduction of Running Cost, which will lead into Reduction in KWH / Tonne of finished product

7)      Minimum effect with Fluctuation of Voltage, as LED Lights work at Voltage Range from 90 – 300 Volts, reducing their failure chances.

8)      Lesser harmonics in Power System due to non use of Choke, Ignitor & Capacitor in HPSV lights.

Regards

Avinash Singh

[email protected]