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Before embarking on the process of an industrial LED retrofit project, building owners and engineers should recognise that there is more to it than just replacing existing lights with LEDs. A good LED retrofit will improve the performance of light output, utilise energy effectively, reduce maintenance costs, and create value during its entire lifespan, without compromising light quality or system reliability. In this article, we will be providing an outline of the way industrial LED retrofit projects work, energy-saving calculations, the applicability of LED retrofit, and the way Pyrotech conducts the assessment of an existing lighting system before proposing a retrofit solution.

What Are Industrial LED Retrofit Solutions?

LED retrofit solutions for industries include the installation of an efficient LED lighting system on an already existing infrastructure system wherever possible. This does not mean the entire lighting system needs replacement but involves improving the lamps, LED drivers, optics, or even some of the fixtures in order to make them more efficient. A good LED retrofit will help improve efficiency as well as illuminate performance while reducing the load and costs of operation.

The design process will involve evaluating a number of aspects, such as compatibility of the fixtures, lux required, hours of operation, environmental conditions, and electrical infrastructure. LED retrofits for industries have been widely used for high bay lighting, flood lighting, well glass lighting, bulkhead lighting, street lighting, warehouse lighting, workshop lighting, and industrial lighting.

Why Industries Upgrade Existing Lighting Systems

From this perspective, the operation of industrial lighting fixtures usually takes place in challenging environmental conditions and requires constant functioning. Energy efficiency and reliability of lighting fixtures are the two major aspects that have to be considered here. In this case, over time, traditional lighting fixtures may consume energy, require regular maintenance, and provide insufficient illumination.

LED retrofitting of your industrial lighting fixtures is a great way to go, due to which you will have the opportunity to improve your lighting system effortlessly through minimising energy consumption, enhancing the efficiency of lighting, optimising the performance of light and adding some additional features (occupancy sensing and daylight harvesting). Nevertheless, whether to use LED retrofits or not has to be estimated.

How Pyrotech Determines Whether an Industrial LED Retrofit Is Required

The process of deciding on conducting the LED lighting retrofits will be carried out in an organised way where Pyrotech will carry out an analysis of the situation at hand regarding the technical and economic aspects, including things like the existing lighting system, load capacity, lighting hours, power consumption, luminescence, status of the fixtures, and lighting controls.

Pyrotech recommends LED lighting retrofits or replacements after the analysis is carried out.

Industrial LED Retrofit Assessment Checklist

Before suggesting an industrial LED retrofit system, Pyrotech takes into account the following factors:

• The existing lighting fixture to check the compatibility for retrofitment.
• Number of fixtures and their wattage to calculate the total connected load.
• Number of operating hours per year to determine the total energy consumption.
• The present value of lux level and lighting uniformity to determine lighting efficacy.
• Beam angle and optics for proper distribution of light.
• Life-cycle cost assessment based on maintenance history.
• Environmental conditions assessment including IP rating and ambient temperature.
• LED surge protection and LED driver performance for improved electrical reliability.
• The existing lighting controls for automation possibilities.
• Feasibility of the retrofit solution to determine whether to retrofit the existing fixture with LEDs or replace it altogether.

Common Mistakes during Industrial LED Retrofitting

The main reason why a retrofit project for industrial LED lighting is inefficient is the ignorance of some important engineering factors during the planning process. The factors that are mostly ignored during the planning process include: 

• Usage of fixture selection based on wattage regardless of its uniformity, 
• Wrong usage of the beam angle
• Ignorance of environmental factors
• Ignorance of surge protection and drivers 
• Not conducting the lighting assessment. 

In conclusion, every premise has special needs, and hence the lighting assessment becomes very crucial in the entire process of lighting.

Industrial Applications of LED Retrofit Solutions

Retrofit solutions of industrial LED lighting can be used in different industries where savings in energy costs and improvements in illumination levels can be achieved. Different premises have unique needs, and thus the right solution will be chosen after technical assessment. The common places where this technology can be used include: 

The lighting applications of this technology in the aforementioned places include high bay lighting, flood lighting, well glass lighting, bulkhead lighting, street lighting, warehouse lighting, workshop lighting, area lighting, utility lighting, and process plant lighting.

Factors to Consider Before Selecting an Industrial LED Retrofit

The following are the technical aspects that need to be kept in mind while deciding upon the right kind of retrofits for industry:

• Required lumens for a particular application.
• Flexibility of the existing fixtures to be used in retrofits.
• LED power and lumens, along with the efficiency of lighting.
• Beam angles and optics of the LEDs.
• COLOR RENDERING INDEX and colour temperature.
• IP rating and capability to work at ambient temperatures.
• Surge protection capability along with the capability to handle input voltages.
• Reliability of LED drivers.
• The way LEDs are to be mounted.
• Controlled lighting system – Occupancy detection, daylight harvesting.
• Hazardous area approval.
• Total cost of maintenance and life cycle.

How Pyrotech Delivers Industrial LED Retrofit Solutions

This is achieved through the engineering approach of designing an application that will be able to meet the requirements of the specific plant. This requires evaluating the existing lighting application and different parameters such as the connected load, operating hours, lighting levels, among others, and technical evaluation of the specific lighting case. At this point, Pyrotech will be able to determine the viability of the retrofitted project, develop the application-specific LED lighting, compare energy savings and lifecycle costs of both systems, and develop an implementation strategy.

Illustrative Example

In an example, if there are 100 LED High Bay light fixtures in a manufacturing plant where the power rating is 200 watts and luminous efficacy is 100 lm/w. Hence, after the lighting audit:

• Power rating of existing light fixtures: 200 watts; Luminous efficacy: 100 lm/w
• Electrical load of existing lights: 100 × 200 watts = 20,000 watts (20 KW)

After the lighting audit, it is clear to Pyrotech that the use of LED High Bay lights, which are more energy efficient (170-180 lm/w), would suffice for lighting.

• Lighting retrofit solution
• Lighting Provided: 90 LED High Bay Light Fixtures
• Power rating of provided light fixtures: 150 watts, 170-180 lm/w
• Electrical load of provided lights: 90 × 150 watts = 13,500 watts (13.5 KW)

Calculation

• Connected electrical load of existing lights = 20.0 KW
• Connected electrical load of provided lights = 13.5 KW
• Connected electrical load reduction = 20.0 –13.5 = 6.5 KW
• Reduction %= (6.5 ÷ 20.0) × 100 = 32.5%

Benefits

• Reduction in connected electrical load
• Reduction in annual energy consumption
• Reduction in number of fixtures to be installed and maintained
• Improvement in lighting efficacy and uniformity
• Reduction in life cycle cost of operation and maintenance

Frequently Asked Questions (FAQs)

1. Why does my industrial plant consume too much energy for its lighting systems?

Yes, since the lighting system could be inefficient. The use of LED retrofit technology will allow me to decrease the total connected load of the lighting system and maintain sufficient light levels.

2. How can I save money on maintenance of my industrial lighting systems?

I can save money on maintenance since LED retrofits will allow me to have more durable LEDs and drivers, reducing lamp changes, maintenance operations, and downtime.

3. Why is the lighting not uniform even though there is a sufficient number of fixtures?

This is due to either the wrong choice of fixtures, poor optical configuration, or an old lighting system. The industrial LED retrofit allows for non-uniform lighting due to the right beam angle and proper placement of lighting.

4. There are frequent malfunctions in my lighting system in industry. How can this problem be solved?

Yes, since this might be due to an old and/or inefficient lighting system. With a properly engineered LED retrofit, I will have reliable LED drivers, surge protection and proper fixtures.

5. Can I reduce my lighting energy expenses without replacing my lights?

Yes, but this can be done if there is the possibility to perform the retrofit taking into account the available fixtures. A lighting audit will help you define whether the LED retrofit or lighting fixtures upgrade is for you.

6. Is LED retrofit possible in an industrial setting?

Yes, but it depends on the LED retrofitting solutions that will suit your conditions of installation. IP protection class, operating temperature, dust and moisture resistance, corrosion and vibrations are the major parameters for selection of LED retrofits.

7. How will I know whether the LED retrofits are profitable for me?

Technical and economic analysis of your lighting will allow you to evaluate the energy consumption, maintenance costs, cost of ownership and ROI of your solution.

8. Do industrial LED lights increase workplace safety?

Yes, if it was done correctly. Improved illumination, lighting uniformity, low levels of glare and reliable light sources ensure better visibility.

9. Are LED retrofits compatible with lighting automation?

Yes, but depending on the specific conditions of your installation, the LED retrofits can be used in combination with lighting automation through occupancy detection and daylight harvesting.

10. How long does an industrial LED retrofit take?

The time required for completing the project depends on the facility size, installation complexity, and operational needs. Proper assessment of the project will allow creating the correct project schedule with minimal disturbance of operations.

11. Can existing fixtures of industrial lighting systems be utilised?

They can be used if they are physically fit and technically compatible with the selected LED retrofit approach. Technical assessment allows evaluating whether it is possible to retain existing fixtures.

Higher performance of the lighting system is more important. LED retrofits aim to provide proper illumination, lighting uniformity, reliability, and lifespan performance.