Chen, K."Industrial Illuminating Systems The electrical Engineering Handbook Ed. Richard C. Dorf Boca raton crc Press llc. 2000
Chen, K. “Industrial Illuminating Systems” The Electrical Engineering Handbook Ed. Richard C. Dorf Boca Raton: CRC Press LLC, 2000
107 Industrial Illuminating Systems 107.1 New Concepts in Designing an Industrial Iluminating Syst Determination of Illuminance Levels. Illuminatio Computational Methods 107.2 Factors Affecting Industrial Illumination Basic Definitions. Factors and Remedies. Daylighting 107.3 System Components Light Sources. Ballasts. Luminaires 107.4 Applications Types of Industrial Illuminating Systems. Selection of the 107.5 System Energy Efficiency Considerations Carlsons Consulting engineers Controls. Lighting and Energy Standards 107.1 New Concepts in Designing an Industrial Illuminating System Determination of illuminance levels Among the many new concepts for lighting design, the first to be discussed is the new method of determining illuminance levels. In the past when illuminating engineers wanted to find the recommended illuminance ley for a given task, they would look in the lighting handbook to find a recommended level and then design an uminating system for the task using the value as a minimum. This procedure provides very little latitude for fine-tuning an illumination design. In the new method, a more ce ive investigation of requir 1. Instead of a single recommended illuminance value, a category letter is assigned. Table 107.1 shows rent category letters for a selected group of industries(partial only; for complete list see IES Lighting Handbook [1993]) 2. The category letters are used to define a range of illuminance. Table 107. 2 details illuminance categories and illuminance values for generic types of activities in interiors 3. From within the recommended range of illuminance, a specific value of illuminance is selected after onsideration is given to the average age of workers, the importance of speed and accuracy, and the The importance of acknowledging the speed and accuracy with which a task must be performed is readily recognized. Less obvious is the need to consider the age of workers and the reflectance of task background. c 2000 by CRC Press LLC
© 2000 by CRC Press LLC 107 Industrial Illuminating Systems 107.1 New Concepts in Designing an Industrial Illuminating System Determination of Illuminance Levels • Illumination Computational Methods 107.2 Factors Affecting Industrial Illumination Basic Definitions • Factors and Remedies • Daylighting 107.3 System Components Light Sources • Ballasts • Luminaires 107.4 Applications Types of Industrial Illuminating Systems • Selection of the Equipment 107.5 System Energy Efficiency Considerations Energy-Saving Lighting Techniques • Lighting Controls • Lighting and Energy Standards 107.1 New Concepts in Designing an Industrial Illuminating System Determination of Illuminance Levels Among the many new concepts for lighting design, the first to be discussed is the new method of determining illuminance levels. In the past when illuminating engineers wanted to find the recommended illuminance level for a given task, they would look in the lighting handbook to find a recommended level and then design an illuminating system for the task using the value as a minimum. This procedure provides very little latitude for fine-tuning an illumination design. In the new method, a more comprehensive investigation of required illuminance is performed according to the following steps: 1. Instead of a single recommended illuminance value, a category letter is assigned. Table 107.1 shows different category letters for a selected group of industries (partial only; for complete list see IES Lighting Handbook [1993]). 2. The category letters are used to define a range of illuminance. Table 107.2 details illuminance categories and illuminance values for generic types of activities in interiors. 3. From within the recommended range of illuminance, a specific value of illuminance is selected after consideration is given to the average age of workers, the importance of speed and accuracy, and the reflectance of task background. The importance of acknowledging the speed and accuracy with which a task must be performed is readily recognized. Less obvious is the need to consider the age of workers and the reflectance of task background. Kao Chen Carlsons Consulting Engineers
TABLE 107.1 Illuminance Categories for Selected Group of Industries Illuminance Continuousbelt ca Hand packing Moderately difficult olives Difficult DEF Examination of canned samples Very difficult Container handling EEDEFFE Automobil GHDDDD Can unscramblers Face of shelves Central stations(see Electric generating stat Inside of mixing bowl al plants) Fermentation room Clay and concrete products Grinding, filter presses, kiln room Sweet yeast-raised products Color and glazing olor and glazing-fine work Fillings and other ingredients DDDDDDDDEDDDEF Cleaning and pressing industry Decorating and icing Mechanical Dry and wet cleaning and steaming Inspection and spotting CDEEFEEGFF Scales and thermometers Wrapping Repair and alteration Cloth products Folding, assembling, pasting Cutting, punching, stitching Embossing and inspection ewin Breweries Clothing manufacture(se GFD Boiling and keg washing Receiving opening, storing, shipping Filling(bottles, cans, kegs) Examining(perching) Candy making Sponging, decanting, winding, measuring Box department Chocolate department snowing, fat extraction, DDDDDD and refining, feeding ning, sorting, dipping, packing Pping E Cream making ewins Gum drops and jellied forms Control rooms (see Electric generating stations--interior) Corridors(see Service spaces Mixing, cooking, molding Die cutting and sorting DDDDEE Cotton gin industry Overhead equipment-separators, driers, grid Kiss making and wrapping cleaners, slick machines, conveyers, feeder Initial grading raw material samples Gin stand D Control console Color grading and cutting int cleaner tomatoes ilk industry Olives F Boiler room Cutting and pitting E Bottle storage Final sorting Bottle sorting Industry representatives have established a table of single illuminance values which, in their opinion, can be used. Illuminance for specific operations can also be determined using illuminance categories of similar tasks and activities found in this t and the application of the appropriate weighting factors Source: IES Lighting Handbook, Application Volume. e 2000 by CRC Press LLC
© 2000 by CRC Press LLC TABLE 107.1 Illuminance Categories for Selected Group of Industries Illuminance Illuminance Area/Activity Category Area/Activity Category Aircraft maintenance a Canning Aircraft manufacturing a Continuous-belt canning E Assembly Sink canning E Simple D Hand packing D Moderately difficult E Olives E Difficult F Examination of canned samples F Very difficult G Container handling Exacting H Inspection F Automobile manufacturing Can unscramblers E Bakeries Labeling and cartoning D Mixing room D Casting (see Foundries) Face of shelves D Central stations (see Electric generating stations) Inside of mixing bowl D Chemical plants (see Petroleum and chemical plants) Fermentation room D Clay and concrete products Make-up room Grinding, filter presses, kiln rooms C Bread D Molding, pressing, cleaning, trimming D Sweet yeast-raised products D Enameling E Proofing room D Color and glazing—rough work E Oven room D Color and glazing—fine work F Fillings and other ingredients D Cleaning and pressing industry Decorating and icing Checking and sorting E Mechanical D Dry and wet cleaning and steaming E Hand E Inspection and spotting G Scales and thermometers D Pressing F Wrapping D Repair and alteration F Book binding Cloth products Folding, assembling, pasting D Cloth inspection I Cutting, punching, stitching E Cutting G Embossing and inspection F Sewing G Breweries Pressing F Brew house D Clothing manufacture (see Sewn Products) Boiling and keg washing D Receiving opening, storing, shipping D Filling (bottles, cans, kegs) D Examining (perching) I Candy making Sponging, decanting, winding, measuring D Box department D Piling up and marking E Chocolate department Cutting G Husking, winnowing, fat extraction, D Pattern making, preparation of trimming, piping, E crushing and refining, feeding canvas and shoulder pads Bean cleaning, sorting, dipping, packing, D Filling, bundling, shading, stitching D wrapping Shops F Milling E Inspection G Cream making Pressing F Mixing, cooking, molding D Sewing G Gum drops and jellied forms D Control rooms Hand decorating D (see Electric generating stations—interior) Hard candy Corridors (see Service spaces) Mixing, cooking, molding D Cotton gin industry Die cutting and sorting E Overhead equipment—separators, driers, grid D Kiss making and wrapping E cleaners, slick machines, conveyers, feeders Canning and preserving and catwalks Initial grading raw material samples D Gin stand D Tomatoes E Control console D Color grading and cutting rooms F Lint cleaner D Preparation Bale press D Preliminary sorting Dairy farms (see Farms) Apricots and peaches D Dairy products Tomatoes E Fluid milk industry Olives F Boiler room D Cutting and pitting E Bottle storage D Final sorting E Bottle sorting E a Industry representatives have established a table of single illuminance values which, in their opinion, can be used. Illuminance values for specific operations can also be determined using illuminance categories of similar tasks and activities found in this table and the application of the appropriate weighting factors. Source: IES Lighting Handbook, Application Volume
TABLE 107.2 Illuminance Categories and Illuminance Values for Generic Typ ivities in Interiors Ranges of Illuminances Category Footcandles Reference work-plane with dark 20-30-50 2-3-5 rientation for short 50-75-100 5-75-10 General lighting pace 100-150-200 10-15-20 throughout spaces casionally performed Performance of visual tasks of high contrast 200-300-500 20.-30-50 r large size Performance of visual tasks of medium E 500-750-1,000 Illuminance on task contrast or small size Performance of visual tasks of low contrast 1,000-1,500-2,000 100-150-200 or very small size Performance of visual tasks of low contrast and very small size over a prolonged perio Performance of very prolonged and exacting 5000-7,500-10000500-750-1,000 nation of ger isual tasks Performance of very special visual tasks of 10000-15000-20,0001,000-1,500-2,000 lighting) Source: IES Lighting Handbook, Application Volume. To compensate for reduced visual acuity, more illuminance is needed. Using the average age of workers as the age criterion is a compromise between the need of the young and the older workers and, therefore, a valid criterion Task background affects the ability to see because it affects contrast, an important aspect of visibility. More illuminance is required to enhance the visibility of tasks with poor contrast. Reflectance is calculated by dividing the reflected value by the incident value. The data given in Tables 107.3 and 107. 4 are taken from the IES Lighting Handbook [1987] and are applied to provide a single value of illuminance from within the range Illuminating system design can begin after the desired value of illuminance for a given task has been determined. Based on the IES Handbook, the zonal cavity method of determining the number of luminaires and lamps to yield a specified maintained luminance remains unchanged. Illumination Computational Methods Zonal Cavity Method. Introduced in 1964, the zonal cavity method of performing lighting computations has gained rapid acceptance as the preferred way to calculate number and placement of luminaires required to tisfy a specified illuminance level requirement. Zonal cavity provides a higher degree of accuracy than does the old lumen method, because it gives individual consideration to factors that are glossed over empirically the lumen method Definition of Cavities. With the zonal cavity method, the room is considered to contain three vertical or cavities. Figure 107.1 defines the various cavities used in this method of computation. Height for luminaire to ceiling is designated as the ceiling cavity (ha). Distance from luminaire to the work plane is the room cavity (hr), and the floor cavity(hg)is measured from the work plane to the floor. for each of the three cavities. Following is the formula for determining the cavity rtig e"cavity ratio"(CR) To apply the zonal cavity method, it is necessary to determine a parameter known as th 5h(room length (107 (room length x room width) where hequals ha for ceiling cavity ratio(CCr),hn for room cavity ratio(rCr),h for floor cavity ratio(FCR) e 2000 by CRC Press LLC
© 2000 by CRC Press LLC To compensate for reduced visual acuity, more illuminance is needed. Using the average age of workers as the age criterion is a compromise between the need of the young and the older workers and, therefore, a valid criterion. Task background affects the ability to see because it affects contrast, an important aspect of visibility. More illuminance is required to enhance the visibility of tasks with poor contrast. Reflectance is calculated by dividing the reflected value by the incident value. The data given in Tables 107.3 and 107.4 are taken from the IES Lighting Handbook [1987] and are applied to provide a single value of illuminance from within the range recommended. Illuminating system design can begin after the desired value of illuminance for a given task has been determined. Based on the IES Handbook, the zonal cavity method of determining the number of luminaires and lamps to yield a specified maintained luminance remains unchanged. Illumination Computational Methods Zonal Cavity Method. Introduced in 1964, the zonal cavity method of performing lighting computations has gained rapid acceptance as the preferred way to calculate number and placement of luminaires required to satisfy a specified illuminance level requirement. Zonal cavity provides a higher degree of accuracy than does the old lumen method, because it gives individual consideration to factors that are glossed over empirically in the lumen method. Definition of Cavities. With the zonal cavity method, the room is considered to contain three vertical zones or cavities. Figure 107.1 defines the various cavities used in this method of computation. Height for luminaire to ceiling is designated as the ceiling cavity (hcc). Distance from luminaire to the work plane is the room cavity (hrc), and the floor cavity (hfc) is measured from the work plane to the floor. To apply the zonal cavity method, it is necessary to determine a parameter known as the “cavity ratio” (CR) for each of the three cavities. Following is the formula for determining the cavity ratio: (107.1) where h equals hcc for ceiling cavity ratio (CCR), hrc for room cavity ratio (RCR), hfc for floor cavity ratio (FCR). TABLE 107.2 Illuminance Categories and Illuminance Values for Generic Types of Activities in Interiors Illuminance Ranges of Illuminances Type of Activity Category Lux Footcandles Reference Work-Plane Public spaces with dark surroundings A 20–30–50 2–3–5 Simple orientation for short temporary visits B 50–75–100 5–7.5–10 General lighting Working spaces where visual tasks are only throughout spaces occasionally performed C 100–150–200 10–15–20 Performance of visual tasks of high contrast or large size D 200–300–500 20–30–50 Performance of visual tasks of medium contrast or small size E 500–750–1,000 50–75–100 Illuminance on task Performance of visual tasks of low contrast or very small size F 1,000–1,500–2,000 100–150–200 Performance of visual tasks of low contrast and very small size over a prolonged period G 2,000–3,000–5,000 200–300–500 Illuminance on task, obtained by a combination of general and local (supplementary lighting) Performance of very prolonged and exacting visual tasks H 5,000–7,500–10,000 500–750–1,000 Performance of very special visual tasks of extremely low contrast and small size I 10,000–15,000–20,000 1,000–1,500–2,000 Source: IES Lighting Handbook, Application Volume. cavity ratio 5 (room length + room width) (room length room width) = ¥ h
TABLE 107.3 Weighting Factors for Selecting Specific Illuminance Within Ranges A, B, and c Weighting Factor 0 Under 40 40to55 Over 55 30to70% <30% Note: This table is used for assessing weighting factors in rooms where a task is not involved. 1. Assign the appropriate weighting factor for each characteristic. 2. Add the two weights; refer to Table 107. 2, Categories A through C: a. If the algebraic sum is -l or-2, use the lowest range value. b. If the algebraic sum is 0, use the middle range value. C. If the algebraic sum is +l or +2, use the highest range value. "To obtain average room reflectance: determine the areas of ceiling, walls, and floor; add the three to establish room surface area; determine the proportion of each surface area to the total multiply each proportion by the pertinent surface reflectance; and add the three numbers obtained TABLE 107.4 Weighting Factors for Selecting Specific Illuminance Within Ranges D Task or worker eighting Factor Workers' age(average) Over 55 Speed or accuracy" Not important Important Reflectance of task background, >70% 30to70% Source: IES Lighting Handbook, Application Volume. Note: Weighting factors are based upon worker and task information. 1. Assign the appropriate weighting factor for each characteristic. 2. Add the two weights; refer to Table 107. 2, Categories D through I a. If the algebraic sum is-2 or-3, use the lowest range value. b. If the algebraic sum is-1, 0, or +l, use the middle range value. c. If the algebraic sum is +2 or +3, use the highest range value. Evaluation of speed and cy requires that time limitations, the effect of error on safety, quality, and cost, etc be considered. For example, leisure reading imposes no restrictions on time, and errors are seldom costly or unsafe. Reading engineering drawings or a micrometer requires curacy and, sometimes, speed. Properly positioning material in a press or mill can impose demands on safety, accuracy, and time. CEILING CAVITY luminaire nares一 ROOM CAVITY Fioor FIGURE 107. 1 Basic cavity divisions of space e 2000 by CRC Press LLC
© 2000 by CRC Press LLC TABLE 107.3 Weighting Factors for Selecting Specific Illuminance Within Ranges A, B, and C Occupant and Room Weighting Factor Characteristics* –1 0 +1 Workers’ age (average) Under 40 40 to 55 Over 55 Average room reflectance1 >70% 30 to 70% <30% Source: IES Lighting Handbook, Application Volume. Note: This table is used for assessing weighting factors in rooms where a task is not involved. 1. Assign the appropriate weighting factor for each characteristic. 2. Add the two weights; refer to Table 107.2, Categories A through C: a. If the algebraic sum is –1 or –2, use the lowest range value. b. If the algebraic sum is 0, use the middle range value. c. If the algebraic sum is +1 or +2, use the highest range value. *To obtain average room reflectance: determine the areas of ceiling, walls, and floor; add the three to establish room surface area; determine the proportion of each surface area to the total; multiply each proportion by the pertinent surface reflectance; and add the three numbers obtained. TABLE 107.4 Weighting Factors for Selecting Specific Illuminance Within Ranges D through I Task or Worker Weighting Factor Characteristics –1 0 +1 Workers’ age (average) Under 40 40 to 55 Over 55 Speed or accuracy* Not important Important Critical Reflectance of task background, % >70% 30 to 70% <30% Source: IES Lighting Handbook, Application Volume. Note: Weighting factors are based upon worker and task information. 1. Assign the appropriate weighting factor for each characteristic. 2. Add the two weights; refer to Table 107.2, Categories D through I: a. If the algebraic sum is –2 or –3, use the lowest range value. b. If the algebraic sum is –1, 0, or +1, use the middle range value. c. If the algebraic sum is +2 or +3, use the highest range value. *Evaluation of speed and accuracy requires that time limitations, the effect of error on safety, quality, and cost, etc. be considered. For example, leisure reading imposes no restrictions on time, and errors are seldom costly or unsafe. Reading engineering drawings or a micrometer requires accuracy and, sometimes, speed. Properly positioning material in a press or mill can impose demands on safety, accuracy, and time. FIGURE 107.1 Basic cavity divisions of space