Job

Job During the last quarters of 2002 and 2003, Retro-Tech Systems, Inc.. completed a two phase lighting upgrade encompassing 600,000 sq. feet in two buildings, including exterior building and parking lot lighting. Scope These projects included the replacement, conversion or retrofit of over 11,000 fixtures. In Phase One, office area 4-lamp, T12 fluorescent lay-in troffers were replaced with new 3-lamp, T8 lay-ins. In the warehouse, 3-lamp, T12 high output industrial fixtures were replaced with new 320-watt, pulse start metal halide low bay fixtures and 2-lamp, T12 high output industrial fixtures were replaced with new T8 fixtures. New modular fixture connections, switches and motion sensors were installed. Remaining T12 fixtures were retrofit with T8 lamps, electronic ballasts and, in some cases, specular reflectors. Remaining 400-watt metal halide low bay fixtures were retrofit with 320-watt pulse start metal halide lamp and ballast kits. Incandescent fixtures were retrofit with screw-in compact fluorescent lamps and all exit signs were replaced with new LED exit signs. Exterior high pressure sodium wallpack fixtures were replaced with new metal halide fixtures.

In Phase Two, office area 3-lamp, T12 lay-in troffers were delamped and retrofit with T8 lamps, electronic ballasts and specular reflectors. New modular fixture and switch connections were installed. Fluorescent dimming controls and motion sensors were also installed in specified areas. Remaining T12 fixtures were retrofit with T8 lamps and electronic ballasts. In the Plant, high pressure sodium and metal halide fixtures were retrofit with pulse start metal halide lamp and ballast kits. Existing 2-lamp, T12 high output industrial fixtures were retrofit with T8 lamps, electronic ballasts and specular reflectors. New timer control panels, including manual overrides, were installed for all metal halide fixtures. New emergency lighting fixtures were installed and connected to the existing generator circuit. All exit signs were replaced with new LED exit signs. Exterior high pressure sodium parking lot, bollard and wallpack fixtures were replaced with new metal halide fixtures. New lenses were installed to replace missing, cracked or discolored lenses. The owner was able to standardize their lamp and ballast inventory, reduce the cooling load and improve the overal quality of their lighting system. Light levels meet IES standards for each respective area type.

Results

The energy savings for this project were impressive. Annual kW and kWh usages were reduced 36% and 49% respectively. The two facilities expect to realize over $180,000 in annual energy cost savings. Maintenance cost savings are also significant. The existing fluorescent lighting system was comprised of standard 4' and high output 8' T12 lamps that have an average life of 20,000 to 12,000 hours, respectively. The long life 4' T8 lamps installed have an average life of 24,000 hours.

For more information, please contact Joe Belda or David Pierce.

Before - Plant highbays with high pressure sodium lamps and ballasts

After - Plant highbays with pulse start metal halide lamp and ballast retrofit kits