Industrial shed I.P.A., Palermo (Italy) Energy saving and intelligent lighting with Intelux controllers
Energy saving and intelligent lighting with Intelux controllers - IPA Carini industries - Palermo (Italy)
The experience

I.P.A. Steel Pole Industry is a factory in Carini, in the province of Palermo, manufacturing lighting road poles and external ones in general. The management of I.P.A. had the aim to contain the top of energy consumption complying with European requests, such as those mentioned in Green-light European program, and conforming the lighting plant to the real productive needs, exploiting at the top the daylight

The solution

To achieve this aims I.P.A. has chosen Revetec, that has realized a special project through the installation of source controllers of Intelux Range. I.P.A.'s shed, having an area of about 1600 m2, has been subdivided into two areas, A and B, having a different daylight contribution.
The A area has been divided into 6 zones, each one served through three-phase line loaded by means of 10 metallic halide lamps of 400W. Each line is controlled by three source controllers of 3,7 kVA, one per phase with a common neutral wire.
During the daylight, the zones 3 and 4, active 24 hours a day, are set by a control unit at four predetermined lighting levels, enabling to choose the requested level according to their activities. All devices are assembled in one ventilated enclosure.
Instead the B area, composed of three zones, is served by three single-phase lines with three source controllers (7x400W) and one of 10 kVA (8x400W). Two photocells have been foreseen, one for the first zone and one for the others two. The necessary devices too, for the B zone are assembled in a ventilated enclosure.

Total number of lamps

82x400w (metal halide)

Total power

36kw

 

A area

18x3,7 kVA Intelux controllers

 

2 lux photocells

 

2 control units

 

 

B area

1x10 kVA Intelux controller (45A)

 

2x5,8 kVA Intelux controllers (25A)

 

2 lux photocells

 

2 control units

Table 1 - Characteristics of controller installation

The benefits

Keeping unchanged the predetermined lighting level in the working area, dimming is varied according to daylight presence, so to have a constant illumination.

The aims of the energy consumption control have been fully achieved. Owing to surveys effected in three zones of the finished plant, here-below the obtained results:

Zone

Nr. of lamps

Intelux controllers

Vin

Vout at max dimming

Max current at full load

Min. Current

 

400W(MH)

KVA

Vac

Vac

A

A

7

8

10

229

204,5

26,4

20,5

8

7

5,8

230

205,5

23,1

18

9

7

5,8

229

204,5

23,1

17,8

1R

2

3,7

226

205,4

6,6

5

1S

4

3,7

227

204,7

13,2

9,8

1T

4

3,7

227

205,2

13,2

9,9

4R

4

3,7

227

204,5

13,2

9,5

4S

2

3,7

226

206

6,6

5,2

4T

4

3,7

228

207

13,2

10,5

Table 2 - Benefits of the dimming system

Moreover, the investment benefits have been really positive:

Yearly working hours

4.225 h

Consumption without INTELUX

152.438 KWh

Consumption with INTELUX

114.338 KWh

Yearly percentage saving

25%

Energy cost

0,085 E/KWh

Yearly energy saving

38.100 KWh

Yearly management saving

770,00 €

Yearly total saving

4.008,00 €

Investment Cost ( installation Cost included)

13.560,00 €

Investment Recovery Time

3,38 anni

Table 3 - Investment benefits evaluation