25 Mar HG Molenaar: Machinery Assembly
BHA Lighting is privileged to have been commissioned to prepare lighting designs for HG Molenaar in phases as identified by the Managing Director to bring the entire factory to compliance and for energy efficiency as they continue to mitigate for load shedding and to become entirely independent from ESKOM.
The First Phase project was for the final assembly area. The area is defined by three bays under sections of the saw tooth roof with translucent vertical panels to allow as much natural daylight into the area as possible.
The overall area is area 37m x 33m. Therefore, each bay is 37m x 11m. The mounting height of the luminaires is 7.1m. In each individual bay, there are two overhead cranes. All luminaires had to be mounted above the moving overhead cranes.
The light levels before the installation varied from 20 lux to 560lux. See below:
Clearly this fell short of the required daylight illuminance levels over the entire floor area. The old luminaires were 54 x 1200mm x 600mm fluorescent 4 x 40W tube luminaires. The Total power per area (1146.60m²) was 6.9W/m². They produced a total of 660,000lm!
THE LIGHTING DESIGN CONCEPT
The aim throughout was to ensure that all new lighting would be designed to comply with both South African National Standards and most importantly with the International standard EN 12464-1: 2021: Light and Lighting: Lighting of Workplaces – Part 1: Indoor Workplaces. The lighting design had to include the provision of emergency lighting, specifically, emergency escape lighting for the safe evacuation considering that large steel manufactured components would have to be negotiated during evacuation. Sometimes, the components of food processing plant and machinery occupy the full length of a bay or more. The lighting design had to make provision for illuminance levels for both daylight and night-time operations to a minimum of 500lx at 0.75m.
The lighting requirement was discussed during a face-to-face meeting was held together with the Managing Director and the Operations Manager.
BHA Lighting, recommended that advanced technology luminaires be used for the project with the following capabilities:
- Occupancy sensing.
- Daylight harvesting.
- Energy management.
- Bluetooth mesh.
- Smart Device software for setup and control.
There was instant buy-in to our recommendations. This was made easier because we had completed the lighting design for the Managing Director’s Knysna holiday home using smart technology. The project was completed and commissioned in December 2021.
THE LIGHTING DESIGN
We spent time researching products that would meet our requirements with capabilities as defined above. We also looked at the reputation of the supplier, the reliability of the supplier especially during the procurement phase and the warranty offered by the supplier. The supplier was also able to provide us with the range of test reports required to meet our stringent requirements.
After careful evaluation, we chose to use products from ALTSA (Alternative Lighting Technical Solutions for Africa). The choice had a further advantage, Philip Hammond had known the CEO of ALTSA, Gerhard Moolman, since 2011.
We completed the lighting design using various luminaires from the ALTSA luminaire range before finally selecting the Galaxy Linear High Bay each fitted with individual sensors. Each luminaire or group of luminaires or all luminaires operate on Bluetooth Mesh which is setup using an application for Android- smartphones.
The target illuminance level defined in SANS 10114-1: 2020: Interior Lighting and EN 12464-1: 2021: Lighting of Interiors, was 500lx at 0.75m working plane.
The new lighting design used 54 x ALTSA 100W Galaxy Linear High Bay produced 3400lm each. The total power per area was 4.70W/m² producing 918,000lm. Apart from being more energy efficient when operating at full power, during daylight hours, they were even more energy efficient as the daylight harvesting and occupancy sensing functioned, thereby reducing power consumption.
Now look at extracts from the Lighting Design Report where it is clearly shown that the entire floor area illumination exceeds the design target illumination of 500lx. The maximum illuminance achieved was 699lx.
The image below is a 3D visualization from the lighting design software showing the aiming of the individual luminaires.
The lighting design was presented during a virtual meeting. The lighting design was accepted and the Purchase Order was issued by the end of the 20 minute virtual meeting.
THE RESULT
The new ALTSA 100W Galaxy Linear High Bay luminaires were delivered and installed in late July 2022. They were commissioned at the beginning of August 2022 and the installation was given the remainder of the year to settle down.
Final Measurement and Verification was completed on 19 December 2022 with no variation or deviation from the lighting design results. This was clear proof of the quality of the luminaires. The Certificate of Conformity was issued on 19 December 2022. See Certificate of Conformity below:
The energy savings to date have been excellent combined with fully a compliant intelligent lighting solution. The energy savings reported by the luminaires via the Application over Bluetooth Mesh is about 25% considering that part of the evaluation period started during winter and went through to mid- summer.
This project was Phase 1 of the lighting upgrade to compliance with all Standards and Regulations. Further case studies will follow for Phase 2, the sand and bead blasting facilities and the paint shop.
BHA LIGHTING DESIGN & CONSULTING – 24 MARCH 2023
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