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Power Plant Facility Lighting


Our power plant lights are DLC Qualified and highly efficient. We have high temperature models rated to replace 400W and 1000W Metal Halide in areas up to 190F...

Power Plant Facilities face a tough task of maintaining safety while decreasing operating costs. With LED power plant facility lighting solutions, you can achieve explosion proof lights that are safe for nuclear power plants and will reduce energy consumption.


One Source LED Solution for Power Plant Facilities


Power Plant Lighting at Night


LED power plant lights are not your typical LED lights. These are lights designed to withstand the hot, dusty, moist environments that power plants have. While other LED lights will break down at the extreme temperatures prevalent in power plants, power plant LED lights have a high temperature limit of 190F and can endure temperatures as low as -85F.

They are powerful enough to replace the traditional 400W-1000W HID lamps commonly used in power plant lighting. These lights are also equipped with a safety cable for added security. They also have an IP66 or higher rating which makes them ideal for the heat-filled and steam-filled environments in power plants.

LED power plant lights are also designed for easy installation and can be quickly mounted when required. They also integrate easily with wireless control systems to allow for ease of use as well as energy saving measures. These lights also emit very little heat in temperature controlled environments and contain no toxic substances, which allows for easy disposal.

Challenges of Power Plant Lighting

Power plants – which are also known as power generation plants or power stations – are a critical component of today's life. Without them, there would be none of the comforts we take for granted. They have been around since the 1800s when water drawn from lakes was used to generate hydropower.

Today, power plants have numerous generators which are used to convert mechanical power into electricity. The construction of a power plant often affects the environment around it. Some of the effects are often permanent while some are temporary.

Coal-fired power plants, for example, have tall buildings and relatively high exhaust stacks which can be a safety hazard for aircrafts. These tall structures can have heights of up to 275M and therefore must have aviation warning lights on top of them.

For a long time, xenon flashers were used on these towers; but today, high power LED lights are used because they are more effective. The cooling towers of a power plant also require aviation lights. These imposing structures can also have an off-putting visual impact on the local people.

The light emitted from some of the tall buildings in power plants can also be a bother to the nearby residents. Stray light at night from aircraft warning lights, coal pile lighting, or plant building lighting are often a huge problem for power plants located near urban settlements. A good lighting system should ensure that there is little or no light spilling onto the neighborhood adjacent to the power plant.

Fossil fuel or biomass fired power plants emit high levels of hot steam and air in the process of spinning turbines to generate electricity. Nuclear power plants, on the other hand, use nuclear fission that creates steam to produce power. This process usually creates exhaust gases.

These byproducts of the electricity generation process make power plants uniquely hot environments. Most light bulbs are not ideal for these locations because they are highly susceptible to damage. Power plants also have strictly regulated lighting fixture requirements and maintenance schedules. In power plants, lighting maintenance cannot go hand in hand with some power generation processes.

Proper lighting in a power plant ensures safety in production, increased productivity by the employees, and also adheres to health and occupational regulations. With the general focus today being efficiency in energy usage, power plants must have energy-efficient lighting mechanisms.

In the past, power plant lighting focused on efficiency of lighting and relegated other important factors to the background. But today's lighting plan has to focus not only on reduction in power usage, but also a decrease in bulb replacements, ease of lighting control, high quality illumination, and maximized lighting of the focus area.

Energy savings must be all about adequate quality and brightness of the light – the right amount of lumens must be used. Power plant lighting must have a safety element to it and also offer convenience in maintenance (the lighting fixtures must be easy to care for). This shows that high-quality lighting fixtures and sources are therefore paramount to power plant lighting efficiency.

Nuclear power plants have tightly regulated lighting requirements. The luminaries used in these environments have to illuminate with the sole of purpose of reducing risks during operations. These environments require luminaries that adhere to the newer nuclear post-Fukushima guidelines.

They need to have rounded and smoother surfaces to ease decontamination. They should also have a high IP rating to withstand hose downs and reduce time spent on them when performing decontamination tasks. Rounded, hot-environment luminaries will also ensure that accidental exposure of workers (like shard features in light fixtures tearing a protective suit or gloves) is eliminated.

Underwater LED lighting fixtures should also have an IP68 rating to ensure that they can be fully immersed under water safely. They should have stainless casing or lexan polycarbonate for protective covers. Lexan polycarbonate is over 30 times more resistant to impact than regular safety glass. This novel material also offers protection from radiation – up to 300 percent more than acrylics.

Lenses in these fixtures are typically resistant to radiation to ensure that the lights have optimal illumination and transitivity. While traditional light fixtures are made with glass or PMMA, these materials turn brownish due to radiation, causing reduced illumination. LED power plant lighting fixtures use crystalline based materials that withstand radiation well.

Nuclear power plant lighting should also have as few small parts as possible. They should be devoid of too many nuts and bolts to ensure fewer accidents happen. One tiny screw falling into the pool can lead to the drainage of the entire pool in order to locate and dispose of it. Lighting fixtures that require meticulous maintenance practices are therefore out of the question. Relamping schedules -when required – should be carried out without the use of excessive tools.

Lighting fixtures for nuclear power plants should be in compliance with IEEE Recommended Practice for Seismic Qualification of Class 1E Equipment for Nuclear Power Generating Stations, also known as IEEE-344.

The lighting fixtures in a nuclear power plant must emit powerful white light and have a CRI rating of 85 and above to ensure contamination is easily detected. They should also be properly enclosed to ensure that dust does not accumulate in them.

Most LED lighting technolgies for nuclear power plant lighting are still under extesive testing for their promising uses in nuclear power stations. They are particularly a favourite in emergency lighting protocols and in-air solutions.

LED Power Plant Lights for the Outdoors

High-Mast Lights

These are light fixtures used to illuminate vast outdoor spaces from a high level. In power plant lighting, they are used to light up pedestrian, transportation areas, storage areas, and also provide security.

High-mast lighting fixtures are usually mounted high (on lighting poles with heights ranging from 40ft to 150ft) and each pole may have anywhere between 4 to 16 light fixtures. Traditional high-mast fixtures utilized HID lights for illumination, but today LED high-mast lights have taken over due to their many advantages over HID lighting.

HID high-mast lighting is very energy inefficient because it produces a lot of infrared energy. These lights also have ballasts that pull additional energy to function properly. Their shorter lifespans than those of LED high-mast lights often cause disruptions in the functions of power plants as lamp or ballasts have to be frequently changed out. The high costs of these replacements and the labor (electricians have to be paid), together with the work interference, can really affect the operations and the bottom line of a power plant.

Metal halide HIDs also experience accelerated lumen degradation, and the light output of the lamps decreases rapidly after installation. The light usually turns from white to pinkish with time, barely providing any illumination.

High pressure sodium lamps, on the other hand, emit orange light and have a very low color rendering index. This means that with HPS lights, colors will hardly be visible to the human eye as they will be rendered almost monochromatic.

Flood-Lights

Flood-lights are exterior lights commonly mounted on lighting poles to provide light to different space types. They are mostly used to provide illumination to pedestrian walks, vehicles, and for safety and security in a power plant.

Traditional flood-lights relied on HID and fluorescents for lighting. But these light sources are very energy inefficient and have very high maintenance costs. LED flood-lights are not only energy efficient, but they also provide high-quality light as well.

LED flood-lights greatly enhance visibility because they have superb color rendering capabilities. Their benefits to outdoor spaces include excellent light distribution – because they emit light in a directional manner, unlike fluorescents and HIDs which are multidirectional.

Exterior lighting in a power plant can be a source of discomfort and light pollution to the neighboring communities. LEDs can help alleviate these shortcomings with their focused light.

LED Shoebox-Lights

LED shoebox-lights make perfect substitutes for older HID shoebox or parking lot lights. They can help save up to 80% of your parking lot lighting costs. They are also long-lasting and can provide bright light for years without any need for replacements. When combined with the right optics, LED shoebox-lights can help create a broad scope of lighting that is intense and effective.

LED Power Plant Lights For the Indoors

High-Temperature High Bays

LED high-temperature high bay lights are perfect for areas exposed to temperatures as low as -85°F and as high as +190°F. Power generating plants are typically high heat environments and require lights with powerful heat sinks to work optimally.

High-temperature high bays not only provide adequate indoor light, they help enhance safety, productivity, and security in a power plant. These lighting fixtures perfectly replace older 200W-1000W HID lamps and have long lifespans, too.

Retrofit Units

Industrial grade LED retrofit-kits for power plant lights are the energy-efficient alternatives to traditional HID lamps. They can increase energy savings by up to 75% since they replace older energy inefficient bulbs and ballasts .

These retrofit-kits are also designed to be paired with intelligent lighting controls to ensure that light is switched on and off on demand. They pair well with photocells, timers, motion sensors, dimmers, occupancy sensors, and other lighting control options. Lighting controls can help save energy by switching off light when it isn’t needed or by adjusting light output and intensity from 100% downwards.

LED Tube-Lights

LED tube-lights are ideal replacements for T12, T10, and T8 fluorescent tubes. They are superior to problematic fluorescents which have a short life expectancy and utilize ballast technology.

Just like fluorescent tubes, they have bi-pin configuration. All an electrician does is bypass or take out the fluorescent ballasts, driving electricity straight to the LED linear tube-lights or the LED drivers and powering the LEDs. With their 50,000-hour plus lifetimes, they are perfect for environments that need high performance lighting.

Top Considerations for LED Power Plant Lighting

Ability to Work with Lighting Controls

LED dimming can do much more than mood lighting. With digital controllers, you can enhance LEDs’ benefits of providing visual comfort, safety, security, and energy efficiency. Due to these advantages and many others, LEDs are quickly gaining traction and replacing older lighting technologies around the globe.

The advancement of LED technology has also given rise to the development of processes and devices that can integrate with this lighting technology. LEDs will pair easily with dimmers, push-buttons, and sensors.

Paired with IoT gadgets, LEDs can deliver smart lighting solutions to power plants. Each LED has an electronic driver that can be locally controlled and digitally addressed. LEDs for power plant lighting can therefore be controlled through dimming daylight and presence detection.

What Are the Benefits of LED Lighting Controls?

  • Energy Savings
    LEDs become even more energy-efficient when dimmed. Once they are integrated with systems like daylight dimming or occupancy sensors, they increase cost savings for power plant lighting. With intelligent controls that turn off lights once a space is vacated by people, lights can be turned off automatically when not in use, saving a lot in energy costs.
  • Comfort
    High-quality lighting drives up workplace productivity. It also enhances the mood of the people in that environment while reducing eye strain. With light sensors, LEDs can be controlled to prevent excess lighting and minimize glare, making the environment more conducive for working.
  • Ease of Use
    LED power plant lights paired with push buttons and pre-programmed scenes can ensure that the facility's manager has full control of all lights in all locations through a simple handheld device. There are mobile apps for advanced lighting systems that ensure that this process is streamlined further.

The Optics

LEDs have a primary optic that gives directional lighting at 180 degrees. This can be too broad for some power plant applications because the light tends to reduce in intensity over distance. Some LED power plant lights therefore have reflectors and/or secondary lenses to alter this light radius and generate more focused light.

These lenses are total internal reflection (TIR) design lenses, often made of silicone or clear acrylic. The lenses have an advantage over reflectors, in that once they cover a light source, they reduce annoying glare from LED lights.

LED power plant lights should have lenses that reduce glare. Poorly designed optics will result in bright spots that create a lot of wasted stray light that can be a nuisance to the neighborhood if used in the exterior. This glare is not only distracting but can be dangerous as well, particularly for people working in the plants.

UL Rating

UL ratings, also known as Underwriters Laboratories Ratings, are very important when choosing LED power plant lights. These ratings identify which lamps can be used in damp, dry, or wet conditions and which ones cannot. A dry rated lamp, for example, will break down fast in a wet or humid environment.

Underwriters Laboratories is an independent international organization that establishes standards and regulations for a wide range of products, ranging from beverage to electric equipment. While you may find that not all lights are UL certified, lights used in special applications like power plants have to undergo performance and compliance testing to meet the required standards.

Types of UL Listings

  • For Dry Locations
    This listing is known as UL Listing for Dry Locations. If a LED light is UL Listed for Dry Locations, it can be used in dry locations indoors (areas not usually subject to dampness). The UL Listing of a light fixture is usually written on its packaging box. It is sometimes labeled as a simple "no" or "yes". A "yes" implies that the lamp should be used in dry locations only while a "no" means that the LED light fixture has not been tested by the UL.
    While brief exposure to temporary dampness may not damage UL Dry Rated lamps, overly wet and continuously damp environments will. LED high-masts, flood-lights. and shoeboxes used in power plant applications should be UL Listed for Dry Locations.
  • For Damp Locations
    This listing is known as UL Listing for Dry Locations. LED lamps and retrofits suitable for use in the often wet and humid power plant environments should be UL Listed for Dry Locations. Lamps with this kind of listing can be used both indoors and outdoors in places where humidity and moisture are prevalent but cannot be submerged in water or installed in places where they are in direct constant with flowing water. LED lamps that are UL Listed for Damp Locations should be used hand in hand with fixtures that are UL Listed for Damp Locations to prevent corrosion and damage to the fixtures.
  • For Wet Locations
    This listing is known as UL Listing for Wet Locations. LED power plant lights ideal for use in wet locations can withstand immersion in liquids. These lamps have extensively been tested in wet environments and their performance has been certified. Lights listed as safe for use in wet environments can be hosed down in nuclear power plants since they are designed to handle drips, flows, and splashes of water.

IK Rating

A LED light's IK rating specifies its degree of protection against automatic wear and tear. It also indicates the amount of physical impact a light can handle without disintegrating. Impact is often measured in joules (J). A joule is a unit of energy. Joules are also units of heat and work and 1 joule is equal the impact of a small apple dropped from a 3- feet height.

IK Rated LED lamps have to withstand five hits of specified joules at specified attack angles, in a controlled laboratory environment. The IK rating system is comprised of the numbers 1 to 10, whereby a higher number indicates the ability to withstand greater impact.

An IK08 rated LED lamp can, for example, withstand 5 joules, which is the impact of at least 1.7kgs of weight dropped from a height of 300mm. The impact tested is not intense or direct force like that of a sledgehammer. An IK10 rated LED light, on the other hand, can withstand four times the impact of an IK08 rated light, meaning it can endure the impact of a heavy tin of paint dropped on it from a height of at least half a meter.

K Code

Protection Achieved

IK00

No protection

IK01

Can withstand 0.14 joules impact. This is equal to the impact of a mass of 0.25kg dropped from a 56mm height.

IK02

Can withstand 0.2 joules impact. This is equal to the impact of a mass of 0.25kg dropped from an 80mm height.

IK03

Can withstand 0.35 joules impact. This is equal to the impact of a mass of 0.25kg dropped from a 140mm height.

IK04

Can withstand 0.5 joules impact. This is equal to the impact of a mass of 0.25kg dropped from a 200mm height.

IK05

Can withstand 0.7 joules impact. This is equal to the impact of a mass of 0.25kg dropped from a 280mm height.

IK06

Can withstand 1 joules impact. This is equal to the impact of a mass of 0.25kg dropped from a 400mm height.

IK07

Can withstand 2 joules impact. This is equal to the impact of a mass of 0.5kg dropped from a 400mm height.

IK08

Can withstand 5 joules impact. This is equal to the impact of a mass of 1.7kg dropped from a 300mm height.

IK09

Can withstand 10 joules impact. This is equal to the impact of a mass of 5kg dropped from a 200mm height.

IK10

Can withstand 20 joules impact. This is equal to the impact of a mass of 5kg dropped from a 400mm height.

 

IP Rating

IP stands for Ingress Protection and shows how well a device is protected against the intrusion of liquid and solid particles like water and dust. The first number after the words “IP” rates protection against solid object intrusion while the second number rates protection against water intrusion.

The first number rates solids intrusion from 1 to 6, with 1 being a solid object larger than 50mm (for example, the size of your hand). A light with a rating of 6 is completely safeguarded against dust. The water rating in the second digit ranges from 1 (for slow drips of water) to 8 for submersion in water.

Most LED power plant lights should be protected from high levels of liquids and solids intrusion. This is because power plants are extreme environments that have a lot of dust and moisture. When it comes to nuclear power plants, submersion is a possibility.

First Number

Protection

Second Number

Protection

0

No protection

0

No protection

1

Objects with a diameter of 50mm

1

Against dripping water

2

Objects with a diameter of 12.5mm

2

Against dripping water, tilted at 15°

3

Objects with a diameter of 2.5 mm

3

Against sprayed water, at a 60°angle

4

Objects with a diameter of 1 mm

4

Splashing water from all directions

5

dust

5

Water jets from all directions

6

Dust tight

6

Powerful water jets and heavy seas

 

 

7

Submersion for a specified time at depths of 15cm to 1m

 

 

8

Long periods of immersion under pressure

 

Anti-Corrosive Abilities

Anticorrosive LED lights for power plants are not only corrosion resistant but water resistant, dust resistant, and shock resistant. They make excellent substitutes for HIDs and fluorescents and offer up to 75% energy savings, helping reduce carbon emissions as well.

These LED lights have non corrosive IK08 polycarbonate casings complete with stainless steel mounting clips. They are commonly known as integrated LED fittings. This is because they are usually retrofitted onto a metal gear waterproof casing. Integrated LED fittings last long thanks to their enhanced heat dissipation technology.

Ability to Withstand Extremely High Temperatures

Most areas in a power plant are high temperature environments and require high temperature light fixtures. There are LEDs that can withstand temperatures as high as 190°F. They often have big heat sinks to keep them functioning in temperatures that will quickly destroy older lighting technologies.

Generally, LEDs function better in low temperature environments than in high temperature environents. The cooler temperatures enhance their light output. But don’t take this to mean that they do not work optimally in high temperatures. High temperatures LEDs with powerfudwfl heat sinks and other mechanisms last longer and produce better-quality light than HIDs or flourescent lights.

To prove this, the Department of Energy carried out a research on solid state lighting performance versus that of quartz metal halide high-output lighting fixtures in high temperature outdoor environments. Done along the US-Mexican border stretch near Yuma, AZ, the research sought to quantify LEDs’ energy saving benefits and their perfomance in the harsh and hot desert climate that has been very unfriendly to older lighting systems.

The temperatures in this location can hit highs of over 100°F, which degrade the light fixtures’ semiconductors, greatly shortening their lifespan. The results from the study were very positive, showing that LED lighting fixtures can not only withstand the high heat and harsh environment better than QMHs, but also provide a higher quality of light for enhanced national security operations.

The high temperature LED light fixtures were able to perform these functions better while mounted at lower heights than the QMH fixtures. This showed that maintenance and installations would be faster, easier, and more cost effective than for QMHs. The LEDs also provided 69% energy savings while lowering light pollution, thanks to their directional lighting capabilities.

Top Benefits of LED Power Plant Lights

Better at Lighting Distribution

Fluorescent tube-lights generally radiate light in a 306-degree angle over their entire surface. LEDs, on the contrary, radiate their light in a 110-120-degree angle. This means that with fluorescents, only half of the light output is directed downwards towards a task area. The rest of the light is lost to the environment, illuminating areas that do not require lighting.

LEDs radiate all their light downwards. So if, for example, an LED power plant light and a florescent tube both emit 1500 lumens, the fluorescent may only direct 750 of its lumens to the target area while the LED directs all of 1500 lumens to the area.

Fluorescent and HID lamp fixtures normally use hoods or reflectors to mitigate the light loss issue but they still lose a significant amount of their light to diffusion and poor directional control, which greatly reduces their operating efficiency.

When LED retrofits are used in place of these traditional light sources, they deliver high quality light directly to the target area and still increase a power plant's energy savings. LEDS last up to 5 times longer than fluorescent tubes. LEDS also have no ballasts that need replacements since they have built-in drivers to regulate the current. They help reduce a power plant's lighting expenses drastically.

They Are Virtually Maintenance-Free

Proper lighting maintenance is paramount for proper light levels and also helps increase energy efficiency. In large power plants and industrial spaces, a process known as group relamping is carried out to cut down on lighting and labor costs. Group relamping also improves the appearance of the space while minimizing the disruptions of spot relamping.

Group relamping is considered a more economical option to spot relamping if the labor costs required to spot relamp one light fixture minus the labor costs to group relamp one lamp end up being greater than the cost of a new lamp. This essentially means that functioning bulbs can be replaced if the labor savings can offset the higher lamp costs.

The case for group relamping is fuelled by the fact that fluorescents should be changed out at 60%-70% of their lamp life. However, group relamping poses a lot of questions on the sustainability of maintenance schedules for older light sources.

LEDs have no need for these maintenance schedules. Their lamp life is rated at the point where a 30% reduction in light output is experienced. For traditional bulbs, lamp life is rated at the point where half of the bulbs are expected to fail!

For LEDs, relamping schedules should not be expected until the lamps have operated for over 50,000 hours. LED power plant lights do not have a mortality curve like HIDs or fluorescents. LEDs therefore eliminate the need for spot relamping. LED lights will keep generating 70% of their original lumens throughout their lifetimes, unless they have an automatic shut off mechanism.

The maintenance and relamping schedules for LED power plant lights can be optimized by combining them with other operations such as cleaning of fixtures. And even with a 70% lumen output, LEDs do not shift color with time like HIDs.

When it comes to disposal, LEDs pose less of a disposal challenge than fluorescents and HIDs because they have less toxic substances in them. In addition, the number of bulbs being disposed of will be less than for traditional light sources.

The powerful technology driving the expansion of the LED lights market is maturing by the day and its benefits go beyond performance and energy efficiency. Yes, LEDs have extremely long lives hitting ranges of 50,000 to 100,000 hours, but there’s more to them. It is possible that in the future, LEDs will end the age of periodic bulb changes.

When Combined with Intelligent Lighting Systems, They Revolutionize Lighting

LED lights today can do more than just light up your power plant. They can lessen the impact of lighting on your environment while boosting comfort, safety, and the productivity of your workers. When LEDs are paired with intelligent systems, they become smarter and even more sustainable lighting solutions for power plants.

LED intelligent lighting systems include power monitoring units, networked communications, and sensors. LEDs can do more when utilized as smart lighting fixtures that adapt to their environment, communicating to the power plant managers on energy use and maintenance schedules. This helps increase energy savings because it optimizes energy, reduces operating costs, and increases lamp life.

Unlike fluorescents and HID lamps that have long warm-up times, LEDs do not have such requirements. HID lamps also have inconvenient restrike time delays as they have to be left to cool down before they are switched on again. LEDs have no restrikes times and can be turned on and off on demand.

HIDs and fluorescents also have a limited dimming range while LEDs are very dimmable. And since LEDs are directional lights, those with a slightly lower lumen output can make perfect replacements for traditional lights with a higher lumen output. This feature also does away with the need to install many LED light fixtures in an application, because the total luxes required can be produced by fewer LEDs – since there is no light wastage.

All these features make it so easy to integrate LEDs with intelligent lighting systems. Intelligent LED light fixtures have inbuilt occupancy and daylight sensors, enabling them to easily adapt to their environments.

Daylight sensors will detect the amount of natural light in the environment and dim or turn off the lights when they are not needed. Occupancy sensors, on the other hand, turn off power plant lights when a space is empty.

With integrated power metering, a facility can also track how much energy each light fixture is expending. This will make it easier for a facility manager to develop better strategies that improve efficiency by cutting down wastage.

A facility manager can, for example, see the variation in energy usage as a sign that certain fixtures require maintenance or replacement. By networking LED power plant lights, the whole power plant lighting system will be smarter, enabling the lights to communicate with each other through central control.

Networked intelligent lighting fixtures can perform remote sensing and shut downs, tracking, reporting, and emergency control. When wireless systems are used, they increase this flexibility and cut costs further.

A Case Study on the Benefits of LED Power Plant Lights

The Drax Power Station in North Yorkshire, England, reported drastic improvements in energy efficiency and costs once the facility converted to LED. Over the years, its HPS lights had become a maintenance headache since they were difficult to access, making the biannual maintenance difficult. Relamping also took up too much time; it was time for a more efficient lighting solution.

The maintenance technicians settled on LED lighting whose installation was done fast – in a period of six days. The total numbers of light fixtures were reduced from 50 to 35, thanks to the focused, high-quality light that LEDs provide. The total wattage consumed dropped from a high 11,050W to a low 4,700W!

LEDs stay cooler than HID lamps and fluorescents and have less dust and dirt clinging to them electrostatically. This means that they require less maintenance and relamping can be done during seasons when it will not affect the power plant in terms of downtime.

LED power plant lights are built for the high abuse environments that are power plants. They are rugged, energy-efficient, easy to use and control, and will bring about up to 90% improvements in lighting costs and efficiency.


Some of our Power Plant Customers

We have completed successful large projects for:
  • Tennessee Valley Authority (TVA)
  • American Energy Power (AEP)
  • DTE Energy