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The opinions and views expressed in the Deciding When and How to Upgrade 12
editorial content in this publication are those
of the authors alone and do not necessarily James Gooding, Staff Writer
represent the views of any organisation with
which they may be associated. Locations of Lighting Solutions on Board the Rig
Material in advertisements and promotional The Choice of Provider
features may be considered to represent the
views of the advertisers and promoters. The A Step Up in Comparable Products
views and opinions expressed in this publication
do not necessarily express the views of the Hazardous Environments
Publishers or the Editor. While every care has
been taken in the preparation of this publication,
Conclusion
neither the Publishers nor the Editor are
responsible for such opinions and views or The Past, Present and Future of LEDs 14
for any inaccuracies in the articles.
Jo Roth, Staff Writer
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In a maintenance area The most efficient power supplies will a) Type I – Long and narrow beam Conclusions environment. In these confusing times,
perform with a PF above 99% and a distribution for applications such as Safety, reliability of operation and high where a misunderstanding can damage
THD below 15%. These performance aisles, catwalks, ramps, tunnels, long maintenance costs of traditional lighting expensive equipment and more importantly,
where the worker must characteristics display how efficiently passageways, conveyer belts, loading systems in harsh and hazardous environments impact human safety, it is crucial to rely on
power supplies minimize interference to docks etc. such as oil and gas refineries, chemical a trusted industry partner. Eaton’s Crouse-
use a black, white and other electrical equipment and reduce the b) T ype III – Semicircular kidney shaped processing plants, drilling and exploration Hinds Business has over 115 years of
load on an electrical system. beam pattern for Narrow crosswalks or rigs, and heavy industrial facilities have experience in dealing with harsh and hazardous
passages with wall luminaires, Tunnels become a critical issue globally. Plant managers applications and our products deliver safety
green wire, the low CRI Lighting Quality and Performance with wall mount, Wall stanchion mount with and engineers are facing safety concerns of and reliability where it matters most. With an
A lumen is the amount of light output in a 180° forward throw. frequent lighting failures and downtime in LED portfolio encompassing over 20 product
will prevent the ability specific angle from a light source. Often c) T
ype V – Circular beam pattern for environments with extreme temperatures, families across multiple global standards and
with LED luminaires the focus is on lumen Pendant, ceiling or stanchion mount explosive gases, combustible dusts and the largest installed base in hazardous
to discern between the output. With LED being such a directional overhead building, Processing mills, fibers, high pressure water hosing, vibration application lighting, Eaton’s Crouse-Hinds is
light, it requires less lumens than traditional industrial plants, large buildings, and corrosive fluids. LED luminaires provide your trusted source to enhance safety and
light sources and thus should not be compared warehouses etc. compelling safety benefits and long-term productivity in any installation.
black and the green to HID or fluorescent luminaires based on operational cost savings driven by long
lumens. Even when comparing LED luminaries According to the Illuminating Engineering maintenance- free economic life, reduced
wires and could result in across manufacturers, luminaire construction Society of North America (IESNA)3, color energy consumption, lower operating Contact
and optics play a major role and a pure lumen rendering indicates the degree to which a temperatures, enhanced electrical protection,
to lumen comparison is not always relevant. light source shows the true colors of the durability against vibration, dust, corrosion and Anshuman Bhargava
improper installation When comparing luminaires across both objects it illuminates. It is expressed in terms humidity, superior lighting quality, instant start/ Product Line Manager – LED Lighting
traditional and LED lighting, focus should be on of a color-rendering index (CRI) on a scale of restrike and ease of installation. As a result
the usable light on the work plane determined 0–100. The higher the CRI the truer people of this increased safety and lower total cost Eaton’s Crouse-Hinds Business
by the footcandle or lux reading. and objects look 4. HPS light luminaires of ownership, the trend has developed and 201 Wolf Street
Syracuse, NY 13208
LEDs, with their directional nature, are well typically have a very low rendering rating, continues to accelerate towards LED luminaires
suited to custom optics designed for specific on the order of CRI = 22. For example, in a replacing traditional light sources. tel: +1 315 477-5262
types of discrete LEDs or arrays to enable maintenance area where the worker must As with any new technology, many FAX: (315) 477-5179
uniform light distribution, higher coverage use a black, white and green wire, the low misconceptions exist around the benefits
and more delivered light to the work plane CRI will prevent the ability to discern between of LED especially as it relates to the anshumanbhargava@eaton.com
with minimal light loss and spill. This, in turn, the black and the green wires and could demanding applications such as the offshore www.crouse-hinds.com
results in maximizing application spacing result in improper installation. Therefore, if a
and minimizing the number of light luminaires processing area was replaced with an LED
required to illuminate effectively a work place. light luminaire with a CRI of 70, it would
Secondary optics also result in reduction of provide the workers three times more accurate References
glare in many applications which need constant color for quality checks, reading gauge
human interface such as control rooms and measurements, and performing precision [1] http://www.cdc.gov/niosh/topics/falls/
monitoring stations with reflective computer tasks. Improved color rendering provides [2] United States Department of Energy Office of Energy Efficiency & Renewable Energy,
screens. Common optics applications for a safer work environment and improves April 2013 (Revised May 2013), Adoption of Light-Emitting Diodes in Common Lighting
industrial locations are: workers’ quality of life. Applications
http://apps1.eere.energy.gov/buildings/publications/pdfs/ssl/led-adoption-report_2013.pdf, Washington, DC
[3] Illuminating Engineering Society of North America Light in Design – An Application Guide
IES CP-2-10 http://www.ies.org/PDF/Education/LightInDesign.pdf, New York, NY
[4] Lighting Research Center Rensselaer Polytechnic Institute What is Color Rendering,
February 2014
http://www.lrc.rpi.edu/programs/nlpip/lightinganswers/lightsources/whatisColorRenderingIndex.asp#
Troy, NY
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by constant switching cycles. The more they are EQUIVALENT AT 65% REDUCTION IN ENERGY COSTS
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SPECIAL REPORT: NEXT GENERATION LED LIGHTING FOR HAZARDOUS OFFSHORE AREAS SPECIAL REPORT: NEXT GENERATION LED LIGHTING FOR HAZARDOUS OFFSHORE AREAS
durable, provide better quality light and in maintenance. Better still, the construction (TARGETED, GENERAL, HIGH-BAY, FLOODLIGHTING, LINEAR)
service life, the rigours consume less energy. Even so, the industry is of LEDs is more robust meaning they are
a long way from adopting LEDs as the norm. less prone to breakages and other
If there is one factor that will change this unplanned failure. system experiences glitches resulting in down bulb by drawing only 50w of energy. In total
and challenges on board situation more than any other, it’s proving the In terms of energy consumption, we witness time and replacement. the refinery has reduced its energy usage by
commercial case. another sizable gulf. A 150W LED can emit • I nstallation cost: The upfront expense $34,668 while decreasing annual maintenance
as much, if not more, light than a 400W high of switching to LEDs. For many years this costs by $766,6479.
an oil rig mean lights Operating Cost pressure sodium tube. They demonstrate an has been the major obstacle to change in Such figures make compelling reading, but on
Oil rigs consume huge quantities of energy. Power energy efficiency improvement of around other industries. top of this we also have to consider other, less
often fail to reach their is normally supplied through diesel generators 50% on fluorescents and up to 80% over However, there are signs that LED technology easily measured factors, which nevertheless
consuming on average 20 – 30 M3 of diesel each incandescents. They also offer 100% brightness has reached a defining moment in its lifecycle have an impact on bottom line performance.
day6. Of that, approximately 20% is accounted on startup and sacrifice no life span when – one where the costs are coming down, and The superior light quality of LEDs contributes
predicted life span for by the demands of lighting the facility. With turned off and on, meaning operators can as a result, so has the payback period. From to increased productivity and worker wellbeing
fuel prices demonstrating a general upward shut down lighting in some areas during a situation in which payback could take as while also reducing the risk of slips, trips
trend, managing energy costs has become a off-peak times. long as 10 years, many sources estimate that and falls. This in turn reduces the danger of
top priority. any system pays for itself within five years. small damages claims made against the
In addition to this, maintenance represents Resistant to Change Small wonder that so many experts are operator, and the reputational impact of a high
a continual drain on production and profits. Even so, for all the apparent benefits, oil and predicting a rapid rise in the LED market in the accident rate.
Bulbs are prone to breakages and every gas remains far behind other industries in next few years7. In the end, any decision about whether to
blackout needs immediate remedy. Although adopting LEDs as the go-to technology. This switch or not is a numbers game. There is a
any bulb comes with a rated service life, the is partly due to the work involved replacing Working in the Real World temptation to be conservative, making the
rigours and challenges on board an oil rig mean millions of light bulbs world-wide with LEDs If there is one demonstration that will convince change only when the status quo becomes
lights often fail to reach their predicted life span. and also the inherently conservative nature of the doubters it’s to see LEDs delivering on uncomfortable. Certainly the majority of those
Maintenance is a round the clock proposition the oil and gas industry. Operators are juggling their promises in the real world, and among operators who have chosen to upgrade to
and with every power failure rigs experience a delicate balancing act; on the one hand those early adopters we already have just that. LED have done so either because energy
frustrating and costly down time. they want the latest and most advanced When Mexico’s largest oil company PEMEX or maintenance costs have started to bite.
technologies, but on the other they are reluctant decided to replace existing lighting with LED However, all the evidence gathered so far
A Compelling Case to commit to anything that does not have a long technology they experienced a 66% reduction suggests that the cost savings are real and the
It is here that lighting operators believe they and reliable track record. Before making a change in energy consumption8. payback could be earlier than initial estimates
have their pressure point, and it is one reason they want to be certain that new technology is Another major oil refinery in the US replaced and the earlier you make the change, the bigger
why so many manufacturers see oil and gas as effective and that it works better than what they incandescent sodium bulbs with LEDs which the potential savings. The old saying is true –
representing a huge growth opportunity. Just have already. provided the same amount of light as a 100W it pays to fix the roof while the sun is shining.
looking at the ratings of LED products illustrates Most of all they need to believe the higher
the scale of potential savings on offer. upfront cost of installation will rapidly be offset
Most LED products have an L70 rating which by long term cost savings. These costs can be
means you can expect them to run 60,000 – summarised as follows:
70,000 hours before light output reduces by •D owntime: the time spent offline during the
30% of maximum capacity. Some of the most replacement of light fittings.
advanced boast ratings of up to 100,000 hours • Risk: the danger that, once installed, the
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Deciding When
and How to Upgrade
James Gooding, Staff Writer
word here is ‘potential’. This is a market at a own multi-million dollar, 60,000 square foot
gas installations hold stage of considerable flux and development, in innovation centre dedicated specifically to products which can perform the same task but a reduction of 85%. In total, the refinery
which there are substantive quality differences research into LED technology10. This enables better. For this reason much of the output from the reduced its total energy usage by $34,668
between the best in class and the rest. Taking it to test and develop cutting edge products leading manufacturers are simply step forwards of while decreasing annual maintenance costs
a substantial lead over into account that an LED lighting system is and innovations, which are designed to existing fluorescent lighting technology. by $766,647.
designed to give many years of continual use, maintain its lead position in what is a highly An example of this can be seen with Eaton’s
decisions made at this point have a profound competitive sector. Crouse-Hinds Champ VMV LED11 series which Hazardous Environments
those who have yet to effect on the long term success or failure of Aside from product development, the centre is designed to exhibit the same durability and Any offshore oil rig will require products rated to
the installation. plays a role in educating and training potential reliability as the existing Champ Luminaire. withstand extreme and hazardous conditions
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The LED market is earmarked for considerable and rapid growth. This article
examines some of the key developments and innovations taking place around
the industry.
Some manufacturers
L EDS HAVE been around in one shape
or form ever since 1907 when Henry
Round discovered that inorganic materials
power consumption of any oil or gas facility.
When you consider that LED lights promise to
extend lifespans by up to 80% and more, and
There is a huge gulf to be filled, and much
like the Gold Rush of the 1800s there is a mad
scramble to fill it and become the acknowledged
have placed the costs of could light up when an electrical current reduce costs by anything between 50% and market leader. For this reason, the leading
was passed through them, but it wasn’t until 90%, this new technology looks like a compelling manufacturers are devoting substantial sums
the sixties that the first LEDs of any type proposition. Factor in the environmental benefits and resources into developing cutting edge
replacing faulty bulbs at made it to the market. It was even more recent, of reduced light pollution, carbon emissions, and technology. The result is that the new generation
in the 90s, that the first white light LEDs the fact that they contain no hazardous chemicals of LED applications provide increasing levels of
appeared. However, it is in the last few years such as mercury, and it is small wonder that so performance and quality.
anything up to $1,000, when the first LEDs outputting 100 lumens or many editorials are being run promoting the It’s with this in mind that we find Eaton’s
more per Watt appeared that they’ve become switch to LEDs. Crouse-Hinds Business opened a 60,000 square
once man hours, shut usable on a large industrial scale. foot LED research centre to trial and develop
With that power output has come a significant A Perfect Storm new technologies. This state of the art
growth in the use of LEDs. Most estimates Conditions certainly seem to be right for the multi-million dollar facility houses research,
down and special place the current share at around 18% of the adoption of LED technology. The safety of development, design, validation and
overall general electric market, but several conditions on board offshore oil rigs has been manufacturing of the very latest and cutting
studies agree that the next five or six years are a cause of growing concern over the past few edge LED technology for every area of
equipment are set for remarkable growth. According to a study years. The surface of an oil rig is a hazardous
LED TASKLIGHT REPLACES 100-200W INCANDESCENT,
PROVIDING 20 TIMES THE LIFE AND 85% REDUCTION IN business or industrial application.
by McKinsey, LEDs will incorporate 60% of the environment with workers often forced to ENERGY COSTS In multiple labs and R&D facilities, teams of
all factored in overall market by 2020. Price Waterhouse Cooper venture out in poor weather conditions, low mechanical, electrical, thermal, optical and
predicts, meanwhile, a 40% growth per year visibility and at night. Like any workplace, the reliability engineers work with industrial designers,
through 2016. LEDs, they say, have reached a operator of an oil rig has an obligation to provide to distinguish and the glare from floodlights technicians and manufacturing personnel to
turning point and could follow a similar trajectory a safe environment for its staff and good, clear, often blinded pilots. The recommended produce the next generation of LED solutions.
to solar panels, which experienced average 66% lighting is a key part of that. Fluorescent bulbs changes suggested included yellow LED13 strip The results of their work can be seen in a range
per year rise over the past three years12. However, are prone to failure and breakages leaving lights outlining the perimeter around the central of specialist LED lighting solutions for every part
an over investment into production led to a areas in the dark and with LEDs providing a illuminated ‘H’. of an offshore platform. For the most part
surplus of solar panels and a dip in prices with significant step forward both in terms of light this simply involved producing lighting products
the result that some manufacturers are struggling quality and reliability, there is an argument to Coming of Age which do the same job better, but there are
to be profitable. say that operators have an obligation to install More importantly, LED technology has now exciting innovations on the horizon such as the
Within this overall trend for LEDs, the oil and the best possible lighting technology. reached a point where quality is high enough use of solar power LEDs. Although incorporating
gas market – both for on and offshore facilities It is air travel, though, that has dominated safety for large scale industrial application, while only a tiny fraction of industrial LED products
– represents something of an undiscovered over the past few years after a series of helicopter solutions have become affordable enough currently, they do have some potential,
country. Thus far, market penetration of LEDs disasters. This places additional pressure on to make the financial proposition worthwhile. particularly in further reducing energy costs
lags far behind other industrial applications, but the quality of lighting on the helideck level. Current estimates suggest that the general and carbon footprint, while also producing a
the potential benefits are vast. Energy costs and Here, the better reliability, brightness, payback period has reduced to 3 years or less reliable and renewable backup to conventional
maintenance of power generation equipment range and penetration of LEDs represents from 10 in just a few years and that figure is lighting systems.
represent two sizable and continuous costs for a significant boost. The value of helideck arguably lower for high power consumption This competition between manufacturers
the oil and gas market. lighting was highlighted in a questionnaire operations such as offshore drilling. This has led to a rapid expansion in the quality and
Some manufacturers have placed the costs put to pilots in the nineties in which they ranked creates a unique moment of opportunity for sophistication of products on offer. The result
of replacing faulty bulbs at anything up to helideck lighting as being the fourth most lighting companies where the product they is that the calculation that rig operators make
$1,000, once man hours, shut down and special important factor in guaranteeing safety. The are developing offers real value for end when assessing the viability of LED lighting
equipment are all factored in. Lighting also responses suggested that current helideck customers. But, as yet, there are relatively low technology is progressively becoming heavily
accounts for approximately 20% of the overall lighting was inadequate; perimeters were hard levels of take up. weighted in its favour.
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SPECIAL REPORT: NEXT GENERATION LED LIGHTING FOR HAZARDOUS OFFSHORE AREAS
http://www.ledsmagazine.com/articles/print/volume-8/issue-9/features/lighting-market-report-predicts-strong-growth-for-led-lighting-magazine.html
2
Goldman Sachs optimistic about LED growth: http://www.ledinside.com/news/2013/10/goldman_sachs_optimistic_about_led_growth_in_2014
resource for senior upstream oil
and gas industry professionals.
3
LED Technology highlights on efficiency:
http://www.rigzone.com/news/oil_gas/a/128751/LED_Technology_Highlights_on_Efficiency_Savings_in_Oil_Gas_Industry
4
Homeowners turn to green energy: http://green-energy-products.com/led-lighting-light-bulbs/
5
Offshore helideck lighting: http://www.hsmemagazine.com/article.php?article_id=167
6
Offshore drilling rigs: http://www.ipieca.org/energyefficiency/solutions/60311
7
LED lighting a big growth story: http://seekingalpha.com/article/1602992-led-lighting-industry-a-big-growth-story
8
Cooper Industries brochure:
http://www.cooperindustries.com/content/dam/public/Corporate/Resources/Cooper%20Oil%20&%20Gas%20Interactive%20Brochure.pdf
9
Oil refinery case study: http://www.eaton.de/DE/Eaton/OurCompany/SuccessStories/ManufacturingIndustrial/OilRefinery/index.htm
Visit http://www.offshoretechnologyreports.com/
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