Stamping High Bay Lighting Retrofit

Project Summary

The facility evaluated in this project produces electric automobiles and powertrain components. The site is anchored by the Main Assembly Building, a two-story, three-million square-foot, steel-framed structure, and several other buildings that house various departments. These departments include Stamping, Plastics, Casting, Paint, Utilities, and ancillary support buildings. Some shops, such as Casting and Utilities, operate on a continuous basis, 8,760 hours per year. Most others run two shifts per day, five days per week. Lockheed Martin Energy's Heavy Industry Energy Efficiency Program (HIEEP) performed a site audit to identify potential energy savings, and found opportunities through replacing the lighting in the Stamping Shop.

The first Energy Efficiency Measure (EEM-1) was Phase I of the replacement of the metal halide fixtures with 162.6-watt LED high bay fixtures. A total of 237 ceiling-mounted fixtures were replaced out of the initial 396 fixtures. Some fixtures were relocated to better suit the equipment layout. A total of 17 new fixtures were added to the retrofit areas. All of the pre-retrofit fixtures were 400 watts. The replacement fixture installed was the HB2011-03-50-3/40-20 by Cool Lumens. The second Energy Efficiency Measure (EEM-2) installed advanced lighting controls to the Stamping Shop high bay lights. The third Energy Efficiency Measure installed seventeen fixtures in Stamping and sixteen in HPDC. The HB2011-03-50-3/40-20 fixtures by Cool Lumens were used for this measure. Lockheed Martin Energy engineers adhered to IPMVP Option C to verify the energy savings for the project.

The EEM-1 lighting efficiency cost savings were $36,890 per year. The project costs totaled to $215,452, and the measure was eligible for an incentive of $40,261, based off the unit incentive rates of $0.08 per kWh and $150 per peak kW. This lowered the capital cost to $175,191. The EEM-3 cost savings were calculated to be $2,084 per year. The actual measure costs totaled to $13,572, and the incentive was $2,274, lowering the capital cost to $11,298. EEM-2 cost savings were not included in Phase I. The total cost of this project was $229,024. This project was eligible for an incentive of $42,535, which lowered the total cost to $186,765. The cost savings per year totaled to $38,974, resulting in a simple pay-back period of 4.79 years.

Project Team

PGE Logo
Program Pacific Gas and
Electric Company
Lockheed Martin Logo
Lockheed Martin Energy
Heavy Industry Energy Efficiency

Goals

Identify and quantify cost-effective energy savings

Strategies

Metal halide lighting fixtures were replaced with LEDs and relocated to better suit the needs of the facility and reduce the quantity of fixture

Benefits:

Energy Savings

442,888 kWh/year 71.04 kW peak

Equipment Installed

162.6-watt LED high bay fixtures

Financial Analysis:

Annual Cost Savings

$38,974

Net Project Cost:

$186,765

Project Incentive

$42,535

Simple Payback

4.79 years

It is our objective to assist PG&E heavy industry customers in:

Improve product quality and production rate
Identify process-focused energy efficiency improvements and other opportunities
Facilitate electricity and natural-gas energy efficiency equipment and demand reduction upgrades
 
Reduce operating costs per unit of product
Reduce waste, pollutants, and Green House Gas emissions
 

Increased production efficiency = Lower production costs = Increased profits