Energy efficiency measures - Other - Agricultural - Lights - Fluorescent T8 - electronic ballast / Canada
Case study assignment
Your client requires you to produce cost estimates and a design for a T8 twin tube fluorescent lighting system for a to-be-constructed (new) dual ventilated broiler turkey barn housing approximately 5,000 grower turkeys, from approximately 4 weeks of age to 16 weeks (in the barn for 12 weeks per turkey crop cycle).
Site information
The producer's existing facilities located on this site are traditionally mechanically ventilated barns with incandescent lighting. There is an interest in reducing energy input costs by upgrading from incandescent to a T8 twin tube fluorescent lighting system. As the barn is naturally ventilated and uses translucent sidewall panels that drop open in warmer weather, the potential to take advantage of natural lighting is present. As a result, the desired system should also use photocells for each row of fixtures. The photocells will then automatically adjust the fluorescent light output up or down as the day light increases or fades. The site is located near Mount Forest, Ontario, Canada.
Although the normal practise is to use inefficient incandescent lighting, there is no credit given towards the waste heat produced by the light system. Heat is typically supplied in the form of infrared radiant and only required under extreme cold and for very short time periods; as a result, the incandescent lighting has a limited impact on supplemental heat requirements.
The building dimensions are the following:
Financial information
Financial figures for the analysis are: inflation and fuel cost escalation rate of 2.5%, debt ratio of 60%, debt interest rate of 8.5%, discount rate of 9%, and debt term of 10 years. The turkey barn owner does not require a tax analysis.
Electricity rates are $0.10/kWh.
The installed cost of the incandescent lighting system is $15/fixture (50/50 labour and parts cost). The incandescent system consists of 204 lamps, 100 W per lamp with a low cost triac type dimmer control. Lamps last about 1,000 hours and cost $1.00 each to replace. Annual maintenance is calculated at $1,340, including lamp costs.
The fluorescent system is a twin tube (32 W per tube) T8 system with 62 fixtures. Each fixture will have digital dimming 4 W electronic ballast. The installed cost is $206/fixture (note: this includes the cost for controller, photocell, low-voltage control wiring, etc.). This works out to an "Incremental initial cost" of $9,712. The system should last about 20 years. Lamp life is about 24,000 hours. Lamp cost is $4.00 each. Assume the "incremental" labour cost for lamp changing is nil. Ballasts last 60,000 hours and cost $70 each. Labour cost is $20/ballast. Annual maintenance is calculated at $611 including lamp and ballast costs. This works out to an annual "Incremental O&M savings" of $729.
Prepare a RETScreen study, documenting any assumptions that you are required to make, and report on the significant conclusions from this analysis.
Solution
The worked-out solution is the data file selected from within the RETScreen Project Database. The user automatically downloads the Project Database file while downloading the RETScreen software.
Teacher's notes
Results
Two dual ventilated broiler turkey barns were constructed northwest of Toronto, Ontario, Canada for a large poultry producer. Many of the barns being operated by this producer are traditional in design. They are mechanically ventilated using exhaust fans and incandescent lighting on timer and dimmer control. The mechanically ventilated barns are completely reliant on electrical energy. This reliance and increasing fuel costs led this producer to consider alternatives to the traditional methods of lighting and ventilating poultry.
The most viable alternative for this type of production was a dual ventilation system with fluorescent tube lighting on dimmer and photocell control. This system provides a more secure option with reduced energy needs as well as lower operating and maintenance costs.
System description
The dual ventilation system uses curtain sidewalls which are partially translucent and allow a great deal of natural light to enter the facility during the day even when the curtains are closed. Supplementary light is reduced or not required as natural daylight increases. The lighting system is installed such that there are 3 rows running the length of the facility. Each row is on a separate circuit. A photocell is installed on each circuit and connected to the control system.
The lighting control system is completely automatic. This system operates on timer and dimmer control. An intermittent lighting schedule is used on this farm with the timer controlling the lighting cycles. The photocells monitor the intensity of light present in the barn. Based on the readings from the photocell, the dimmer adjusts the light intensity according to preset limits to meet the lighting needs of the birds. The dimmer simulates dusk and dawn by gradually raising light levels when the lights come on and gently lowering light levels just before lights go off. Instant on at full light output can startle the birds potentially causing production losses. By simulating dusk, the birds have time to settle before lights go off.
The controller is a GVA Control Lux-D with photocells. The dimmable T8 twin tube fluorescent lighting system and digital dimming electronic ballast is a GVA FA-D.
Lessons learned
The Province of Ontario is encouraging the adoption of energy conserving technologies. Electrical energy prices have been increasing in Ontario placing pressure on producers to reduce their electrical consumption. Dual ventilated turkey grower barns incorporating dimmable T8 twin tube fluorescent lighting systems and electronic ballasts on photocell control present an opportunity for producers to reduce their energy costs.
Photo
Barn - Daylight, Ontario, Canada
Barn - Incandescent light, Ontario, Canada
References
Case study assignment
Your client requires you to produce cost estimates and a design for a T8 twin tube fluorescent lighting system for a to-be-constructed (new) dual ventilated broiler turkey barn housing approximately 5,000 grower turkeys, from approximately 4 weeks of age to 16 weeks (in the barn for 12 weeks per turkey crop cycle).
Site information
The producer's existing facilities located on this site are traditionally mechanically ventilated barns with incandescent lighting. There is an interest in reducing energy input costs by upgrading from incandescent to a T8 twin tube fluorescent lighting system. As the barn is naturally ventilated and uses translucent sidewall panels that drop open in warmer weather, the potential to take advantage of natural lighting is present. As a result, the desired system should also use photocells for each row of fixtures. The photocells will then automatically adjust the fluorescent light output up or down as the day light increases or fades. The site is located near Mount Forest, Ontario, Canada.
Although the normal practise is to use inefficient incandescent lighting, there is no credit given towards the waste heat produced by the light system. Heat is typically supplied in the form of infrared radiant and only required under extreme cold and for very short time periods; as a result, the incandescent lighting has a limited impact on supplemental heat requirements.
The building dimensions are the following:
- Length: 122.5 m (402 ft);
- Width: 19.5 m (64 ft);
- Average height: 2.85 m (9.3 ft); and
- Area 2,389 m2 (25,728 ft2).
Financial information
Financial figures for the analysis are: inflation and fuel cost escalation rate of 2.5%, debt ratio of 60%, debt interest rate of 8.5%, discount rate of 9%, and debt term of 10 years. The turkey barn owner does not require a tax analysis.
Electricity rates are $0.10/kWh.
The installed cost of the incandescent lighting system is $15/fixture (50/50 labour and parts cost). The incandescent system consists of 204 lamps, 100 W per lamp with a low cost triac type dimmer control. Lamps last about 1,000 hours and cost $1.00 each to replace. Annual maintenance is calculated at $1,340, including lamp costs.
The fluorescent system is a twin tube (32 W per tube) T8 system with 62 fixtures. Each fixture will have digital dimming 4 W electronic ballast. The installed cost is $206/fixture (note: this includes the cost for controller, photocell, low-voltage control wiring, etc.). This works out to an "Incremental initial cost" of $9,712. The system should last about 20 years. Lamp life is about 24,000 hours. Lamp cost is $4.00 each. Assume the "incremental" labour cost for lamp changing is nil. Ballasts last 60,000 hours and cost $70 each. Labour cost is $20/ballast. Annual maintenance is calculated at $611 including lamp and ballast costs. This works out to an annual "Incremental O&M savings" of $729.
Prepare a RETScreen study, documenting any assumptions that you are required to make, and report on the significant conclusions from this analysis.
Solution
The worked-out solution is the data file selected from within the RETScreen Project Database. The user automatically downloads the Project Database file while downloading the RETScreen software.
Teacher's notes
- The dual ventilation system incorporates both forced and natural ventilation. Natural ventilation is through operable translucent wall panels.
- The barn will undergo extreme temperature swings in the winter. During cleanout, it will be unheated. When a new crop of birds goes in, temperatures can reach 30°C. The electrical system conduit must include thermal expansion joints to allow for expansion and contraction of the building structure.
- Maintenance includes photocell cleaning at least every crop. Cleaning involves wiping the surface with a damp cloth to remove dust and fly specks. In addition, each lighting fixture lens should be cleaned at least once per year to remove dust and dirt that builds up over time.
- Light levels are measured at bird height, about 0.3 m above the floor.
- Light distribution needs to be reasonably uniform to prevent shadows on the floor. Uneven light distribution can result in birds crowding.
Results
Two dual ventilated broiler turkey barns were constructed northwest of Toronto, Ontario, Canada for a large poultry producer. Many of the barns being operated by this producer are traditional in design. They are mechanically ventilated using exhaust fans and incandescent lighting on timer and dimmer control. The mechanically ventilated barns are completely reliant on electrical energy. This reliance and increasing fuel costs led this producer to consider alternatives to the traditional methods of lighting and ventilating poultry.
The most viable alternative for this type of production was a dual ventilation system with fluorescent tube lighting on dimmer and photocell control. This system provides a more secure option with reduced energy needs as well as lower operating and maintenance costs.
System description
The dual ventilation system uses curtain sidewalls which are partially translucent and allow a great deal of natural light to enter the facility during the day even when the curtains are closed. Supplementary light is reduced or not required as natural daylight increases. The lighting system is installed such that there are 3 rows running the length of the facility. Each row is on a separate circuit. A photocell is installed on each circuit and connected to the control system.
The lighting control system is completely automatic. This system operates on timer and dimmer control. An intermittent lighting schedule is used on this farm with the timer controlling the lighting cycles. The photocells monitor the intensity of light present in the barn. Based on the readings from the photocell, the dimmer adjusts the light intensity according to preset limits to meet the lighting needs of the birds. The dimmer simulates dusk and dawn by gradually raising light levels when the lights come on and gently lowering light levels just before lights go off. Instant on at full light output can startle the birds potentially causing production losses. By simulating dusk, the birds have time to settle before lights go off.
The controller is a GVA Control Lux-D with photocells. The dimmable T8 twin tube fluorescent lighting system and digital dimming electronic ballast is a GVA FA-D.
Lessons learned
- As poultry facilities trend towards natural ventilation, the potential to take advantage of natural lighting and save more fuel costs is apparent.
- The lighting system must be robust and designed for high moisture applications, with attention paid to installation to ensure sealed connections and expansion joints to prevent premature failure.
- The dimmable component can save an additional 50% on the operating costs of a modern poultry facility.
The Province of Ontario is encouraging the adoption of energy conserving technologies. Electrical energy prices have been increasing in Ontario placing pressure on producers to reduce their electrical consumption. Dual ventilated turkey grower barns incorporating dimmable T8 twin tube fluorescent lighting systems and electronic ballasts on photocell control present an opportunity for producers to reduce their energy costs.
Photo
Barn - Daylight, Ontario, Canada
Barn - Incandescent light, Ontario, Canada
References
- Gibb, Katie, "Personal Communication," Agviro Inc., 2007.
- MacDonald, Ron, "Personal Communication," Agviro Inc., 2007.
- Turkey Farm Owner, "Personal Communication," 2007.
