Energy Efficiency in Industrial Lighting: Bulgaria - BSREC, Bulgaria

Summary
In the framework of the CHP/DHC project, WP5, Task 4, the Black Sea Regional Energy Centre (BSREC) worked with Agencia para a Energia (ADENE), Portugal, EKODOMA, Latvia and Institute Jožev Stefan (IJS), Slovenia. The project was funded by the EC, DG for Energy & Transport within the framework of OPET Network and was coordinated by DTI, Teknologik Institut, Denmark.

The project aimed at promotion and utilization of EU state-of-the-art lighting technologies in industry, with a view to increasing energy efficiency and decreasing greenhouse gas emissions. The main project activity in Bulgaria concerned practical lighting renovation of an industrial building linked to a wider dissemination of information, targeted at the industry sector audience, including decision-makers, energy experts, managers and workers.

End-user area	Industry Refurbishment of buildings
Target audience	Architects and engineers Decision makers Property owners Utilities
Technical scope	Energy efficiency Lighting

Context
At present, d ue to the economic crisis in Bulgaria, the condition of lighting within industrial enterprises is poor. L uminaires are obsolete and worn out, their light distribution capacity is deteriorated and their efficiency impaired. Consequently, the measured illuminance indicators are lower than the standard norms and additional energy consumption is significant.

The Sorting and Packaging department of SVILOZA Viscose Rayon Filament Plant, in the town of Svishtov, was chosen by the BSREC as suitable for practical lighting renovation, with the aim of bringing the department into line with EU norms and technologies for energy efficient lighting. The project started on April 1, 2003 and lasted 14 months.

Objectives
Specific project objectives included a reduction in energy consumption and energy costs, a short payback time for equipment installed, and abatement of the GHG emissions. In addition, the project aimed to improve working conditions (sanitary, hygienic and ergonomic) and facilitate an increase in efficiency and output quality, and a reduction in work accidents).

The objectives were achieved based on the elaboration and implementation of an Action Methodology, comprising the following general steps:

1. Assessment of the existing illumination and specific visual tasks in the department.
2. Design of the new lighting system.
3. Assessment of the energy and cost savings and the environmental impact.
4. Exchange of experience between the international partners - participants in WP5, Task4.

Process
The main phases of the project were as follows:

1. Research and analysis of the existing illumination in the Sorting and Packaging department:
   As per the original design the total installed capacity amounted to 19.054 kW, and the annual electricity consumption was 38,412 kWh.
   
   
   The workshop before the reconstruction
   
   
2. Specification of the lighting norms:
   Four visual tasks are typical for the Sorting and Packaging department: bobbins' quality check, weighing of the bobbins, packaging and transportation.
   The lighting requirments were met by construction of local and general lighting systems. In accordance with the EU norms for indoor lighting, it is recommended to use colour rendering index Ra ≥ 90, discomfort glare index UGR ≤ 16 and colour temperature Tcol ≥ 4000K.
   
   
   Working place for quality check before the reconstruction
   
   
3. Design of the general illumination:
   Tabular luminescent lamps 50 2x58 W, IP 65, type Lumilux, having a luminous flux of 5400 lm, were chosen to ensur e high energy efficiency. The lamps are equipped with a n odised aluminium reflectors and were mounted at a height of 3,5 m. The lamps produce white light with colour temperature Tcol. = 4000K and colour rendering index Ra ≥ 80.
   
   
4. Design of the local illumination at the workplaces for bobbins' quality check and sorting:
   The workers should check for bobbins' defects. The bobbins are then sorted according to the number and type of defects. The worker should be able to adjust the local luminaire to focus on himself and the bobbin in order to achieve the optimum observing position. Each local luminaire is open and mounted on a special post, allowing adjustment of the suspension level and the luminous flux in accordance with individual needs. Furthermore, the luminaire can be positioned in the horizontal plane. The luminaires are equipped with electronic ballast, thus eliminating any luminous flicker. The electronic ballast can be regulated, which allows individual dimming of the luminaire at each working place. At each working place a compact luminescent lamp 55W is used, having white colour temperature Tcol.=4000K and colour rendering index Ra ≥ 90.
   
   
5. Promotion and dissemination of state-of-the art lighting systems and project results:

• Workshop entitled "Reducing Energy Costs in Textile Industry by using EU Norms and Technologies". The event took place in the premises of SVILOZA JSC on November 21st, 2003 and was targeted to managers, decision-makers and energy experts from textile industry and Technical Universities, lighting equipment suppliers, etc.
• Site visit to the project pilot building - Sorting and Packaging department.
• Preparation and dissemination of Workshop Proceedings, two articles and a leaflet.

Actions
- Initializing projects
- Seminar
- Web Page
- Technical Handbook
- Newsletter
- Articles, Leaflet

Financial resources and partners

Results
Successful energy efficient, ergonomic and ecological design and reconstruction of the lighting system was completed.


The workshop after the reconstruction

The achieved lighting improvements are shown in table 1,
the assessment of energy and cost savings, and GHG emissions reduction - in table 2.

The results are as follows:

1. A three fold increase in the illuminance.
2. A three fold reduction in the installed capacity.
3. Annual energy consumption of lighting reduced to approximately a third of previous levels.
4. Energy costs for lighting reduced to approximately a third of previous levels.
5. Greenhouse gases emissions were more than halved.
6. The payback period of investment is less than one-year (0.8).

Deliverables:

1. Action Methodology and Design Study
2. Workshop Proceedings
3. Proceedings from the (Technical) Meetings
4. Leaflet and two articles

Key performance indicators:
Identification of 20 (twenty) industrial textile companies in Bulgaria as being potential candidates for energy efficient lighting reconstruction; technical meetings (with site-visits) held: eight (8); promotion of energy efficiency lighting and dissemination of the project results through workshop, workshop proceedings (42), CD-ROMs (20), articles, leaflet; workshop attendees: forty (40).

Lessons learned and replication potential
All requirements of the European norms concerning lighting uniformity, luminance discomfort and colour rendering have been met. The EU lighting norms were achieved together with lighting improvement, reduction of the luminance discomfort, and respectively - better working conditions and an increase of the productivity.

Technical solutions used:

• Luminescent lamps, having high light output:
• For general illumination: 58 W, 5400 lm
• For local illumination: 55 W, 3000 lm, Ra ≥ 90
• Electronic ballast
• Energy efficient luminaires, having an expedient colour rendering and high efficiency
• Optimal positioning of the luminaires, dedicated for general illumination
• Expedient direction of the luminous flux towards the working place with a view to increase the illuminance contrast between the object and background (creation of negative contrast)

Further Project Impact in Bulgaria was the decision, taken by SVILOZA authorities, to carry out an energy efficient, ergonomic and ecological lighting renovation of another industrial building of the Viscose Rayon Filament Plant - the Re-reeling department.


Re-reeling department of the Viscose Rayon Filament Plant

Other contacts
Prof. Nikolay Vassilev, BSREC Expert
RTD Laboratory on Lighting, Sofia Technical University
Tel.: +359 2 965 39 03
E-mail:
- onilot@tu-sofia.bg
- nvassilev@tu-sofia.bg

Mrs. Ekaterina Kanatova, BSREC Expert
BSREC
Tel.: +359 2 980 68 54
Fax: +359 2 980 68 55
E-mail:
- katlen@bsrec.bg