TPPL TUBULAR PROFESSIONAL PERFORMANCE LIGHTING SMART LIGHTING FOR HARSH ENVIRONMENTS

Transcription

1 TPPL TUBULAR PROFESSIONAL PERFORMANCE LIGHTING SMART LIGHTING FOR HARSH ENVIRONMENTS

2 ATEX DIRECTIVES The ATEX directives 2014/34/EU & 1999/92/EC are commonly referred to as the two European Directives governing explosive atmospheres describing what equipment and work environment is allowed in a potentially explosive atmosphere. ATEX ZONING APPLICATIONS AREAS OF RISK ATEX FIXTURES MINIUM RATING* GAS DUST ZONE 0 An area in which an explosive gas is continuously present for long periods II 1G ZONE 1 An area in which an explosive gas is likely to occur in normal operations II 2G ZONE 2 An area in which an explosive gas is not likely to occur in normal operations, and if it does, only for short periods II 3G ZONE 20 An area in which an explosive dust mixture is continuously present or present for long periods II 1D ZONE 21 An area in which an explosive dust mixture is likely to occur in normal operations II 2D ZONE 22 An area in which an explosive dust mixture is not likely to occur in normal operations, and if it does, only for short periods II 3D ATEX PROTECTION MODES ATEX protection modes and relevance versus risks: PROTECTION MODE** BY... ZONE Ex e Increased safety 1, 2 Ex ib Intrinsic safety level b 1, 2, 21, 22 Ex mb Encapsulation level b 1, 2, 21, 22 Ex tb Enclosure 21, 22 Ex op is Optical radiation limitation 1, 2, 21, 22 Temperature ratings T5 (temperature class for gas): maximum temperature at any point, inside or outside the luminaire, is below 100 C. T75 C: maximum temperature at any point on the outside surface is below 75 C. Explosion group IIC: all gas IIIC: all dust * There are two equipment groups - Group I, which concerns mining and is very restrictive due to the highly volatile methane gas and dusts present, and Group II, which concerns all other above ground industries. ** Protection modes as used on TPPL luminaires. 2

3 TPPL TUBULAR PROFESSIONAL PERFORMANCE LIGHTING PSPL is a technology and business development company in the field of smart industrial lighting solutions. DIETAL is an industry-leading manufacturer with extensive experience in the design and production of lighting solutions. DIETAL & PSPL were given the opportunity to implement brand new smart lighting solutions for harsh environments in a real-life project involving the refurbishment of the Sitech Chemelot worksite. Key project drivers: SAFETY Because safety is always the first priority, a secured and proven sealed-for-life system seamlessly adapts the lighting equipment to hazardous areas where ATEX specifications must be met. OPEX SAVINGS High-efficiency (150 lm/w) high-reliability (failure rate < 0.2%/yr) LED light sources and drivers combined with integrated light sensors enable vastly lower OPerational EXpenditures (more than 80% energy savings compared to conventional fluorescent lamps solutions). SUSTAINABILITY Based on cutting-edge developments in the field of IoT applications, advanced functionalities with embedded software enables the end-user to command and control their lighting installation to reduce energy bills and cut light pollution. we chose to equip our luminaires with Bluethooth Low Energy Mesh technology as it is the most robust solution available for industrial equipment control and monitoring. 3

4 All processes where an EXplosive ATmosphere can be potentially present must meet the DIRECTIVES 2014/34/EU & 1999/92/EC OF THE EUROPEAN PARLIAMENT. TPPL ATEX/IECEx APPLICATIONS In practice, they cover a host of process industry applications where GAS & DUST are sufficiently concentrated for a fire or explosion to occur in certain conditions: chemical industries, waste dump areas, electricity production plants, waste water treatment plants, oil and gas delivery companies, wood processing industries, coating/painting workshops, agricultural premises, metal processing locations, food industries, pharmaceutical industries, refineries (oil and gas), recycling industries, and more. 4

5 SITECH CHEMELOT PROJECT, THE NETHERLANDS At Sitech, we strive to constantly improve the site services for the various chemical companies at the Chemelot premises in Geleen, the Netherlands. In 2014, DIETAL and PSPL approached us with a lighting solution combining ATEX certified LED with smart connectivity. We immediately recognized the potential benefits and together we developed a detailed business case based on more than 20 plants. After a successful initial pilot of 1,000 units, in which the reliability and business case of the solution were proven, we had no doubt to continue with the replacement of all 15,000 fixtures under an operational lease contract. The DIETAL LED fixtures respond to their environment, have a very long lifetime and provide consistent light levels for over 15 years. The smart PSPL connectivity gives us continuous insight into the lighting system and flexible control over where and when to provide light. With DIETAL and PSPL, we have been able to decrease our environmental footprint and light pollution, create a pleasant and safer working environment for our operators and together with these advantages we were able to reduce our operational costs: a great contribution to the services we provide to our customers at Chemelot. Marc Dassen CEO Sitech 5

6 CONTROL & MONITORING PACKAGE RADIO FREQUENCY CONTROL: how does it work? The smart TPPL luminaires are interconnected through a secure local wireless (Bluetooth Mesh) network into a group and via secure gateways or WNIs (wireless network interfaces) to the local control room and remote off-site service center. The lamps can be functionally grouped to support user-defined setting and control requirements for a specific area. Status information for individual lamps, (group) control signals, and firmware updates are all distributed from or to the entire facility lighting system. Routine control settings (e.g. twilight control, specific dimming schedule, etc.) can be manually overridden at any time from the control room, or automatically in an alarm situation. The off-site service center (OSC) continuously monitors and updates lighting system functionality and issues periodic performance reports. On-site (replacement) services can be provided as and when needed. The built-in ambient light sensor makes it possible to enable a Twilight regulation mode for automatic dimming depending on outside conditions and to adapt to daytime and nighttime illumination levels. A CONSISTENT RANGE FOR BOTH ATEX AND NON ATEX AREAS Beside the ATEX certified fixtures (EX), an Industrial Quality version (IQ) offers the same performance, reliability, quality and wireless functionalities. EX and IQ can be mixed in the same network to be driven and monitored in the same way. Both versions can also be delivered without wireless connection, simply switched on via MCB. 6

7 All powered TPPL luminaires are automatically connected in a wireless mesh network. TPPL luminaires are commissioned to be placed in groups and on a map with a GPS location. Each TPPL luminaire is a node, receives & transmits messages and commands to neighbours in both directions. ATEX ZONE ATEX ZONE IQ NON ATEX ZONE 3G/4G GATEWAY WNI Gateway(s) are linked to back-office(s) & databases via 3/4G router or internet cable Control room with emergency buttons EMERGENCY GATEWAY INTERNET Secure LAN/intranet Back-office is linked to TPPL luminaires in the field via 3/4G router or internet to collect and report data into the customer s tools Customer dashboard and control panels can remotely analyse and monitor the complete installation Bluetooth Low Energy Mesh OSC RADIO FREQUENCY CONTROL: what does it offer? Point-by-point refurbishment: an existing installation, where only mains are wired, can be used by replacing old fluorescent fixtures point-by-point with no need to wire for controlling and monitoring. Efficient monitoring of the installation: each light fixture is individually located on a dashboard, where it gives real-time feedback on all relevant status information: - Power consumption - Burning hours - Weighted burning hours - Failure modes - Ambient temperature - Internal temperature - Constant Lighting Output (CLO) - Remaining lifetime - Light output - Ambient light level High energy savings: the light is only used when and where necessary. Migration from traditional to TPPL luminaires typically comes with more than 80% energy savings. 100% safe: any operator can switch to 100% light level in any part of the premises, through emergency buttons to override remote control. 7

8 RADIO AND SOFTWARE SPECIFICATIONS FEATURES Frequency range Channels Range Maximum RF Output power Typical antenna gain VALUE Mhz 40 channels according to Bluetooth Low Energy 4.X and 5.0 Up to 70m (open field) 10mW +3 dbi SPECIFIC RULES FOR RADIO-FREQUENCY MESH NETWORK TPPL RFC is designed to be installed in a Bluetooth Mesh network in which each TPPL is equipped with a Wireless Control Module (WCM) and seen by the overall system as a node with its own unique ID; other kinds of nodes in the network are gateways and WNIs. Maximum distance between 2 nodes is 70 meters in open field conditions; the installation is designed so that every node has at least 2 or more neighbours for guaranteed connectivity. This rule is also key for any gateway of the installation; even if one node should fail, connectivity remains ensured. When TPPL RFC is installed straight from the factory, the node is added automatically to the network, and is ready to be commissioned immediately (grouping, GPS positioning and reference light output all individually assigned). Each node has a unique ID to be managed later on through the OSC backoffice. Re-commissioning can be executed centrally via the OSC Luminizer dashboard and control software, which can serve to: Manage several groups Place any TPPL groups in automatic Twilight operating mode Adjust the reference light output settings Bypass all automatic modes in an emergency to set all the lights to 100% ON (Alarm modes) Monitor lighting parameters (% dimming, flux, lighting level, light states, lifetime performance, energy consumption, etc.) Monitor energy consumption parameters and remaining lifetime Monitor temperature outside and inside any TPPL Report power supply and/or internal TPPL failures Deliver Constant Lumen Output (CLO) over lifetime of the TPPL luminaires 8

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10 WORKING WITH THE RIGHT LUMINANCE Comfortable luminance allows operators to execute their tasks efficiently and in safety. With light fixtures installed at low and medium height, it is necessary to limit light from glare sources. TPPL is made of a special plastic material filled with a diffusing component that delivers a very high transmission factor with a low glare value. LONG-LIFE MATERIALS The outer tube is made of high-grade UV-protected polycarbonate to deliver more than 15 years of permanent operation in outdoor conditions. The endcaps are made of high-shock-resistance black reinforced polyamide, with bases glued onto the outer tube for sealed-for-life operation. The design of each component is executed in such a way that the system is expected to deliver a 20-year lifetime in normal conditions. This high reliability has been proven over several months of laboratory testing within a high-temperature enclosure to artificially accelerate the materials aging process; the built-in ambient temperature sensors makes it possible to enable autoprotective dimming and full temperature monitoring of each lamp. This prevents from early failures due to process heat influences as well as failures due to out of temperature range usage of the luminaires. VERSIONS LENGTH (mm) SINGLE-ENTRY CABLE a OVERALL LENGTH b ILLUMINATING LENGTH FEED-THROUGH OPTION a OVERALL LENGTH b ILLUMINATING LENGTH L Réf. L L

11 Wireless Control Module (WCM) PCB Lid made of glass-fibre reinforced polyamide LEDs PCB mounted on aluminium smart cooling plate Multi-extruded housing (diffuse/opaque) made of high efficient anti-uv polycarbonate Long-life driver mounted on aluminium passive cooling plate ATEX cable gland 3- or 5- pole connector ATEX Lid screwed on the base Cable pass-through Base glued on the housing Multi-extruded housing Driver ON-DEMAND DESIGN ACCESSORIES Industrial premises present all kinds of installation demands: on top of poles; horizontally or vertically mounted, or tilted at a proper angle; under cable trays; etc. With its easy-fit stainless steel brackets and tubular shape, TPPL can seamlessly install in any situation. When special mounting components are necessary, DIETAL can design and produce any kind of tailored solution in its TPPL dedicated workshop. Specific endcap bracket Versatile backets for fast installation 11

12 MAIN FEATURES (ATEX ZONES) SMART INDUSTRIAL LED LIGHTING FEATURE VALUE Hazardous area classification (EN :2016) ZONE 1 ; 2 ; 21 ; 22 Gas certification standard (EN :2016) II 2G Ex e ib mb op is IIC T5 Gb Dust certification standard (EN :2016) II 2 D Ex op is tb ib IIIC T75 C Db ATEX/IECEx certification number CE KIWA 18ATEX0006 X / IECEx KIWA X LED light source (EN :2012) SPECIAL Ex LED MODULES / INTRINSIC SAFETY ib Color temperature 5000 K Color consistency < 4 SDCM Color rendering index > 70 LED module (EN :2012) Power supply (EN :2014) Feed through wiring (EN :2016) Wireless control module (EN :2012) Outer tube material (EN :2014) Outside tube diameter / inner mounting ring diameter Endcaps material (EN :2015) Degree of ingress protection (EN 60598: 2015) IK Class (EN 50102:1995/A1:1998) Temperature range (EN : 2016) Primary voltage range (EN :2014) Primary frequency range (EN :2014) Electrical class (EN 62384:2006+A1:2009) Glow wire test (EN : 2014) Glow wire flammability index ( : 2011) Glow wire ignition temperature ( : 2011) Electrical certifications (European Low Voltage Directive 2006/95/EC) European Directive 2006/25/EC on minimum health and safety requirements European ErP Directive on 1194/2012 LED Ex ib module EX V30x30 or EX V30x30 3 to 100% dimming driver, specifically designed for high safety (potting) and super-low failure rates (designed for less than 3%@87,000 h) FT3: 3x2.5 mm², de-rating max ambient temperature by 2K FT5: 5x2.5 mm², de-rating max ambient temperature by 5K WCM 2.4 GHz ISM operation according to Bluetooth 4.2 Radio Ex ib module (according to EN group IIC) Co-extruded polycarbonate + Techfiller for LED diffusion 100 mm Polycarbonate with integrated weatherable UV protection IP66 & IP67 IK10 (20J) 20 C/+55 C Vac / Vdc 50/60 Hz Class I 850 C / 30 s 850 C / 30 s 650 C / 30 s EN (safety on LED control gear), referring to EN :2014 (Lamp control gear), referring to EN EN 62493:2015 (Human exposure to electromagnetic fields) ATEX annual production inspection according to EN by Intertek EN 62471:2006 optical radiation group risk 0 Level of standby power: less than 0.5 Watt European EMC Directive 2004/108/EG IEC 61547:2009/IS 01:2013 (EMC Immunity) EN Electrostatic discharge EN Radiated RFI immunity EN Electrical fast transients EN Electrical surge, 6kV class EN RF conducted and injected currents EN Magnetic field immunity EN Voltage dips, short interrupts and fluctuations (crit. B) EN :2009 (Harmonics) Class C EN :2013 (Voltage Flicker) EN 55015:2013/A1:2015 (Radiated and conducted emission) 12

13 REF. TOTAL SYSTEM 100% (initial) CONSTANT LIGHTING OUTPUT (end-of-life) LUMINOUS FLUX TOTAL SYSTEM LIGHT EFFICIENCY (initial) L800 STD 19,8 W 23,8 W 2800 lm 141 lm/w L1200 STD 37,6 W 45,1 W 5600 lm 149 lm/w L1700 STD 54 W 64,8 W 8400 lm 156 lm/w L800 BW 19,3 W 23,2 W 2800 lm 145 lm/w L1700 HB 57,3 W 68,8 W 8400 lm 147 lm/w OPTICAL DISTRIBUTION High bay (HB) = 60 beam angle typically for height above 6 meters Standard (STD) = 120 beam angle typically for height from 3 to 6 meters Batwing (BW) = 180 beam angle typically for height below 3 meters Height, position and tilt should be chosen using light planning software, e.g. DIALux: ask DIETAL for the relevant plugin files. References HIGH-BAY NARROW BEAM (HB) 60-DEGREE BEAM ANGLE TPPL EX D100 L LM HB STANDARD SPREAD (STD) 120-DEGREE BEAM ANGLE TPPL EX D100 L LM STD TPPL EX D100 L LM STD TPPL EX D100 L LM STD BATWING LIGHT DISTRIBUTION (BW) 180-DEGREE BEAM ANGLE TPPL EX D100 L LM BW HB STD BW Pictures, drawing and technical data are provided for information only, subject to changes. 13

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16 ABOUT DIETAL SINCE 1979, WE HAVE SPECIALIZED IN DESIGNING AND MANUFACTURING PROFESSIONAL FLUORESCENT AND LED LIGHTING FIXTURES. WE THUS PROVIDE RELIABLE, INNOVATIVE, CUSTOM-MADE LIGHTING SOLUTIONS, AND DELIVER EVERY YEAR 1 MILLION LUMINAIRES TO OUR CUSTOMERS WORLDWIDE. ABOUT PSPL PSPL PROVIDES SMART INDUSTRIAL LIGHTING SOLUTIONS TO DEMANDING INDUSTRIAL ENVIRONMENTS LIKE (PETRO)CHEMICAL, OIL & GAS AND SIMILAR INDUSTRIES. WE OFFER AN UNIQUE LIGHT-AS-A-SERVICE SOLUTION COMPRISING OF ULTRA-INTELLIGENT LIGHTING, FULL SERVICING AND ATTRACTIVE FINANCING THROUGH OPERATIONAL LEASE. PSPL ENABLES YOU TO MIGRATE YOUR ENTIRE LIGHT SYSTEM INTO A SUSTAINABLE FUTURE. - RCS LIGHTING INNOVATOR PSPL PROFESSIONAL & SUSTAINABLE PERFORMANCE LIGHTING DIETAL ROUTE DE QUEUILLE SAINT GEORGES DE MONS FRANCE PHONE: +33 (0) FAX: +33 (0) TPPL@DIETAL.COM PSPL B.V. KVK MOLENWEG NB MAASTRICHT THE NETHERLANDS PHONE: INFO@PSPLIGHTING.COM DIETAL_MK_TPPL_LL_EN_201801