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Study on Diesel Savings By Replacement of Prism Lightings Rubber Tyred Gantry Cranes (RTGC) 30 th April 2012 PT PRISLIGHT

Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

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Page 1: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Study on Diesel Savings

By

Replacement of Prism Lightings

Rubber Tyred Gantry Cranes (RTGC)

30th April 2012

PT PRISLIGHT

Page 2: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

RTG Lightings

Background & Objective

Light Installation

RTG Light Testing

Comparison Photos

Payback Period

Data Collection

Conclusion

Project Implementation

PT PRISLIGHT

Page 3: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Background

Existing RTG Work Lightings Used

- Girder 1: 4 X 450W Metal Halide

- Girder 2: 1 X 450W HPS + 3 X 450W Metal Halide

- Gantry Paths: 4 X 300W Metal Halide

- Cabin: 3 X 500W HPS

Total: 15 units of Work Lightings

Problems Faced

High bulbs failure rate (lifespan of 2 to 3 months)

Many different types of wattages and lamps used for RTG Work Lightings

Failed lux requirement for area under driver and girder room

Huge storage spaces required for bulb spares & ballast

Misconception view (Poor color rendering)

PT PRISLIGHT

Page 4: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Objective

Objective

Standardization of work lights (Same wattage, type, color)

Energy savings without compromising safety

Compact light weight (Reduce storage space for spares)

Reduce frequent bulb maintenance

Improve night operation view

HPS (Yellow) CDM (Natural Daylight)

PT PRISLIGHT

Page 5: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

RTG Light Trial Testing

Light Product

Brand: Prismalence

Model: LK

Wattage: 150W

Type: Ceramic Discharge Metal halide

IP Class: IP65

RA Index: <90

Color Temperature: 4200° K

NOTE: LK150W CDM = 400W HPS / Metal Halide

PT PRISLIGHT

Page 6: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

RTG Light Trial Testing

Using LK 150W CDM

Light Installed on

RTG 01

Girder (8 units)

Gantry Paths (4 units)

Cabin (4 units)

Total: 16 units of Work Lighting

Lens: 2 types

30° X 60° (Used on: Girder, Cabin)

60° X 90° (Used on: Gantry Paths)

PT PRISLIGHT

Page 7: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Lux Checking:

RTG 08 (Existing)

Lux checked on 18th May 2011

Achieved average lux of 105.9 (Area below Girder)

Achieved average lux of 196.5 (Area below Cabin)

RTG 02 (Existing)

Lux checked on 22nd November 2011

Achieved average lux of 102.5 (Area below Girder)

Achieved average lux of 167.5 (Area below Cabin)

RTG 01 (Light Testing)

Lux checked on 24th April 2012

Achieved average lux of 246.6 (Area below Girder)

Achieved average lux of 310 (Area below Cabin)

RTG Light Trial TestingPT PRISLIGHT

Page 8: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

138 / 144

/ 60

157.7 /

45 / 49

127.5 /

48 / 51

117 / 94

/ 98

271.5 /

87 / 73

349.5 /

71 / 60

207 / 120

/ 60

321 / 74

/ 108

319.5 /

73 / 71

414 / 76

/ 80

336 / 97

/ 116

310.5 /

154 / 217

229.5 /

78 / 73

267 / 83

/ 78

295.5 /

106 / 102

186 / 194

/ 228

238.5 /

88 / 74

291 / 80

/ 76

205.5 /

87 / 91

150 / 250

/ 264

RTG 01: Light Trial Testing (BLUE Numeric)

RTG 02: Existing (BLACK Numeric)

RTG 08: Existing (Red Numeric)

22

.5m

7m

Average

Lux

Results

RTG 01

(Prismalence)

RTG 02 RTG 08

Area Below

Girder

246.6 102.5 105.9

Average lux requirement for Area Below Girder:

200 lux

RTG Light Trial TestingPT PRISLIGHT

Page 9: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Lux level results – Area Below Cabin

291 / 195

/ 208

267 / 242

/ 260

414 / 173

/ 224

349.5 / 143

/ 171

205.5 / 162

/ 168

295.5 / 155

/ 210

336 / 145

/ 180

321 / 125

/ 151

RTG 01: Light Trial Testing (BLUE Numeric)

RTG 02: Existing (BLACK Numeric)

RTG 08: Existing (Red Numeric)

6m

7m

Average

Lux

Results

RTG 01

(Prismalence)

RTG

02

RTG

08

Area Below

Cabin

310 167.5 196.5

Average lux requirement for Area Below

Cabin: 400 lux

RTG Light Trial TestingPT PRISLIGHT

Page 10: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Comparison Photos

Cabin Lights

Prismalence LK

150W CDM

PT PRISLIGHT

Page 11: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Existing – 4.45 Ampere

Prismalence LK150W CDM – 0.69

Ampere

Ballast

LK150W CDM –

Philips Ballast

Comparison PhotosPT PRISLIGHT

Page 12: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Philips 150W

CDM

Current:

400W MH

Lamp

Comparison PhotosPT PRISLIGHT

Page 13: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Comparison Photos

LK150W CDM

Existing RTG Light

PT PRISLIGHT

Page 14: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Comparison Photos

Prismalence LUKA 150W CDM

Existing Lights

PT PRISLIGHT

Page 15: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Payback Period

Data collected:

• Based on 16 units of work light used on RTG

• Diesel savings of average 1 liter per night running hour

Diesel Cost: US$1.10 / liter based on 2012

Investment Cost: 16 units x US$800 = US$12,800

Yearly Savings of RTG operation based on 12 hour operation per day:

12 hours x 365 days x US$1.10 = US$4,818

Payback Period:

• US$12,800 / US$4,818 = 2.6 Years (ROI of upfront investment)

• US$6,050 / US$4,818 = 1.3 Years (ROI of difference in investment cost)

12 units of RTGs in Terminal – Diesel savings of US$57,816 yearly

Note: Diesel costs may fluctuate and reduce the payback period.

PT PRISLIGHT

Page 16: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Actual Data Between 2010-2014

.

Savings of 7.96%

PT PRISLIGHT

Page 17: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Conclusion

Conclusion:

Compact light weight design

Improved night vision with natural daylight

Standardization of lighting wattage and type (ease of maintenance)

Lesser maintenance

Fuel savings of average 1 liter per running hour during night operation

Save 13 tons of CO2 yearly (1 RTG)

Save 64 trees yearly (1 RTG)

PT PRISLIGHT

Page 18: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Proposal on Deisel Savings

By

Replacement of Prism Lightings

On

A Quay-side Cranes For

BICT

Quay-Side Crane LightingsPT PRISLIGHT

Page 19: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Quay-Side Crane Lightings

Assumptions:

- 42 units of 1000W HPS Lightings replaced by AP315w CDM Prism.Energy savings of 28.7kw

- Based on 1.22litres savings per engine hour or savings 3.9Kw or about 3.19kwh/litre

- 12 hours utilisation

- Dieisel price in Indonesia US$0.9

PT PRISLIGHT

Page 20: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Typical QC Simulated PlotsPT PRISLIGHT

Page 21: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Payback Period Calculation

Investment Cost: 42units x US$1350 = US$56,700

Yearly Savings of QC operation based on 12 hour operation

per day:

12 hours x 365 days x US$0.9x (28.7/3.19) = US$35,465

Payback Period:

• US$56,700/ US$35,465 = 1.59 Years (ROI of upfront

investment)

10 units of QCs in BICT – Diesel savings of US$350,465

yearly

PT PRISLIGHT

Page 22: Proposal for BICT QCs - Savings of Deisel Thru Replacement of Prism Lightings

Supporting Documents PT PRISLIGHT