Magnet undertook a project at Transnet with the aim of introducing energy-efficient lighting to their rail house, and implementing control systems for this lighting. The first phase of this project took place in Durban and entailed the replacement of existing fittings, retrofitting where necessary, and re-lamping. To control the lighting and contribute to its overall energy efficiency, occupancy sensors were also installed. The second phase of this project involved the rollout of energy-efficient lighting and sensors to 15 sites on a national basis.
The site was comprised of 70 bays that were lit by outdated 400W High Bay fittings, 2500 of which were replaced with energy-efficient fluorescent High Bays during phase 1. The average savings achieved was in excess of 45%. Furthermore, 4000 open channels and dustproof fittings were also replaced with more efficient and lower wattage units.
With the installation of occupancy sensors to control two thirds of the lighting inside the bays, the total kWh of the lighting was reduced by 60%. Moreover, the occupancy sensors were installed to control 3 fittings per sensor, with alternative lights bring left for general lighting. Additional occupancy sensors were also installed in the admin areas and ablutions. In sum, approximately 1200 occupancy sensors were installed.
The project was run over a duration of 11 months, with the majority of the work entailing the replacement of lighting in the bays. The new technology used was 3 to 4 and 5 x 58W fluorescent fittings with high bay sensors. The sensors were also linked to Magnet’s Lite-C wireless system.
As with any project, challenges abound which necessitates appropriate planning. In this project, an area of concern was the team’s safety, owing to the fact that there was no shut down during this project, resulting in the team having to work around production with continuous overhead crane activities.
In spite of this challenge, the project was a resounding success with the total value being R16.5 million and a 93% target savings achieved.