Optimized LED Installation
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1 New Kassel-Calden Airport Optimized LED Installation Presented by Helmut Hengvoss Helge Mack
2 New Kassel-Calden Airport Topics The Kassel-Calden Airport project Used technology concepts The implementation in practice The energy benefits in total compared to a standard installation The lifetime benefits and Technology and cost estimation for the increase of work safety by implementation of the Safety Extra Low Voltage (SELV) standard.
3 New Kassel-Calden Airport The Kassel-Calden Airport Project Regional Airport Kassel-Calden: IATA-Code: KSF ICAO-CODE: EDVK Opening date: 04 April 2013 Runway details: length: m width: 45 m orientation: 09 / 27 ILS CAT I (09) and CAT III/b (27) operation
4 New Kassel-Calden Airport Halogen Lights (6.6A) 708 LED Lights (2.2 A) 981 LED-Flash Lights (35 VAC) 44 Single Lamp Control Units 781 Primary Cable Secondary Cable (2,5 mm²; AWG 13) 147 km (91 miles) 59 km (37 miles) CCRs 52 Total Power for all Circuits 181 kw LED Circuits only 91 kw
5 New Kassel-Calden Airport Used technology concepts Construction details airfield lighting A 2,2 A 2,2 A 2,2 A 2,2 A RU 1 RU 2 RU 3 RU 4 LED LED LED A
6 New Kassel-Calden Airport LED Taxiway Light Fixture Light fixture constructed for both secondary current systems Automatically adapting electronic for 6.6 A or 2.2 A use
7 New Kassel-Calden Airport LED Approach Sequence Flash Light Light fixture are powered with SELV 35 VAC Light fixture constructed for max cd peak intensity
8 New Kassel-Calden Airport Power station Construction details CCR cabinet CCR concentration in racks: Footprint saving space Easy to maintain
9 New Kassel-Calden Airport Construction CCR transformer Primary transformer cabinets: Footprint saving Easy to maintain Clear separation between high (transformer) and low (CCR) voltage
10 New Kassel-Calden Airport Construction details transformer rack Max. three levels of transformer s STB 3 Cut Out (secondary circuit) Disconnection secondary cable Grounding Transformer Secondary cable Result Clear separation between transformer level and secondary circuit
11 New Kassel-Calden Airport Construction details cabling All cabling is done under the elevated floor level each room has a fire separation Result Clear room concept
12 New Kassel-Calden Airport Field installation runway system Cable trace on both side s of runway for primary cable At each PVC pipe crossing a manhole for: Primary Cable Lamp Transformer Single Lamp Control Unit PVC pipes for secondary cables
13 New Kassel-Calden Airport Taxiway system Cable trace on one side s of taxiway for primary cable At the PVC pipe concentration one manhole for: Primary Cable Lamp Transformer Single Lamp Control Unit PVC pipes for secondary cables: From each second lamp direct to the manhole and One PVC center pipe
14 New Kassel-Calden Airport Manhole installation First level Lamp transformers Single Lamp Control Units Second level Primary cable Secondary cable
15 What are the reasons to go for a new LED circuit design Technical Background
16 Objectives for a new LED circuit design The aim of the system design is to get the best balance in between Energy saving Reduction of maintenance Life time of the installations Minimum of different spare parts High grade of work safety
17 Where are the losses in the LED circuits? The total losses at nominal power are ~57 kw The losses on the secondary cable forms with 31 kw (54%) the major portion. To reduce that losses it was decided to reduce the secondary current to 2.2 A
18 Principle design of the 6.6 / 2.2 series circuit Control & Monitoring INetz IThyristor IKreis UNetz ICCR-intern CCR Electronic UCCRTrafo_prim UKreis CCR 6.6 A Transformer Pit Transformer Pit maximum output load 2.2 A 2.2 A 2.2 A 2.2 A Nominal Load and 100 % intensity Dimmed to low intensity step W Up to 100 m
19 The savings in losses for the 2,2 A on the secondary The 2,2 A secondary current decrease the losses on the sec. cable about 89% The savings losses are in total ~55% at nominal power The interesting question: What are the actual effective savings and how much the change of primary current could add?
20 What is the share of the intensity steps in the AGL? Statistically share for a midsize CAT III Airport in Germany
21 What are finally the effective savings? Savings at nominal power Effective savings at rated power As the diagram shows the effective losses are just 1/10 of the calculated nominal losses!
22 What happened if we reduce the primary current? Could there be any disadvantages to go for the additional saving by reducing the primary current? Decreasing the current automatically requires an increase of the voltage. Traditional Current Low Current Current Low Voltage Current Voltage Voltage Voltage
23 What is the effect of the voltage to the installation? Voltage results an electrical field that stresses the insulation material Particular in areas with a high concentration of the electrical field the aging of material results a treeing with micro discharges
24 Life time related to the nominal Voltage What is the effect to the life time of the installation? The literature gives an empirical life time law Life time ~ 1/U n (n= 9 11) *) 1,000,000 Life Time depending on the Voltage 100,000 10,000 1, % 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Operating voltage relatively to the nominal voltage *Tilman Weiers; Diss. ETH Nr ; Eine Methode zur aussagekräftigeren Bewertung von Maschinenisolierungen
25 Lower voltage compared to lower current? Reducing the circuit voltage provides Ever lasting installations (particular for joints, connectors, transformers) Higher grade of work safety with circuits less than 1000 V Best support of SELV-Installations Reducing the primary current 1,1 kw additional effective savings on the whole AGL
26 The current situation at Kassel-Calden? The black columns are the theoretical 2,2A low current circuits
27 Personal safety aspects The new 6.6 A / 2.2 A transformers installed at Kassel- Calden Airport fulfills already the proposed new IEC about the SELV supply for the LED-lights. All LED circuits are below 700 VAC and does not require high voltage certifications. The LED sequence flash light is powered with 35 VAC according to SELV.
28 Conclusion Energy optimized installations will not consider automatically safety and life time aspects. To stay on the 6,6 A and choose for the lower voltage brings best benefits for installation life time and work safety The change to the SELV supply provides the first time real work safety on the airport. To change to 2,2 A on the secondary minimize the major losses. Automatically adapting light fixtures allow to operate mixed installations
29 What installation provides the best? Savings in Maintenance Cost Life Time / / /6.6 Work Safety Savings in Installation Cost Power Saving Considering all aspects the 6.6 A / 2.2 A installation provides the optimum in energy, life time and safety.
30 Thank you for your attention. Questions?
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