CHRYSLER KOKOMO CASTING

PLANT LIGHTING AUDIT REPORT

ECET 53500 Energy

Management

Building Information
Address: 1001 East
Boulevard, Kokomo , Indiana
, United States

Floor Space: 625,000

square feet

Products: Aluminum parts

for automotive components,
transmission and transaxle
cases; engine block castings

Employment: 1,245 (1,190

hourly; 155 salaried)

Mechanical Systems:
Primarily die cast machines
and furnaces
Sources of energy: Main
sources of energy are
electric and natural gas
Operating schedule: 24/7

Lighting systems
Administration Area
Recently halogen to LED in all offices, break room areas,
bathrooms, etc.
voltage 120-277V.
The fixtures used are Lithonia 2RTL4 48L D49 LP850 N100.
Hours of operation: 24 hours
Future initiatives: Add occupation sensors to shut the lights off
when no movement is detected.

Plant Production Areas

Recently, 250 W induction fixtures instead 400W pulse-start metal

halide fixtures.
Hours of operation: 24/7
Operating voltages: varies between 480V and 277V. There are
also lights at 120V in the old building.
Future initiatives: Corporate Chrysler has suggested to use the T8
fixtures.

Exterior Areas

Replacing with LED lights in all outside areas.

only when it is dark outside.
Most are currently run with a timer but I in the future they could be changed to photo-eyes.
Parking lot and out front lights works with 480V a
Lithonia Fixture DSX2 80C 1000 50K T3M MVOLT RPA DDBXD.
Under outside mezzanine is 120V and the fixtures recently installed are Kenall MS11FD-PPMW-26L50K-1-DV.

Fan Rooms/Substations

Removing lights and putting in sealed LEDs.

On couple hours each day.
No occupation sensors
Light fixture used: Kenall MS11FD-PP-MW-26L50K-1-DV.
Operating voltages: 120V.

Basements
Similar as the fan rooms and substations except that they are on 24/7 due to cameras
monitoring scrap conveyors.

Utility Summary

Electricity Analysis

KWh use
smaller during
the winter
months and
higher in the
summer months.

KW profile

Similar
pattern
than the
KWh
usage

PF
Fluctuating
between
88.5% and
89.5%.
Around $8000
per month.

Gas Analysis
Contrary to electricity
pattern.

Energy Utilization Index

(EUI)

Energy Conservation of Lighting System

ROW 20 - 30

2D Row 20 30 Plot

3D Row 20 30 Plot

Foot Candle Measurements

ROW 20 30
1
2
3
4
5
6
7
8
9
10
11
12
13

ROW 60 70

45
45
34
45
34
45
82
45
35
82
63
45
12

27
42
40
41
44
47
51
55
54
56
58
51
36

33
47
43
40
45
49
50
44
54
51
50
43
42

14
45
46
45
35
43
45
45
53
44
24
53
31

1
2
3
4
5
6
7
8
9
10
11
12
13

17
17
5
17
5
17
62
17
6
62
63
17
12

11
10
13
12
13
13
15
16
17
18
20
21
19

10
11
13
13
14
14
15
15
18
18
19
20
18

7
17
46
5
35
43
17
17
53
44
24
53
16

Working spaces where visual tasks are only

occasional performed: Category C, 10 - 15- 20
foot candles.
Performance of visual tasks of medium contrast
or small size: Category E, 50-75-100

Illuminance profile
ROW 20 30

ROW 60 70

ECM Description

foot candle levels very high in the corridor and in

the machine areas, but between machines the
levels are low. Some levels in the operator tables
are high because of the T8 fixtures.

Delamping strategy using only 32

induction fixtures instead of the 64

With Motion sensors:

Renewable energy or DG
integration
The Power needed is:

$250W
8 KW
32 fixtures
fixture
The energy needed per month is :

hours
days
30
8 KW 24
5760 KWh
day
month

The cost of the PV project

$2.60 / Watt * 8000Watts $20800
The payback

$20800
23.26 years
$894

Operation and Maintenance

not operation and
maintenance
plans scheduled
for lighting at
KCP
the T8 lenses at
operator tables
dirty due to the
lube/stem mist
generated by
the machinery