Case Study: PPL Power Generation facility in Bangor, PA

Dialight’s LED Obstruction Lighting Helps PPL Save Energy, Reduce Maintenance Costs and Meet FAA Regulations

Project Snapshot
2 level 395’ Height – 20’ Diameter Chimney Stacks
PPL Chimney Stacks – Bangor, PA
All White beacon (6)
Replaces 330W Xenon Strobe

PPL Generation LLC works diligently to reduce its environmental impact and encourage the responsible use of energy through innovative technology, conservation initiatives and educational programs both inside its facilities and in the surrounding communities. Like many Americans, the company recently discovered that changing out a few light bulbs to install Dialight’s highly efficient LED-based obstruction lighting can make a big difference in reducing energy consumption and maintenance costs, while providing more reliable safety lighting to meet FAA requirements.

Lower Mount Bethel Energy in Bangor, PA boasts two natural gas-fired turbine generators and one combined cycle steam generator capable of churning out some 600 megawatts of electricity. Well-known for its exceptional employee safety program, the facility is applying this year for the U.S. Occupational Safety and Health Administration’s Voluntary Protection Program (VPP) as a “Star” worksite, the highest honor within the program, recognizing the company’s efforts beyond compliance to protect worker health and safety. In addition to its focus on safety, the LMBE facility emphasizes responsible energy consumption on-site, both for the environmental benefits and the cost savings. By conserving energy, the plant reduces its carbon footprint and each kilowatt not consumed on premises can be sold on the open market.

Look Up for Energy

Cost Savings As part of its efforts to reduce energy consumption and cut back on maintenance costs for its twin 400-foot exhaust chimney stacks, the company turned to Fuellgraf Chimney & Tower Inc. to retrofit the stacks with Dialight’s high-efficiency LED obstruction lighting. The result has been not only lower operating costs, but also confidence in its ongoing compliance with Federal Aviation Administration standards for obstruction lighting requirements.

The Lower Mount Bethel chimneys’ six Xenon medium-intensity bulbs were not only expensive to operate, but costly to replace and dispose of. Annual replacement bills ran about $12,000, with each lamp costing $1500. In addition to the cost, safety was a factor, especially considering Lower Mount Bethel Energy’s exceptional record. Should one of the bulbs fail unexpectedly, FAA fines could top thousands of dollars per day, for each light that is out. With few crews certified and available to perform this kind of maintenance, the fines could easily add up quickly if the short-lived Xenon bulbs aren’t replaced immediately. Xenon bulb disposal was also an issue, with special handling required - another added cost.

Dialight Hi-Efficiency LED Beacons Save Energy, Meet FAA Specs At Fuellgraf’s recommendation, PPL installed six new Dialight L864/L865 dual LED obstruction fixtures in place of the antiquated Xenon fixtures. Powered by ultra-long life LEDs, the new Dialight LED beacons deliver the equivalent of 330-watt illumination from a 110/230VAC 50/60 Hz power supply with exceptional performance and reliability for up to 10 years, in most cases. Solid state construction resists shock and vibration, while the fixture itself is much smaller, reducing wind load interference and damage.

The dual beacon uses 90% less electricity than traditional incandescent bulbs to reduce energy consumption and the plant’s overall carbon footprint. Pursuant to the company’s environmental stewardship, the Dialight beacons also meet the U.S. Fish and Wildlife Services’ recommendation for the protection of migratory birds. And, the new LED units are safer for humans, too: the Dialight L864/L865 LED beacons operate at a much lower voltage than traditional Xenon flashtubes, reducing the risk of injury due to electrical shock for installers and maintenance crews. The L864/L865 power supply/control box can be positioned at the base of the tower for added safety and convenience when servicing the units.

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Dialight’s LED based DUAL (Red and White) obstruction systems are ideal for FAA classified E-style towers and the lights carry a L-865 / L-864 (medium intensity) classification.  These systems typically are illuminated white for daytime operation and red for night operation.  Our DUAL systems can be used to illuminate E1 and E2 style towers as well as other structures.  Our dual systems are ETL certified, fully monitored, and the system is configurable (flash rate, side marker flashing, etc).  The Dialight Gateway is optional and provides remote monitoring of the system.

Dialight’s LED based High Intensity obstruction systems are ideal for FAA classified as B, C, or F-style towers and the lights carry a L-856 (high intensity white) and L-864 (medium red) classification.  B and C-style towers utilize the L-856 white high intensity lights.  C-style towers have an additional medium intensity white (L-865) AOL.  F-style towers have a white day and red night protection method. Our system integrates the high intensity white and medium intensity red lights in a single fixture.  Low intensity (L-810) side markers are needed as well on F-style towers.  These high intensity systems are typically used on towers and structures that exceed 500 feet in height. Our white systems are ETL certified, fully monitored, and configurable.  The Dialight Gateway is optional and provides remote monitoring of the system.
Dialight’s LED based red obstruction systems are ideal for FAA classified A-style towers and the lights carry a L-810 (low intensity) or L-864 (medium intensity) classification.  These systems typically turn on at night and are off during the day via the photocell and controller.   Our red systems can be used to illuminate A1-A6 style towers as well as other structures.  Our red L-810 and L-864 lights are ETL certified, fully monitored, and the system is configurable (flash rate, side marker flashing, etc).  The Dialight Gateway is optional and provides remote monitoring of the system.
Dialight’s LED based WHITE obstruction systems are ideal for FAA classified D-style towers and the lights carry a L-865 (medium intensity) classification.  These systems typically are illuminated white (20,000 candela) for daytime operation and white (2,000) for night operation.  Our WHITE systems can be used to illuminate D1 and D2 style towers as well as other structures.  Our white systems are ETL certified, fully monitored, and configurable.  The Dialight Gateway is optional and provides remote monitoring of the system.
Dialight’s wind turbine lighting and control systems are highly efficient and have the sharpest cutoff in the industry as a result of the patented optics.  This assists in eliminating light pollution and affect on surrounding communities.   Our robust LED based products are ideal for maintenance free installations for on and offshore wind turbines around the world.  Our wind systems are certified though ETL to the FAA standards.