Novolipetsk Steel also known NLMK PJSC is the leader in energy saving in the steel industry. For this reason, the project set stringent requirements for the results of the modernization of the lighting system.

The Customer’s goals:

- The guaranteed project payback period should be 3 years;
- The lighting system should have the lowest total cost of ownership (TCO);
- The lighting costs should be reduced at least by 50% compared to already energy-efficient MHL lamps;
- The project should enable standard illumination and maximum uniformity of lighting in the workshop;
- The works should be performed without changing the location of the light points;
- It is necessary to reduce the number of light points while preserving the illumination level and uniformity of lighting;
- It is necessary to take into consideration the location of equipment and machines in calculations and design.

To create a comprehensive solution conforming to the technical specifications and specific features of the facility, the Enercom specialists conducted an onsite “lighting audit” in order to get a complete and clear picture for accurate lighting calculations and maximum correlation of the calculated and actually obtained data.

The audit included a 3D scanning of the premises which allowed to develop its digital twin for carrying out further calculations in the Dialux EVO software. This process made it possible to consider the important details in workshops with their complex geometry and high equipment density, as well as to develop a technical project that leverages 100% of the capabilities of lighting equipment and provides the required illumination level with minimal energy costs.

To fulfil the requirements of the technical project, the customized modifications of the Enercom HB-240-740-60 and HB-200-740-60 light fixtures were manufactured.

The customized industrial light fixture for heights of 14-45 m was based on the Enercom HB series device with specialized borosilicate lenses. Unlike standard polycarbonate lenses, those maintain light transmittance capability and are resistant to dust and high temperatures.

The light fixture also featured vertical convection fins for cooling that do not accumulate dust.

Also, for the convenience and speed of installation, the light fixtures were modified to fit the existing installation hardware on the lighting bridges.

The fixtures used special programmable dimmable drivers by Inventronics, which enable remote control of the current load and light flux.

As part of the lighting system modernization, it is planned to introduce a control system (currently, installation works are underway).

Thanks to a set of technical solutions, the customized light fixtures by Enercom ensure high savings, efficient comfortable standard-compliant illumination, long useful life, flexible configuration and ease of maintenance.

During the project, 2,112 old 400 W MHL lamps were dismantled and 1,713 new energy-efficient Enercom HB series 200 and 240 W light fixtures were installed.

The project was completed in full accordance with the customer's specification:

- The energy consumption of the lighting system reduced by 65%;
- The payback period of 2.5 years conforms to the customer’s requirements;
- The level of illumination was increased by 2.5-3 times and brought into line with the internal customer’s regulations;
- The customer was provided with a 5-year absolute warranty on equipment and illumination level;
- The illumination quality and visual comfort have improved;
- The workforce productivity has increased;
- The product quality control has improved.

The customer obtained a modernized lighting system with the lowest total cost of ownership (TCO) on the market, which guarantees the required level of illumination throughout the life of the equipment.

The success of NLMK's first large-scale project to replace lighting with LEDs is regarded as one of the exemplary cases for the entire steel industry.