Proposed Electrical Engineering and Electrical Installation of a Green Warehousing Facility Project


As an electrical contractors houston, our firm is often contacted to work on the electrical engineering of buildings that are still in project phase, and present detailed design plans that enable the architect, the general contractor and the owners of a facility to integrate the constraints of the electrical installation in the overall master plan of this facility.

In this article, we have planned out a theoretical framework for the electrical installation of a 100,000 sq. ft. warehousing facility with large parking and cargo hold outdoor area.

1. Scope of project

A. Project scope for a 100,000 sq.ft. warehousing facility

The facility will be fully air conditioned, fully secured, with a large 2,000 ft docking bay area on one side, and 20,000 ft of fully lit parking space and temporary cargo hold area.  The warehouse will be separated in 2 major areas: (a) a 70,000 ft open warehousing space with stocking shelves stacked up for a total height of 25 ft; (b) a 20,000 ft refrigerated enclosed hold with a height of 15 ft. The rest of the square footage will harbor staff offices, including a separate security room, enclosed gender-differentiated restrooms with 5 stalls each, and common access areas including aisles. The warehousing facility will be 45 ft under the ceiling. It will be LED lit, with waterproof LED high bays spaced every 30 ft. The security system will be comprised of 50 cameras hooked up to a CCTV system inside the security room.

B.    Further constraints and unique characteristics of the project

We present an innovative design engineered to save money on materials, installation, and electrical usage. The facility will be built according to "green" specifications which will encompass the type of material included in the build. The project proposal details our engineering ideas and plans for each area, and ends with a summary showing how our ideas contribute to the objectives of the owner: a human-friendly, environment friendly electrical installation meeting the best power usage, power savings, and lighting requirements for the warehousing facility and its outside perimeter.

2. Overall Electrical System Design

2.1 Power Distribution:

To ensure efficient power distribution, we propose to install a three-phase electrical system throughout the facility. This system will consist of energy-efficient transformers, distribution panels, and circuit breakers. By utilizing three-phase power, we can evenly distribute electrical loads, minimize power losses, and improve the overall power quality within the facility. Furthermore, the system will be designed with expansion capabilities to accommodate future electrical needs, ensuring scalability and flexibility for your growing operations.

2.2 Lighting Design

Our lighting design focuses on maximizing energy efficiency and providing optimal illumination for various areas of the facility. For the open warehousing space, we will install waterproof LED high bays spaced every 30 ft. These high bays will provide uniform lighting while minimizing shadows and ensuring clear visibility for workers. Additionally, we will incorporate dimming capabilities and daylight harvesting sensors, allowing the lighting system to adjust itself based on natural light levels and to reduce energy consumption further.

In the refrigerated enclosed hold, we will install LED lighting fixtures specifically designed for low-temperature environments. These fixtures are highly efficient, generate less heat, and have excellent performance in cold conditions. They will ensure proper lighting while minimizing energy usage and providing a suitable environment for cold storage operations.

2.3 Power Usage Monitoring

To support the owner’s objective of optimizing power usage, we propose the implementation of a comprehensive power usage monitoring system. This system will consist of smart meters, sub-meters, and a centralized monitoring platform. It will provide real-time data on energy consumption, including detailed information on individual circuits, equipment, and areas of the facility.

With this monitoring system, the facility manager will be able to identify areas of high energy usage, implement energy-saving measures, and track the effectiveness of energy management strategies. The platform will offer intuitive visualization and reporting tools to help make informed decisions regarding energy conservation, load balancing, and demand response programs.

3. Indoor Electrical Design

3.1 Open Warehousing Space

In the open warehousing space, we will optimize the electrical design for efficient operations and cost savings. To minimize material and installation costs, we propose utilizing overhead busway systems for power distribution. The busway system eliminates the need for extensive electrical wiring and conduit runs, reducing material usage and labor requirements. This streamlined approach not only saves on installation costs but also provides flexibility for future modifications and rearrangement of power connections as needed.

To ensure proper illumination and ease of maintenance, we will install LED strip lighting along the stocking shelves. These LED strips will be strategically placed to deliver uniform light distribution, minimizing shadows and ensuring clear visibility for workers. The LED technology will provide energy savings, long lifespan, and low maintenance requirements, further contributing to the overall efficiency and cost-effectiveness of the lighting system.

3.2 Refrigerated Enclosed Hold

The electrical design for the refrigerated enclosed hold will focus on maintaining precise temperature control while minimizing energy consumption. Energy-efficient refrigeration units with advanced control systems will be employed to regulate the temperature within the hold. These units will utilize smart sensors and adaptive algorithms to optimize cooling cycles and minimize energy usage while ensuring the desired temperature is maintained accurately.

LED lighting fixtures specifically designed for low-temperature environments will be installed in the refrigerated hold. These fixtures will provide sufficient lighting while operating efficiently in cold conditions. By using LED technology, the facility can achieve energy savings, reduce heat generation, and eliminate the need for warm-up periods, ensuring immediate illumination whenever required.

3.3 Staff Offices and Restrooms

To ensure a comfortable working environment, the staff offices will be equipped with energy-efficient LED lighting, occupancy sensors, and programmable thermostats for efficient temperature control. The enclosed gender-differentiated restrooms will have LED lighting, low-flow water fixtures, and occupancy sensors to maximize energy and water savings.

4. Outdoor Electrical Design

4.1 Docking Bay Area

The large docking bay area requires ample lighting for safety and productivity. We propose the installation of LED high mast lights strategically positioned to provide uniform illumination throughout the area. These high mast lights will be mounted at an appropriate height to ensure optimal light distribution, minimizing shadows and providing clear visibility for loading and unloading operations. The LED technology used in these fixtures offers high energy efficiency, long lifespan, and reduced maintenance requirements, contributing to overall cost savings.

To enhance energy efficiency, motion sensors will be integrated into the lighting system of the docking bay area. These sensors will detect movement and activate the lights only when needed. This intelligent lighting control will significantly reduce energy wastage during periods of inactivity, such as when the bay area is unoccupied or during daylight hours.

4.2 Parking Space and Cargo Hold Area

The parking space and temporary cargo hold area will be well-lit using LED parking lot lights. These lights will be strategically positioned to ensure uniform illumination throughout the space, enhancing safety and security. Photocell sensors will be integrated into the lighting system, enabling automatic adjustment of brightness based on ambient light levels. This feature ensures that the lights operate at optimal levels, minimizing energy consumption during daylight hours when natural lighting is sufficient.

Furthermore, the LED parking lot lights selected for this area will have a high color rendering index (CRI), which enhances visibility and color accuracy. This is particularly important for tasks such as inspecting cargo and ensuring accurate identification of items in the temporary cargo hold area.

By combining LED lighting technology, motion sensors, and photocell sensors, the lighting design for the parking space and cargo hold area achieves both energy efficiency and operational effectiveness. This approach ensures a well-lit environment while maximizing power savings and reducing unnecessary energy usage.

5. Security System

5.1 CCTV System

To ensure the facility's security, we will integrate a comprehensive closed-circuit television (CCTV) system. Fifty cameras will be strategically placed throughout the facility and connected to a central monitoring system inside the dedicated security room. These cameras will use efficient video compression technology to minimize data storage requirements.

An innovative electrical engineering design project

Our project outlines an innovative engineering design that incorporates cost-effective solutions and green materials to meet the owner’s objectives of a human-friendly and environmentally friendly electrical installation. By utilizing LED lighting, motion sensors, power monitoring systems, and energy-efficient technologies, we aim to achieve significant power savings and optimize electrical usage throughout the warehousing facility.

Our proposed design includes the following key features:

LED Lighting: By utilizing LED lighting fixtures, we can achieve energy savings of up to 50% compared to traditional lighting systems. LED lights have a longer lifespan, require minimal maintenance, and provide superior illumination, ensuring a safe and well-lit environment for workers.

Motion Sensors: Incorporating motion sensors in both indoor and outdoor areas allows for automated lighting control. Lights will only activate when motion is detected, reducing energy wastage in unoccupied spaces and storage aisles. This feature significantly contributes to overall energy efficiency.

Power Monitoring System: Our design includes a comprehensive power monitoring system that provides real-time data on energy consumption. By identifying areas of high power usage, you can implement targeted energy-saving strategies and optimize operational efficiency. The power monitoring system will enable you to make informed decisions regarding energy management and conservation.

Green Materials: We will prioritize the use of environmentally friendly materials throughout the electrical installation. This includes selecting energy-efficient transformers, distribution panels, and wiring components with high energy ratings. Our choice of green materials not only aligns with your sustainability goals but also contributes to long-term cost savings.

Power Distribution Efficiency: To minimize power losses and ensure reliable distribution, we will design and implement a three-phase electrical system. This system will support the current power requirements of the facility while allowing for future expansion, if needed.

Security System Integration: The CCTV system with 50 strategically placed cameras will enhance the security of the facility. By centralizing the monitoring in a dedicated security room, you will have real-time surveillance and video recording capabilities, helping to protect your assets and maintain a secure environment.

In summary, our design project incorporates innovative engineering solutions that focus on reducing material costs, optimizing electrical usage, and promoting sustainability. By leveraging energy-efficient technologies, utilizing green materials, and implementing intelligent lighting and monitoring systems, we aim to deliver a human-friendly and environment-friendly electrical installation for the warehousing facility. This design will not only enhance operational efficiency and cost-effectiveness but also align with the owner’s commitment to sustainability.