Replacing fluorescent tubes with LED tubes in Uniper power plants

The Challenge

Uniper’s power plants required a highly reliable lighting system capable of withstanding extreme temperature conditions. The previously installed T5 and T8 fluorescent tubes were no longer RoHS-compliant, caused high energy costs, and due to their short lifetime, resulted in significant maintenance efforts – especially in hard-to-reach areas. This posed a risk to operational safety and efficiency. A solution was needed that would combine energy efficiency, compliance with technical standards, and long service life under demanding industrial conditions.

The Solution – LED Retrofit with GLT LED TUBE

In the Staudinger and Ingolstadt power plants operated by Uniper, all existing T5 and T8 fluorescent tubes were completely replaced with 11,400 GLT LED TUBES “Made in Germany.”The conversion was carried out as an LED retrofit solution with full standards compliance according to ENEC / IEC 62776, allowing the existing luminaires and fixtures to be retained and efficiently modernized.

Especially under extreme temperature conditions from –40 °C to +70 °C, the GLT LED TUBE demonstrates its strengths: the integrated high-performance power supply and patented heat dissipation ensure maximum operational reliability and a lifetime of up to 130,000 operating hours – ideal for continuous use in demanding industrial and power plant environments.

With an annual energy saving of approximately 5 million kWh, the project achieved a payback period of just one year. The virtually maintenance-free lighting system significantly reduces maintenance efforts and operating costs – a crucial advantage in hard-to-reach areas where servicing was previously complex and costly.

By implementing GLT LED TUBES, Uniper realized a durable, safe, and sustainable lighting solution that perfectly combines efficiency, reliability, and economic performance.

Key advantages of our LED retrofit for Uniper’s power plants:

• ENEC-certified temperature resistance from –40 °C to +70 °C – ideal for continuous use in power plants and technical facilities.
• Integrated high-performance power supply and patented heat dissipation ensure maximum efficiency and up to 130,000 hours of service life.
• Annual energy savings of around 5 million kWh with a payback period of one year.
• Maintenance-free and long-lasting lighting solution, particularly advantageous in hard-to-access areas and extreme environmental conditions.

Key Benefits & Advantages

Conclusion

By replacing fluorescent tubes with GLT LED TUBESGLT LED TUBES, Uniper implemented a lighting solution that meets both the high technical demands of power plants and economic objectives. The combination of energy savings, operational reliability and long lifespan makes this project a benchmark for sustainable and efficient LED lighting in the energy sector.

Other power plant operators, including EnBW Energie Baden-Württemberg AG, have also chosen the GLT LED TUBEGLT LED TUBE, based on the findings of a study conducted by the Fraunhofer Institute for Building Physics (IBP). The study confirms that, in the EF 3.0 Climate Change impact category, the GLT LED TUBE outperforms a conventional 58 W fluorescent tube after only 15 days of operation.