GENERAL OBSERVATIONS FROM THE PHES EVALUATIONS TO DATE June 18, 2009 AVERAGE ANNUAL PROPANE USE 1
AVERAGE ANNUAL ELECTRICITY USE THERMAL IMAGING 2
Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative. Item Estimated cost Estimated savings Payback (years) Insulate sidewall curtain $4,000 800 gal 2.5 Insulate ceiling $2,800 450 gal 3.1 Add attic inlets $1,800 600 gal 1.5 Tunnel inlet doors $5,800 500 gal 5.8 Mixing i fans $ 500 100 gal 25 2.5 Radiant tube heaters $7,000 500 gal 7.0 Cold cathode lights $1,000 11,000 kwh 0.8 Close and insulate sidewall curtains 3 ½ inch fiberglass + plastic + blandex Therm All fiberglass blanket w/reinforced backing Save 600 to 1000 gal LP/house/yr Payback 2 to 4 yrs Trade and brand names are used for information only and does not imply approval of any product to the exclusion of others that may be suitable 3
SIDEWALL CURTAINS SIDEWALL CURTAINS 4
SOLID SIDEWALLS END DOORS A. Thermal image of a poorly sealed end door B. Thermal image of a well sealed end door 5
Thermal Images End Wall Cold air is leaking along the top of the door Cold air is leaking along the ceiling line at the end wall Air Leaks Foundation & Wall Cold air is leaking into the barn through a hole in the wall covering Cold air is leaking under the Cold air is leaking under the frame wall at the top of a concrete foundation 6
Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative. Item Estimated cost Estimated savings Payback (years) Insulate sidewall curtain $4,000 800 gal 2.5 Insulate ceiling $2,800 450 gal 3.1 Add attic inlets $1,800 600 gal 1.5 Tunnel inlet doors $5,800 500 gal 5.8 Mixing i fans $ 500 100 gal 25 2.5 Radiant tube heaters $7,000 500 gal 7.0 Cold cathode lights $1,000 11,000 kwh 0.8 ATTIC INSULATION Most barns 2 to 4 inches Could add 3 to 6 inches Save 300 to 600 gal LP/house/year Payback 2.5 to 5 years 7
ATTIC INSULATION ATTIC INSULATION 8
ATTIC INSULATION Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative. Item Estimated cost Estimated savings Payback (years) Insulate sidewall curtain $4,000 800 gal 2.5 Insulate ceiling $2,800 450 gal 3.1 Add attic inlets $1,800 600 gal 1.5 Tunnel inlet doors $5,800 500 gal 5.8 Mixing i fans $ 500 100 gal 25 2.5 Radiant tube heaters $7,000 500 gal 7.0 Cold cathode lights $1,000 11,000 kwh 0.8 9
ATTIC INLETS Capture solar heat from the attic Save 400 to 800 gal LP/house/yr Gravity Inlets Need tight house Management (open/close) issues Payback 2 to 4 years Controlled (winch and static pressure) inlets House tightness not as critical Some more energy savings possible Payback 5 to 10 years ATTIC INLETS Winch controlled Static pressure operated Gravity operated Counterweighted 10
Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative. Item Estimated cost Estimated savings Payback (years) Insulate sidewall curtain $4,000 800 gal 2.5 Insulate ceiling $2,800 450 gal 3.1 Add attic inlets $1,800 600 gal 1.5 Tunnel inlet doors $5,800 500 gal 5.8 Mixing i fans $ 500 100 gal 25 2.5 Radiant tube heaters $7,000 500 gal 7.0 Cold cathode lights $1,000 11,000 kwh 0.8 Thermal Images -Tunnel Inlets Tunnel Inlet Leakage Air Leakage at the top of the tunnel inlet curtain 11
INSTALLING TUNNEL DOORS A. Thermal image of poorly sealed tunnel inlets B. Thermal image of a well sealed tunnel doors TUNNEL DOORS Insulated tunnel doors Save 400 to 600 gal LP/house/yr Payback 5 to 8 years 12
Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative. Item Estimated cost Estimated savings Payback (years) Insulate sidewall curtain $4,000 800 gal 2.5 Insulate ceiling $2,800 450 gal 3.1 Add attic inlets $1,800 600 gal 1.5 Tunnel inlet doors $5,800 500 gal 5.8 Mixing i fans $ 500 100 gal 25 2.5 Radiant tube heaters $7,000 500 gal 7.0 Cold cathode lights $1,000 11,000 kwh 0.8 MIXING FANS 13
MIXING FANS Most helpful in leaky houses Save 100 gal LP/house/yr Payback 2 to 4years Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative. Item Estimated cost Estimated savings Payback (years) Insulate sidewall curtain $4,000 800 gal 2.5 Insulate ceiling $2,800 450 gal 3.1 Add attic inlets $1,800 600 gal 1.5 Tunnel inlet doors $5,800 500 gal 5.8 Mixing i fans $ 500 100 gal 25 2.5 Radiant tube heaters $7,000 500 gal 7.0 Cold cathode lights $1,000 11,000 kwh 0.8 14
HEATING SYSTEMS HEATING SYSTEMS Radiant tube or Quad heaters Fewer units to maintain Save energy if house air temperature is lowered Save 300 to 600 gal LP/house/yr Payback 6 to 10 years 15
Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative. Item Estimated cost Estimated savings Payback (years) Insulate sidewall curtain $4,000 800 gal 2.5 Insulate ceiling $2,800 450 gal 3.1 Add attic inlets $1,800 600 gal 1.5 Tunnel inlet doors $5,800 500 gal 5.8 Mixing i fans $ 500 100 gal 25 2.5 Radiant tube heaters $7,000 500 gal 7.0 Cold cathode lights $1,000 11,000 kwh 0.8 RECOMMENDATIONS RELATED TO LIGHTING Change from incandescent lights to cold cathode or compact fluorescents 16
LIGHTING Replace Incandescent bulbs CFLs &/or Dimmable Cold Cathode Do 8 W CC bulbs provide enough light? May need to add some fixtures Save 8,000 to 12,000 kwh/house/yr (full house replacement) Payback <1 to 2 years RECOMMENDATIONS RELATED TO LIGHTING Keep light bulbs clean 17
VENTILATION 36-inch Fans Fan Airflow, CFM 12000 10000 8000 6000 4000 2000 Approx. 9000 CFM Operating range 0 0.00 0.05 0.10 0.15 0.20 0.25 Static Pressure 18
Tunnel Fans Air flow (CFM) 25,000 20,000000 15,000 10,000 5,000 0 0.00 0.10 0.20 0.30 Static Pressure (inches of water) Farm 1, Fan 1 Farm 1, Fan 2 Farm 2, Fan 1 Farm 2, Fan 2 Farm 2, Fan 3 Farm 3, Fan 1 Farm 3, Fan 2 Farm 3, Fan 3 Farm 3, Fan 4 Farm 3, Fan 5 Farm 4, Fan 1 48-inch Fans 25,000 20,000000 Air flow (CFM) 15,000 10,000 5,000 Farm 3, Fan 1 Farm 3, Fan 2 Farm 3, Fan 3 Farm 3, Fan 4 Farm 3, Fan 5 0 0.00 0.05 0.10 0.15 0.20 0.25 Static Pressure (inches of water) 19
50-inch Fans 25,000 Farm 1, Fan 1 Farm 1, Fan 2 Airflow (CFM) 20,000000 15,000 10,000 5,000 Farm 1, Fan 3 Farm 1, Fan 4 Farm 1, Fan 5 Farm 2, Fan 2 Farm 2, Fan 3 Farm 2, Fan 4 Farm 2, Fan 1 0 0.00 0.05 0.10 0.15 0.20 0.25 Static Pressure (inches of water) 50-inch Fans with and without a cones 25,000 20,000000 w/cone Farm 1, Fan 1 Farm 1, Fan 2 Air flow (CFM) 15,000 10,000 5,000 0 0.00 0.05 0.10 0.15 0.20 0.25 Static Pressure (inches of water) 20
Comparisons with BESS data Reduced fan performance C k ll i Cracks allow air to leak back into the barn 21
Worn Pulleys & Belts Worn Pulleys & Belts 22
Keeping fans clean 20,000 18,000 Clean Dirty 16,000 Airflow (CFM) 14,000 12,000 10,000 8,000 6,000 4,000 0.00 0.05 0.10 0.15 0.20 0.25 Static Pressure (inches of water) Shutter maintenance 23
Worn Pulleys & Belts Average house tightness of the 14 farms participating in the PHES evaluations (Values determined with a single tunnel fan running) 24
Average air leakage at 0.1 inches SP for 12 of the 14 farms participating in the PHES evaluations AVERAGE AIR SPEED MEASURED AT BROILER LEVEL WITH ALL TUNNEL FANS RUNNING (Measured 75.5 ft upstream from tunnel fans) 25
ELECTRICAL Services not overloaded Building loads below 75 A Some voltage drops more than 5% (20 25 V) Voltage at fans OK (> 215) Few overheated components ELECTRICAL Thermal image showing overheating in a breaker due to a poor contact Thermal image showing overheating due to a poor relay connection 26
ELECTRICAL Overheated Motor Main Breaker & lugs 35 F degrees air temperature CONTROLS Fan Thermostat 27
HOW POULTRY HOUSES LOOSE HEAT Building Envelope (structure or shell) Ventilation Approx 50% each Don t be over sold!! 28