cold room: medium temperature (chiller) for meat · pdf filecold room: medium temperature...

COLD ROOM: Medium Temperature (Chiller) For Meat Storage LOCATION: Bangkok, THAILAND BY: EMERSON PARTNER+ PROJECT DESIGN GROUP

DATE: June 30, 2016

Table of Contents

I. Introduction .............................................................. Page 1

II. Design Input .............................................................

III. Design Assumptions ....…........................................ Page 3

IV. Design Results ….…………………………………….... Page 4

V. Product Selections ……………………………………… Page 5

VI. Annual Coefficient of Performance (ACOP) ……….. Page 6

VII. Energy Usage Summary …..…………………………… Page 7

VIII. Energy Usage Details ……………………….……….… Page 8-9

IX. Life Cycle Costs (LCC) Analysis …………………..… Page 10

X. Project Design Contact Details ……………….….….. Page 11

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I. INTRODUCTION

Emerson’s Partner+ program was created in 2011 as a service initiative focused on customers

who serve the Refrigeration Cold Chain industry. Our goal is simple, help members become more

effective in taking on the challenging issues they face in today’s HVACR market. We accomplish

this goal with industry leading product and skills training, tool development programs to enhance

member productivity and providing valued technical services and support offerings.

Our team of professional refrigeration engineers deliver technical training to improve front line

operator’s and technician’s relevant field service skills (including installation, commissioning,

troubleshooting and repair / service maintenance), as well as focused training to help end-users

tackle operational issues affecting their bottom line.

In addition to training, we also support our members with complete software and mobile tools to

improve their productivity and increase their effectiveness. We also develop user friendly tools

that aid customers in the design and selection of Emerson engineered solutions.

And in the same spirit of providing time saving tools, we also offer members personalized

assistance through our Project Design Services team. Members can receive custom heat load

calculations based on project design data known at any stage in the bidding process.

Our Partner+ program is constantly evolving. We will continue to develop additional valued

services and offerings to make you a more effective professional. We look forward to providing

assistance to you, our member, and hope you find our Partner+ programs valuable.

About Project Design Services

Our team employs industry best practices for cold chain engineered solutions by utilizing the most

appropriate and industry accepted design estimating techniques. Our finished product documents

the design in an easy to read report, giving you the ability to review your initial assumptions and

understand the impact of each assumption on the finished result. And if you gain new information

on the project that can influence the calculation results, resubmit your request and let us fine-tune

your solution. This approach makes you the expert and allows you to have a clear and meaningful

communication on the solution you provide to your customer.

In addition, we provide exact Emerson product selection options and detailed energy usage

estimates that offer life of ownership solutions to your customer. Show the impact of product

choices when operated over the course of 1-3 years and inform your customer on the payback on

their equipment investment. No longer be limited to only having a first cost discussion and

competing on lowest cost, turn your company into a trusted solution provider that understands

and addresses your customer’s real problems.

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II. DESIGN INPUTS

Project Request

Requested to calculate heat loads based on the following customer provided data:

Project: Chiller Cold Room

Location: Bangkok, Thailand

Room Dimension: 10m L x 8m W x 6.5m H

Room Temperature: 0°C

Insulation Type and Thickness o Walls: 100mm Polystyrene (Expanded) o Ceiling: 100mm Polystyrene (Expanded) o Floor: 100mm Polystyrene (Expanded)

Surrounding Temperatures

Product To Be Stored: Meat

Product Input Load Per Day: 24,000 kg

Initial Product Temperature: 18°C

Final Product Temperature: 3°C

Total Weight of Product In Store: 120,000 kg

Air Changes Per Day: Heavy Traffic Usage Factor

No. Of Personnel: 3, working 5 hrs/day

Lighting: 15W/m2

Equipment Run Time: 18 hours

40°C

40°C

40°C 40°C Ceiling Temp: 40°C

Floor Temp: 35°C

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III. DESIGN ASSUMPTIONS

In addition to the customer’s given data, the following assumptions were used in the calculation of heat load.

Climatic Design Condition Dry Bulb Temperature: 35°C Relative Humidity: 50.3% RH Thermal Property of Meat

Moisture Content: 72.63% Specific Heat Above Freezing: 3.59 kJ/kg-K

Insulation Material Thermal Conductivity of Polystyrene: 0.033 W/m-K

Room Condition: 0°C, 90% RH

Air Change Factor: Heavy, 7.34 Equipment: One 1800kg battery operated forklift operating for 2 hours/day

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IV. DESIGN RESULTS Project Design Result

The total heat load is calculated at 27.49 kW.

Transmission Load 5.07 kW

Infiltration Load 3.81 kW

Product Load 14.96 kW

Miscellaneous Loads

Lighting 1.20 kW

Fan 1.58 kW

Equipment (Forklift) 0.64 kW

People 0.23 kW

Total Heat Load 27.49 kW

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V. PRODUCT SELECTIONS

Selection Parameters

Ambient Temp: 35°C

Condenser TD: 10K

Saturated Condensing Temp: 45°C

Room Temp: 0°C

Evaporator TD: 5K

Evaporating Temp: -5°C

Refrigerant: R404A

Suction Line Pressure Drop Equivalent: 1K

Saturated Suction Temp: -6°C

Equipment Capacity Based on 18 Hrs Runtime + 10% Safety Factor: 40.32 kW

Equipment Capacity Based on 20 Hrs Runtime (No Safety Factor): 32.98 kW

Option 1: Based on 40.32kW Equipment Capacity

Component Quantity Specification Model No.

Compressor 1 Useful Capacity: 42.50 kW

Power Supply: 380-420V/3Ph/50Hz Condenser Heat of Rejection: 66.7kW

4MI-30X-AWM





4SJH-300E-AWM





4MA-22X-AWM

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VI. ANNUAL COEFFICIENT OF PERFORMANCE (ACOP) What is ACOP? ACOP is the Annual Coefficient of Performance and refers to the average amount of heat a system can

remove per unit of power, measured in a year and takes into account the changes in capacity and

power consumption because of varying (seasonal) ambient temperatures. It is a useful measurement

to reference and easily compare different system and compressor options to select the optimum

energy efficient design.

Compressor Model No.

Total Heat Removed In A Year

kW-hr

Annual Energy Consumption

kW-hr

Annual Coefficient of Performance (ACOP)

4MI-30X-AWM

214,416.7

74,568.8 2.88

4SJH-300E-AWM 81,178.0 2.64

4MA-22X-AWM 73,412.2 2.92

𝐀𝐂𝐎𝐏 =Total Heat Removed In A Year


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VII. ENERGY USAGE SUMMARY How to calculate Annual Energy Consumption Why do we use this method? Our approach adjusts for seasonal weather patterns as both hot and cooler times of the year impact the operation and performance of the equipment. All things being equal in design and operation, the heat load increases when the weather is at its’ hottest and decreases during cooler seasons. Likewise, your refrigeration equipment operates longer during the hot season and operates less during the cooler season, and the longer it operates the more energy (or power) it consumes (and costs). How do we do it? We first use annual temperature data for a given geographical location, grouping temperature data into equal intervals and summing the hours spent within each equal interval - this tells us how much time the equipment will operate at these ambient temperatures, within any year. We then calculate seasonal heat loads and determine equipment run time and power consumption at these defined ambient conditions. Using the local cost of energy (what you pay for a kW-hr of power) we provide an accurate estimate of your future annual energy consumption.

ENERGY USAGE SUMMARY TABLE

Compressor Model No.


kW-hr

Annual Energy Cost (Thai Baht*)

Savings Compared To Base Model

(Thai Baht)

4MI-30X-AWM 74,568.8 293,801 26,040

4SJH-300E-AWM 81,178.0 319,841 Base Model

4MA-22X-AWM 73,412.2 289,244 30,597

*Based on 3.94 Thai Baht/kW-hrs energy cost

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VIII. ENERGY USAGE DETAILS Option 1 – 4MI-30X-AWM

Ambient Temp

°C

Bin Hours

Heat Load kW

Capacity kW

Power Input kW

Operating Hours

% Run Time

Heat Removed

kW-hr

Energy Consumption

kW-hrs

12.8 2 20.90 61.70 13.40 0.7 34% 41.8 9.1

15.6 35 21.54 59.40 14.10 12.7 36% 754.0 179.0

18.3 125 22.19 57.20 14.80 48.5 39% 2,773.3 717.6

21.1 377 22.87 54.90 15.50 157.1 42% 8,622.8 2,434.5

23.9 1,969 23.58 52.50 16.25 884.4 45% 46,433.3 14,372.2

26.7 2,980 24.32 50.00 16.95 1449.5 49% 72,474.3 24,568.8

29.4 2,042 25.06 47.60 17.65 1075.1 53% 51,173.1 18,974.9

32.2 1,025 25.86 45.10 18.35 587.8 57% 26,508.9 10,785.8

35.0 199 27.49 42.50 19.00 128.7 65% 5,469.6 2,445.2

37.8 6 27.59 39.90 19.70 4.1 69% 165.5 81.7

Annual Energy Consumption 74,568.8 kW-hr

Total Heat Removed 214,416.7 kW-hr

Annual COP = 2.88 Annual Energy Cost = 293,801 Thai Baht Average Annual Run Time % = 50%

Option 2 – 4SJH-300E-AWM

Ambient Temp

°C

Bin Hours

Heat Load kW

Capacity kW

Power Input kW

Operating Hours

% Run Time

Heat Removed

kW-hr

Energy Consumption

kW-hrs

12.8 2 20.90 64.80 15.25 0.6 32% 41.8 9.8

15.6 35 21.54 62.00 16.05 12.2 35% 754.0 195.2

18.3 125 22.19 59.30 16.75 46.8 37% 2,773.3 783.3

21.1 377 22.87 56.60 17.50 152.3 40% 8,622.8 2,666.1

23.9 1,969 23.58 53.80 18.20 863.1 44% 46,433.3 15,707.9

26.7 2,980 24.32 51.00 18.85 1,421.1 48% 72,474.3 26,787.1

29.4 2,042 25.06 48.40 19.50 1,057.3 52% 51,173.1 20,617.3

32.2 1,025 25.86 45.60 20.10 581.3 57% 26,508.9 11,684.8

35.0 199 27.49 42.90 20.70 127.5 64% 5,469.6 2,639.2

37.8 6 27.59 40.20 21.20 4.1 69% 165.5 87.3




9

Option 3 – 4MA-22X-AWM

Ambient Temp

°C

Bin Hours

Heat Load kW

Capacity kW

Power Input kW

Operating Hours

% Run Time

Heat Removed

kW-hr

Energy Consumption

kW-hrs

12.8 2 20.90 49.10 10.05 0.9 43% 41.8 8.6

15.6 35 21.54 47.00 10.65 16.0 46% 754.0 170.9

18.3 125 22.19 44.90 11.20 61.8 49% 2,773.3 691.8

21.1 377 22.87 42.90 11.80 201.0 53% 8,622.8 2,371.8

23.9 1,969 23.58 40.80 12.35 1,138.1 58% 46,433.3 14,055.2

26.7 2,980 24.32 38.70 12.90 1,872.7 63% 72,474.3 24,158.1

29.4 2,042 25.06 36.70 13.45 1,394.4 68% 51,173.1 18,754.2

32.2 1,025 25.86 34.70 14.00 763.9 75% 26,508.9 10,695.2

35.0 199 27.49 32.70 14.50 167.3 85% 5,469.6 2,425.4

37.8 6 27.59 30.60 15.00 5.4 90% 165.5 81.1




NOTE: Option 3 is provided to give the client further selection options when confidence in the usage

and application is high and design assumptions are well defined. This option disregards setting a pre-

described run time assumption as was defined in Options 1 & 2 and it avoids adding additional safety

factors. And rather than select a model for the highest annual ambient condition of 37.8oC, it is

optimized for the majority of the seasonal ambient conditions (23.9 to 32.2oC). Therefore, it will have a

longer average annual run time as well as a longer run time during the peak ambient temperatures

(199 hours at 35oC and 6 hours at 37.8oC) but these only occur for 2.3% of the year and the

compressor’s operation remain well within design limits.

Assumptions: 1. Evaporating temperature is fixed. 2. Condensing temperature floats by 10K condenser TD. 3. Temperature bin data is based on Bangkok. 4. Energy cost is 3.94 Thai Baht / kW-hr.

Formulas Used:

𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐧𝐠 𝐇𝐨𝐮𝐫𝐬 = Heat Load

Capacity∗ Bin Hours

𝐄𝐧𝐞𝐫𝐠𝐲 𝐂𝐨𝐧𝐬𝐮𝐦𝐩𝐭𝐢𝐨𝐧 = Power Input ∗ Operating Hours

𝐀𝐧𝐧𝐮𝐚𝐥 𝐄𝐧𝐞𝐫𝐠𝐲 𝐂𝐨𝐬𝐭 = Energy Consumption ∗ Energy Cost

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IX. LIFE CYCLE COST (LCC) ANALYSIS What is Life Cycle Cost? Life Cycle Cost refers to a complete or total view of costs when evaluating equipment purchases. It is made up of the initial purchase price of the equipment plus the operating cost of the equipment and can further include costs for installation, commissioning / start-up and costs for future service and maintenance expenses. For our purposes we focus on the Initial purchase price plus equipment operational costs, which is why we provide energy usage costs for annual operation. Since most customers expect to see a payback from their equipment investments in a range of 18-24 months (1 ½ – 2 years), it is important to be able to show them that an investment in higher efficiency product is in their best interest and that they will recover the higher cost of the initial purchase in a reasonable amount of time.

Return on Investment (ROI) is another common term used to describe when the premium paid for a product is recovered (or paid back). The below formula and example is provided to help you educate your customers on the potential ROI so that when they are considering alternative equipment choices they take into account the impact of operational energy savings into their evaluation process.

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X. Project Design Contact Details

HOTLINE: 1800 209 1700 E-MAIL: [email protected] While we endeavor to keep the information up to date and correct, we make no representations or warranties of any kind, express or implied, about the completeness, accuracy, reliability, suitability with respect to the information, products, services, or related graphics contained on this for any purpose. Any reliance you place on such information is therefore strictly at your own risk .

In no event will we be liable for any loss or damage including without limitation, indirect or consequential loss or damage, or any loss or damage whatsoever arising from loss of data or profits arising out of, or in connection with, the use of any information, product, service, or process disclosed in this report.

mailto:[email protected]

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