Load calculation
(1) Insulation heat leak through walls, roof and floor
Conductivity of polystyrene 0.033 0.033 kcal/h mC
Temperature difference between ambient and store 35°C and -30°C = 65 degC
Thickness of polystyrene = 0.25 m
Surface area of store = 771.5 m 2
Heat leak = 771.5 x 65 × 0.033 ÷ 0.033 = 7422 kcal/h
(2) Air changes
Average of 2.7 air changes in 24 h
Store volume = 1000m 3
Heat gain (35C and 60% R.H. air) 40 kcal/m 3
Air change heat gain = 1000 × 2.7 × 40 ÷ 24 = 4500 kcal/h
(3) Lights (left on during working day)
1000W = 860 kcal/h
(4) Men working
1 man working at -30C gives off 378 kcal/h
2 men working is equivalent to 756 kcal/h
(5) Product load
5.5 kcal/kg for fish load at an average temperature of -20C
Fish loaded per day 35 000 kg
Product load = 3500 × 5.5 ÷ 24 = 8020 kcal/h
(6) Fan load
3 × 250W = 644 kcal/h
(7) Defrost heat
1 defrost of 8440 W for 1 h (recovered over 6 h) = 1 209 kcal/h
Total calculated refrigeration load (sum of Items 1 to 7) = 23411 kcal/h
Total refrigeration requirement with allowances 23411 × 24 ÷ 18 = 31215 kcal/h
If a pump is used to circulate refrigerant, the heat equivalent must be added to the capacity of the refrigeration condensing unit but not to the capacity of the room cooler.
The minimum refrigeration requirement will be when there is only an insulation heat load and the fans are in operation. In this example, the minimum load corresponds to only about 25 percent of the capacity of the installed refrigeration plant. This minimum load factor will vary considerably with the type of store and mode of operation but some account may have to be taken of this difference between the maximum and minimum refrigeration requirements. Large cold stores should be operated with a number of compressors, which can be switched on and off as required. Large compressors may be fitted with off-loading equipment which allows them to work efficiently on partial loads. The reliance on one large compressor for a large cold store could be catastrophic in the event of its failure. In the case of smaller stores it may be that only one compressor is viable. Other arrangements can be made to cater for the variation in refrigeration demand. What must not happen is that a large compressor should operate with a low load and hence operate with a very low suction pressure or stop and start too frequently. The first condition is bad for the compressor and the second for the electrical equipment.