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GENERAL OBSERVATIONS FROM THE PHES EVALUATIONS TO DATE

June 18, 2009

AVERAGE ANNUAL PROPANE USE

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AVERAGE ANNUAL ELECTRICITY USE

THERMAL IMAGING

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ItemEstimated

costEstimated savings

Payback (years)

Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative.

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

Mi i f $ 500 100 l 2 5Mixing fans $ 500 100 gal 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

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SIDEWALL CURTAINS

SIDEWALL CURTAINS

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SOLID SIDEWALLS

END DOORSA. Thermal image of a poorly‐sealed end door B. Thermal image of a well‐sealed end door

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Thermal Images – End Wall

Cold air is leaking along the top of the door

Cold air is leaking along theceiling 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 theCold air is leaking under the frame wall at the top of a concrete foundation

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ItemEstimated

costEstimated savings

Payback (years)

Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative.

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

Mi i f $ 500 100 l 2 5Mixing fans $ 500 100 gal 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

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ATTIC INSULATION

ATTIC INSULATION

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ATTIC INSULATION

ItemEstimated

costEstimated savings

Payback (years)

Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative.

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

Mi i f $ 500 100 l 2 5Mixing fans $ 500 100 gal 2.5

Radiant tube heaters $7,000 500 gal 7.0

Cold cathode lights $1,000 11,000 kWh 0.8

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• Save 400 to 800 gal LP/house/yr

ATTIC INLETSCapture 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) inletsControlled (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

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ItemEstimated

costEstimated savings

Payback (years)

Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative.

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

Mi i f $ 500 100 l 2 5Mixing fans $ 500 100 gal 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

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INSTALLING TUNNEL DOORSA. 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

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ItemEstimated

costEstimated savings

Payback (years)

Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative.

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

Mi i f $ 500 100 l 2 5Mixing fans $ 500 100 gal 2.5

Radiant tube heaters $7,000 500 gal 7.0

Cold cathode lights $1,000 11,000 kWh 0.8

MIXING FANS

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MIXING FANS

• Most helpful in leaky houses• Save 100 gal LP/house/yr• Payback 2 to 4years

ItemEstimated

costEstimated savings

Payback (years)

Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative.

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

Mi i f $ 500 100 l 2 5Mixing fans $ 500 100 gal 2.5

Radiant tube heaters $7,000 500 gal 7.0

Cold cathode lights $1,000 11,000 kWh 0.8

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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

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ItemEstimated

costEstimated savings

Payback (years)

Overview of the improvement options recommended Note: Estimated savings will vary from farm to farm and, because of interactions, are not necessarily cumulative.

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

Mi i f $ 500 100 l 2 5Mixing fans $ 500 100 gal 2.5

Radiant tube heaters $7,000 500 gal 7.0

Cold cathode lights $1,000 11,000 kWh 0.8

RECOMMENDATIONS RELATED TO LIGHTINGChange from incandescent lights

to cold cathode or compact fluorescents

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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 LIGHTINGKeep light bulbs clean

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VENTILATION

36-inch Fans

10000

12000Approx. 9000 CFM

2000

4000

6000

8000

10000

Fan Airflo

w, CFM

Operating range

0

2000

0.00 0.05 0.10 0.15 0.20 0.25

Static Pressure

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Tunnel Fans

20 000

25,000 Farm 1, Fan 1

Farm 1, Fan 2

5,000

10,000

15,000

20,000

Air

flow

(CFM

) 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

F 3 F 5

00.00 0.10 0.20 0.30

Static Pressure (inches of water)

Farm 3, Fan 5

Farm 4, Fan 1

48-inch Fans

20 000

25,000

5 000

10,000

15,000

20,000

Air f

low

(CFM

)

Farm 3, Fan 1Farm 3, Fan 2Farm 3, Fan 3

0

5,000

0.00 0.05 0.10 0.15 0.20 0.25Static Pressure (inches of water)

Farm 3, Fan 4Farm 3, Fan 5

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50-inch Fans

20 000

25,000 Farm 1, Fan 1

Farm 1, Fan 2

Farm 1, Fan 3

5,000

10,000

15,000

20,000

Airf

low

(CFM

)

,

Farm 1, Fan 4

Farm 1, Fan 5

Farm 2, Fan 2

Farm 2, Fan 3

Farm 2, Fan 4

Farm 2, Fan 1

00.00 0.05 0.10 0.15 0.20 0.25

Static Pressure (inches of water)

50-inch Fans – with and without a cones

20 000

25,000Farm 1, Fan 1Farm 1, Fan 2

w/Cone

5,000

10,000

15,000

20,000

Air f

low

(CFM

)

0

5,000

0.00 0.05 0.10 0.15 0.20 0.25Static Pressure (inches of water)

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Comparisons with BESS data

Reduced fan performance

C k ll iCracks allow air to leak back into 

the barn 

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Worn Pulleys & Belts

Worn Pulleys & Belts

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Keeping fans clean

18 000

20,000Clean

10,000

12,000

14,000

16,000

18,000

Airf

low

(CFM

)

Dirty

4,000

6,000

8,000

0.00 0.05 0.10 0.15 0.20 0.25Static Pressure (inches of water)

Shutter maintenance

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Worn Pulleys & Belts

Average house tightness of the 14 farms participating in the PHES evaluations

(Values determined with a single tunnel fan running)

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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)

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ELECTRICAL• Services not overloaded

– Building loads below 75 ABuilding loads below 75 A• Some voltage drops more than 5% (20 – 25 V)• Voltage at fans OK (> 215)• Few overheated components

Thermal image showing overheating in a breaker due to a poor contact

Thermal image showing overheating due to a poor relay connection

ELECTRICAL

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ELECTRICAL

Overheated Motor Main Breaker & lugs – 35°F degrees air temperature

CONTROLSFan 

Thermostat

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HOW POULTRY HOUSES LOOSE HEAT

• Building Envelope (structure or shell)• Ventilation• Approx 50% each

• Don’t be over sold ! !