INNOVATIVE HEATING AND COOLING FOR A BROILER CHICKEN HOUSE USING A HEAT PUMP WATER HEATER

1. INNOVATIVE HEATING AND COOLING FOR A BROILER CHICKEN HOUSE USING A HEAT PUMP WATER HEATER FRANK MAIDI SFUNDO NKOMO RAISHAN NAIDU

2. INTRODUCTION • Broiler chickens susceptible to temperature change • Primary Objective - Design and construct a hydronic heating/cooling system for a broiler house using a heat pump water heater - Replace existing methods of temperature regulation - Optimum growth conditions for broiler chickens

3. DESIGN TEAM • Frank Maidi Components inside the broiler house • Sfundo Nkomo Components outside the broiler house • Raishan Naidu Control system

4. CURRENT HEATING AND COOLING SYSTEM

5. MECH METHOD-FAN

6. NATURAL VENTILATION

7. HEATING - SPOT BROODER

8. UKULINGA SET BROILER TEMPERATURES

9. PIPE CONFIGURATIONSONE PIPE SERIES LOOP

10. TWO PIPE DIRECT RETURN HYDRONIC LOOP

11. WHICH DID WE OPT FOR? • Opted for the two direct return hydronic loop • Advantage - Uniform heating/cooling • Disadvantage – Too much pipe material

12. DESIGN TEMPERATURES • Extremities considered are 60C and 340C air temperatures • Designed temperature are 410C and 200C respectively

13. Given maximum nominal head into HPWH of 20 m Used as a guide to sizing in this loop Assumed at most 10 % of this head is lost (both frictional and minor losses) Use Lamont equation (IDM, 2008) Assumed pipe length of 5 m PIPE SIZING FOR WT – HPWH LOOP

14. PIPE SIZING • Making D subject of formula yielded D = 27.69 mm • Recommended pipe size = 50 mm • Minimise frictional losses (advantage) • Most widely used (economical) • Heat Pumps Inlet/Outlet with 50 mm openings

15. Lamont equation (IDM,2008) Continuity equation (Roberson, 1998) Minor losses equation (Roberson, 1998) TDH = 23.10 m PUMP SIZING

16. PUMP SIZING • WHP and BHP (Michael, 1981), with pump efficiency of 75 % assumed.

17. PUMP SIZING • Pump size = 0.8123 kW • Recommended pump size = 1.1 kW • Most widely used and most economical

18. TANK SIZING FOR WT – BROILER HOUSE LOOP • Given heat requirement of 1783.2 W • Thermodynamics equation used • Using normal density equation • Converted to litres per day gave 4089 l/day • Recommended 4500 l tank

19. PUMP SIZING • Using equations as previous • Pump size recommended = 1.1 kW • Same reasoning and logic

20. COOLING OPERATION CHECK Cooling load Four hours of cold spell assumed per day Total volume required = 4088 l/day Would be met by 4500 l tank chosen for heating operation

21. CONTROL SYSTEM DESIGN • Components Requiring Control - Circulation pump for the delivery/return to and from broiler house - Circulation pump for heat pump storage tank unit - Heat pump has built in PLC

22. CONTROL SYSTEM DESIGN • Control Strategy - Heat pump set temperatures  41 oC for heating  20 oC for cooling - Staging of circulation pumps by temperature controller • Control algorithms for control of circulation pumps

23. Start Temperature measured in Tank , TT Thermocouple connected to Fuji controller No No No No TT ≥ Tset + 1o ? No Tset ≤ TT < Tset + 1o ? TT < Tset ? No Fuji controller Yes Yes Yes Fuji controller relay switch function Pump on Pump off No action Heat Pump switched on HP switched on by built in thermostat Heating Mode End

24. Start Temperature measured in Tank , TT Thermocouple connected to Fuji controller No No No No TT≤ Tset - 1o ? No Tset ≥TT > Tset - 1o ? TT > Tset ? No Fuji controller Yes Yes Yes Fuji controller relay switch function Pump on Pump off No action Heat Pump switched on HP switched on by built in thermostat Cooling Mode End

25. Start Temperature measured , Tm Thermocouple connected to Fuji controller No No No No Tset ≤ Tm < Tset + 1o ? Tm < Tset ? Tm ≥ Tset + 1o ? No No Fuji controller Yes Yes Yes Fuji controller relay switch function Pump on Pump off No action End Heating Mode

26. Start Temperature measured , Tm Thermocouple connected to Fuji controller No No No No Tset ≥ Tm > Tset - 1o ? Tm > Tset ? Tm≤ Tset - 1o ? No No Fuji controller Yes Yes Yes Fuji controller relay switch function Pump on Pump off No action End Cooling Mode

27. HEADERS

28. VALVES PLACEMENT

31. PIPE CONF.. CONT

32. INTO THE COLLECTOR

33. PIPE LEAKAGES CHALLENGES FACED

34. PIPE IS BRITTLE DRILLING NEEDED A TECHNIQUE CHALLENGES FACED…CONT

35. WT – HPWH LOOP CONSTRUCTION

36. NEW BROILER HOUSE

37. RISER

38. ELONGATED RISER

39. NON-RETURN VALVE

40. SIPHON BRIDGE

41. CONTROL SYSTEM IMPLEMENTATION • Timer - To control circulation pump for heat pump storage tank unit - Heating mode  6 pm to 8 am Cooling mode  8 am to 6 pm - 10 A external relay connection to 3 A internal relay

42. CONTROL SYSTEM IMPLEMENTATION • Fuji PXR Temperature Controller - To control circulation pump for delivery/return to and from broiler house - Wiring  10 A external relay connection to 3 A internal relay  K-Type Thermocouple  Alarm System

46. SYSTEM EVALUATION • Overall System Test - Temperature measured at 6 points 1 Outdoor air temperature 2 Indoor air temperature 3 Water entering broiler house 4 Water exiting broiler house 5 Lateral distribution pipe in pen closest to entry 6 Lateral distribution pipe in pen furthest from entry

50. RECOMMENDATIONS • Two tanks for water storage • All pens should be installed with pipes • Operation cooling and heating systems must be SWITCHED OFF