When Mike McClendon, then of Boone and Boone Sales Co., Tulsa, Okla., made a presentation to a large chicken hatchery, he was informed that there were a couple of old chillers that needed replacement. He looked into the situation and identified several problems in need of addressing.
The hatchery was having major problems with its chilling system. The existing unit was undersized by five to six tons, and the unit condenser coil required cleaning two times each week due to chicken dander and tree pollen. In addition, the unit would not run in ambient temperatures over 110°F (38°C) without a sprinkler system added to the condenser coil. The result was added cost as well as scale buildup on the condenser, which further reduced its ability to reject heat.
The unit’s evaporator barrel was fouled to a point that heat transfer had been greatly reduced, further restricting the capacity the system could deliver. In addition, officials at the hatchery wanted to move pumps and a tank from inside the building to an outside location in order to use the additional space it would provide.
McClendon worked with Technical Systems Inc. (TSI), a division of RAE Corp., Pryor, Okla., to propose a new air-cooled, packaged chiller with an integrated dual-pump package and storage tank. The new unit contained a 10 FPI condenser coil with washdown access ports at each fan bay, TEAO fan motors and seal-tight conduit. This permitted washing of the coil from the top down and made cleaning easy and quick compared to previous efforts.
The packaged chiller also contained an oversized condenser coil designed to run at 105°F (40°C) ambient. The benefits of this chiller design were felt almost immediately as the hatchery experienced 21 straight days of temperatures from 107 to 110°F (41 to 43°C) in the days after installation. The unit never failed to keep the supply water temperature at 50°F (10°C) throughout this period.
The unit integrated a pump vestibule with the chiller and moved the chilled water (load) and chiller recirculation pumps along with an 800-gal tank outside with the chiller.
During the project development, other concerns, such as voltage issues, surfaced that TSI was able to address. A phase-fail monitor was added to the unit to protect the investment from early motor/compressor failure due to “dirty power.” Also included was a three-valve bypass around the replaceable core liquid line dryer to help facilitate maintenance on dryer cores.