1、Design Essentials for Refrigerated Storage FacilitiesThis publication was prepared under ASHRAE Research Project RP-1214 in coop-eration with TC 10.5, Refrigerated Distribution and Storage Facilites.About the AuthorsBryan R. Becker, PhD, PE, is a professor of mechanical engineering at theUniversity
2、of Missouri-Kansas City. His current research interests focus on bio-thermics, the study of thermal and transport processes in biological materials,including foods. During his more than 17 years at the University of Missouri, Dr.Becker has conducted, as principal investigator or co-investigator, 35
3、researchprojects totaling in excess of $2.2M. Dr. Becker has authored 153 journal arti-cles, chapters in books, presentations, and research reports. He is a Fellow ofboth the American Society of Heating, Refrigerating and Air-ConditioningEngineers (ASHRAE) and the American Society of Mechanical Engi
4、neers(ASME).Brian A. Fricke, PhD, is an assistant professor in mechanical engineeringat the University of Missouri-Kansas City. His current research interests focuson biothermics, the study of thermal and transport processes in biological mate-rials, including foods. Dr. Fricke has authored 95 journ
5、al articles, chapters inbooks, presentations, and research reports.RP-1214Design Essentials for Refrigerated Storage FacilitiesBryan R. BeckerBrian A. FrickeAmerican Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc.ISBN 1-931862-74-5Library of Congress Control Number: 2005921112
6、2005 American Society of Heating, Refrigeratingand Air-Conditioning Engineers, Inc.1791 Tullie Circle, N.E.Atlanta, GA 30329www.ashrae.orgAll rights reserved.Printed in the United States of AmericaCover design by Tracy Becker.ASHRAE has compiled this publication with care, but ASHRAE has not investi
7、gated, andASHRAE expressly disclaims any duty to investigate, any product, service, process, procedure,design, or the like that may be described herein. The appearance of any technical data or edito-rial material in this publication does not constitute endorsement, warranty, or guaranty byASHRAE of
8、any product, service, process, procedure, design, or the like. ASHRAE does notwarrant that the information in the publication is free of errors, and ASHRAE does not neces-sarily agree with any statement or opinion in this publication. The entire risk of the use of anyinformation in this publication
9、is assumed by the user.No part of this book may be reproduced without permission in writing from ASHRAE, exceptby a reviewer who may quote brief passages or reproduce illustrations in a review with appro-priate credit; nor may any part of this book be reproduced, stored in a retrieval system, or tra
10、ns-mitted in any way or by any meanselectronic, photocopying, recording, or otherwithoutpermission in writing from ASHRAE.ASHRAE STAFFSPECIAL PUBLICATIONSMildred GeshwilerEditorErin HowardAssociate EditorChristina HelmsAssociate EditorMichshell PhillipsSecretaryPUBLISHING SERVICESDavid SoltisManager
11、Jayne JacksonProduction AssistantPUBLISHERW. Stephen ComstockvContentsPreface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiAcknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiChapter 1 Introduction to Refrigerated St
12、orage Facility Design1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Basic Design Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Chapter 2 Design Fundamentals2.1 Preliminary Considerations . . . . . . . . . . . . . . . . . . . . .
13、. . . . . 52.2 Internal Layout for a Single-Story Configuration . . . . . . . . 102.3 Safety Standards in a Refrigerated Storage Facility. . . . . . . 21Chapter 3 Design Details3.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393.2 Structures . . . . . . . . .
14、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413.3 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453.4 Vapor Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543.5 Roofs . . . . . . . . . . . . . . . . . . . . .
15、 . . . . . . . . . . . . . . . . . . . . . 603.6 Walls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653.7 Floors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Contentsvi3.8 Doors . . . . . . . . . . . . . . . . . . . . .
16、 . . . . . . . . . . . . . . . . . . . . . 753.9 Shipping and Receiving Docks . . . . . . . . . . . . . . . . . . . . . . 843.10 Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Chapter 4 Refrigeration System Design4.1 Heat Load Calculations . . . . . . . .
17、. . . . . . . . . . . . . . . . . . . . 914.2 Refrigeration Systems for Cold Storages. . . . . . . . . . . . . . 1174.3 Refrigeration System Components . . . . . . . . . . . . . . . . . . 1224.4 Choice of Refrigerants. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1394.5 Controls and Instrum
18、entation. . . . . . . . . . . . . . . . . . . . . . . 1434.6 Blast Coolers and Freezers . . . . . . . . . . . . . . . . . . . . . . . . 1504.7 Cryogenics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Chapter 5 Refrigerated Storage Facility Management5.1 Commissioning a
19、nd Training. . . . . . . . . . . . . . . . . . . . . . . 1555.2 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1585.3 Life-Cycle Costing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1585.4 Energy Strategies and Alternatives . . . . . . . . . . . . . . . . .
20、. 1595.5 Insurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Index . . . .
21、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169viiPrefaceThe design of refrigerated storage facilities requires knowledge and under-standing of a wide range of issues. Design engineers in the food refrigeration indus-try are in need of a comprehensive design gui
22、de that deals with these various issuesas well as the current, established trends in refrigerated facility design.Currently, there is ample information regarding the design of refrigerated stor-age facilities. The pertinent information, however, is scattered throughout variouspublications by organiz
23、ations such as the International Association of RefrigeratedWarehousemen (IARW), the International Institute of Ammonia Refrigeration(IIAR), the International Institute of Refrigeration (IIR), the Occupational Safetyand Health Administration (OSHA), the United States Department of Agriculture(USDA),
24、 the Food and Drug Administration (FDA), American Society of Heating,Refrigerating and Air-Conditioning Engineers (ASHRAE), and others. Thus, it isdifficult to access and make efficient use of the information needed for the designof refrigerated storage facilities.Chapter 13 of the 2002 ASHRAE Handb
25、ookRefrigeration, entitled “Refrig-erated Facility Design,” covers issues related to the design of refrigerated storagefacilities for perishable foods. Topics covered include facility size, location selec-tion, and load calculation considerations including brief discussions on insulation,vapor barri
26、ers, and infiltration through doors. Also included is a section on refrig-eration equipment selection with details on configuration and placement of fan-coilunits. Other topics briefly covered include controlled atmosphere storage, auto-mated storage and retrieval systems, and blast freezers. Howeve
27、r, the informationin chapter 13 is presented as an overview and is not intended as a design guide,although it may be useful as a check-list for the design engineer. Additional guid-Prefaceviiiance is needed in the areas of load calculations, system requirements and perfor-mance, as well as control a
28、nd operation. ASHRAE Research Project 1214 was initiated to develop a design guide thatwill be used by designers of refrigerated storage facilities for perishable food items.The design guide covers those areas where ASHRAE is uniquely qualified. Theguide does not include the architectural, civil, el
29、ectrical, mechanical, and structuraldesign details required to prepare the plans and specifications for the constructionof facilities. That is the function of qualified architectural/engineering and design-build firms. Furthermore, this guide does not provide the construction, selection,placement, p
30、iping, and installation details required to prepare the final design andspecifications of a complete refrigeration system. That is the function of qualifiedrefrigeration engineers/contractors and design-build firms.A brief introduction to refrigerated storage facilities and the focus of the designgu
31、ide are presented in chapter 1. In chapter 2, specifications for the storage facilityare discussed, including the storage conditions, storage capacity, storage arrange-ments, facility configuration and layout, and site planning. In addition, informationis given regarding specialized refrigerated fac
32、ilities, including controlled atmo-sphere storage, modified atmosphere packaging, and meat thawing and temperingrooms. Chapter 2 also contains information regarding building codes, fire codes,and food safety codes as they pertain to the design of refrigerated storage facilities.Chapter 3 provides ba
33、sic information on the design of the refrigerated storage facil-ity structure, including the design of the support structure, walls, roofs, floors,doors, and docks. Particular attention is given to the design of insulation and vaporretarders. Refrigeration system design is discussed in detail in cha
34、pter 4, includingload calculations, system types and components, refrigerants, controls and instru-mentation, blast coolers and freezers, and cryogenics. The components of the heatload, including transmission heat load, solar heat load, infiltration, product load,internal load, and defrost heat load
35、, are discussed and methods for determiningthese heat loads are presented. Details of refrigeration system design and systemcomponents are given, including discussions about evaporators, compressors, andcondensers. Finally, in chapter 5, a discussion of refrigerated storage facility man-agement is g
36、iven. Topics include commissioning and training, inspection and main-tenance, life-cycle costing, and energy strategies and alternatives.The references and bibliography at the end of the book contain many relevantand applicable references, which provide an excellent source for additional infor-matio
37、n regarding related subject matter.During the preparation of this design guide, deficiencies in the state of the artwere noted in the areas of dock dehumidification, optimal evaporator placement,and simulation of airflow patterns within refrigerated storage facilities. AdditionalDesign Essentials fo
38、r Refrigerated Storage Facilitiesixresearch projects in these areas would lead to the design of more efficient refrig-erated storage facilities.This design guide is viewed as a living document that should be updated peri-odically when significant engineering developments or research warrant it. Fore
39、xample, research is needed regarding refrigerated docks, evaporator placement,and airflow within refrigerated storage facilities.xiAcknowledgmentsThe authors would like to recognize the following students for their originalcontributions to the text of this book: Prithipal S. Dhaliwal, William J.S. D
40、olla,Phani S.K. Mylavarapu, and Timothy R. Sady. The authors are also indebted toGordon E. Follette for his extensive editing and rewriting of the text. In addition,the editorial comments of Kent Anderson, Don Cleland, Richard Connell, DanielDettmers, Jon Edmonds, Ed Fuhrmann, William Humm, Todd Jek
41、el, Garry Peak-man, Brian Simkins, George Smith, and Brian Webb were greatly appreciated.This book is based upon research project RP-1214 funded by the AmericanSociety of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE).The authors wish to acknowledge the support of ASHRAE Technical Co
42、mmittee10.5, Refrigerated Distribution and Storage Facilities.1Chapter 1Introduction to Refrigerated StorageFacility Design1.1 BACKGROUNDFood preservation, in which perishable foodstuffs are stored in controlledenvironments to maximize their shelf life, encompasses more than two-thirds ofrefrigerate
43、d storage. Although “the colder, the better” is widely accepted as amethod for retarding microbial, physiological, and chemical changes in food,each commodity requires unique temperature and humidity conditions for max-imum shelf life and product quality retention, for which accurate technical dataa
44、s well as efficient design methods, operation, and maintenance are needed.Annual consumption of frozen food worldwide amounts to more than 30 mil-lion tons (27 million metric tons) per year, with a growth rate of over 50% forthe past decade. The amount of chilled food is about 10 to 12 times greater
45、 thanthe supply of frozen products, making a total volume of refrigerated food ofsome 350 million tons (318 million metric tons) per year (Garone and Clasbey2000). As this trend continues and spreads into developing countries, there willbe a great demand for modern refrigerated warehousing design te
46、chniques aswell as efficient refrigeration system design practices.A refrigerated storage facility is any building or section of a building thatachieves controlled storage conditions using thermal insulation and refrigerationequipment. Such facilities can usually be classified into two groups: (1) c
47、oolerswith commodities stored at temperatures usually above 32F (0C) and,(2) freezers or low-temperature rooms operating below 32F (0C). They canalso be classified into small, intermediate, and large storage rooms, ranging fromsmall rooms utilizing prepackaged refrigerator units to mammoth cold stor
48、agecooler/freezer warehouses. Currently, footprints of 300,000 ft2(28,000 m2) andcapacities of millions of cubic feet (tens of thousands of cubic meters) and largerIntroduction to Refrigerated Storage Facility Design2are not uncommon. In most cases, the large and moderate sized cold storagewarehouse
49、s are designed by either a specialist engineer or a design contractor,for whom this design guide is intended to be a quick reference.1.2 BASIC DESIGN SEQUENCEProcedures for refrigerated storage facility design are complex in nature dueto the considerable variety of tasks involved, including planning, financing, siteselection, architectural and structural design, refrigeration system design, equip-ment selection and installation, construction, inspection, and maintenance. Inaddition, considerations of building and safety codes, efficient operation, andcost-effectiveness make the design
