An Engineering Extension energy feature
An Engineering Extension energy feature
By Tom Logan
The number and size of farm shops have grown since the downturn in the farm economy in the
early '80s. When many farm equipment dealerships closed their doors, those farmers still
in business had to do more equipment repair and maintenance on their own.
Most farm operators delay major repairs and equipment maintenance until winter, when the pace is slower. Colder weather conditions call for an environment that is comfortable and well-lighted in order to perform the various tasks.
Adequate lighting an essential
Heating and lighting requirements are as varied as the number and size of the shops.
Therefore, a shop operator should choose the most efficient system that fits his needs.
Adequate lighting is essential to repair shops, particularly when dealing with small parts. Areas where power tools are used should have a higher level of illumination to ensure safety of the operator.
Three options for lighting a farm shop are incandescent, fluorescent, or metal halide lamps.
Incandescents have low light output compared to their wattage (energy consumed). Incandescent lighting is not only inefficient, but the bulbs have a short lifespan (only about 800 hours). Extended life bulbs are available, but they are even less efficient than standard incandescents.
Fluorescent strip fixtures, which come in lengths of four or eight feet, are more practical light sources. They are two and a half to three times more efficient than incandescents, and the lamps last approximately 10,000 hours. Used strip fixtures are inexpensive, costing five dollars or less.
One drawback of fluorescents rises when temperatures dip below 40 degrees. At these temperatures, the fluorescent bulb will flicker when first turned on. The blinking will continue for several minutes, depending on the temperature inside the shop.
Energy-efficient fluorescent bulbs are more prone to flickering than standard fluorescents. An alternate approach is to use incandescent bulbs to light key areas until the space has warmed.
Metal halide lamps are another type to consider if the shop is large and is used extensively. The bulbs and fixtures are more expensive initially, but are three and a half to five times more efficient than incandescent bulbs.
A negative feature of metal halides is their slow warm-up and restart times. It may take them two to four minutes to warm up and ten minutes before they can restart.
If possible, use sectional or zone lighting, especially if the shop is large. An example would be to have the workbench area on one circuit and the balance of the shop divided into two to four sections. This arrangement cuts down on wasteful lighting since individual areas are lighted only when in use.
To reduce lighting costs, shut off incandescents when not in use. Shut off fluorescent lights if unneeded for longer than five minutes. Due to the slow warm-up and restart times of metal halide lamps, do not shut them off unless the shop is unoccupied for over 45 minutes.
Because shop areas are generally dirty, clean bulbs and fixtures periodically to assure total light output.
When replacing a bulb, take time to clean the fixture and replace all the bulbs in that fixture. Doing this will both decrease labor and improve light output. A bulb with a darkened end uses just as much energy as a new bulb, but has only about 60 percent as much output. The low cost and increased output of the replacement bulb outweighs the advantage of leaving the old bulb in the fixture.
Making repair work cozy
Farm shop heat often comes from a wood stove, and the barrel stove is an old favorite.
While not very efficient, low cost often justifies the use of barrel stoves. Many farm operators use wood cut on the farmstead to burn in their shops as well as their homes. Scrap wood, shipping crates and pallets are other sources of inexpensive fuel.
Natural gas or propane unit heaters or radiant heaters are also appropriate for shop heating. Unit heaters are commonly hung around the perimeter of the work area and use built-in fans to circulate heat. Radiant heaters warm objects or surfaces, not the air. Thus, the room temperature may be cool, but the person working remains comfortable.
We know it is unsafe to let vehicles and machinery run in an enclosed space. Likewise, we must make sure that the combustion products from shop heaters are properly vented outside.
Another heating option for farm shops are waste oil heaters, which burn waste motor and hydraulic oils. This type of unit requires a large volume of waste oil and a storage tank. Unless a farm operator has many vehicles and equipment to generate waste oil, this form of heating may not be practical.
One version of the waste oil heater produces 110,000 BTU of heat and burns one gallon of oil in an hour. An operator who used a shop extensively would need approximately 400 to 500 gallons of waste oil a winter to feed such a heater.
Waste oil used for heating purposes must be clean and free of solvents and other hazardous materials. Additionally, current regulations require all waste oil burning equipment to be registered with the Kansas Department of Health and Environment.
To reduce fuel use, farmer operators should treat heated shop areas as they do their homes—taking measures to keep the cold out and the heat in.
Insulate shop walls and roof to keep the interior warmer in the winter and cooler in the summer.
Next, make sure doors and windows have tight seals to reduce air infiltration. The large shop doors necessary to allow farm equipment to enter often do not seal well. Check rubber seals and stripping to make sure they are not damaged.
Shop operators should follow these lighting and heating suggestions to keep operating expenses to a minimum and ensure their own safety and comfort.