Cold Warehouse Fault Examples — Scenario, Calculation and Next Step
Five real-world warehouse faults, each worked through step by step: what the operator sees, how the fault changes the required refrigeration duty, what it adds to annual energy use, and which calculator to run next. Every figure uses the same method as the Facility Sizing Calculator.
How each example is calculated
Pallet positions → gross volume at 3.2 m³ per pallet (tonnes × 1.33 = pallets).
Base duty = volume × 22 W/m³ chilled or 32 W/m³ frozen; design duty = base × 1.2.
Extra electricity per year = uplift kW × running hours × 365 ÷ seasonal COP (≈3.0 chilled, ≈1.8 frozen).
Limitations: indicative planning figures for briefing only. No prices are shown — multiply kWh by your own tariff in the electricity cost calculator. Equipment selection requires a verified heat-load calculation. Imperial: 1 kW = 3,412 BTU/h = 0.284 TR; 1 m³ = 35.31 ft³.
Frozen cross-dock losing temperature at the doors
A 3PL runs a 2,000-pallet frozen cross-dock at −22 °C. During evening dispatch peaks the dock doors stay open for long periods and the room drifts to −16 °C.
What the operator sees
• Frost and ice build-up around door frames
• Fog at the dock opening
• Room recovers only after the peak ends
Diagnosed fault: Warm air ingress (doors, seals)
Calculation
2,000 pallets × 3.2 = 6,400 m³ (226,014 ft³)
Base duty 204.8 kW × 1.2 = 245.8 kW design
+15% fault uplift = +36.8 kW
36.8 kW × 10 h × 365 ÷ 1.8 ≈ 74,622 kWh/yr extra
Result
Required duty 282.6 kW (964,231 BTU/h · 80.4 TR) at -22 °C, ~1,067 m² floor. The fault alone accounts for 36.8 kW and ~74,622 kWh of electricity a year.
What to do next
• Measure door open time per hour and run the door infiltration calculator before buying plant.
• Fast-roll doors, dock shelters and air curtains usually remove most of the uplift — compare them against extra duty.
Frozen fish store that cannot hold −22 °C in summer
A seafood processor holds 1,200 tonnes of frozen fish. Intake has doubled since the plant was designed, and on hot days compressors run continuously without reaching set point.
What the operator sees
• Compressors at 100% for hours
• Product core temperature rising after intake
• Alarms during afternoon peaks
Diagnosed fault: Current plant cannot hold temperature
Calculation
1,600 pallets × 3.2 = 5,120 m³ (180,811 ft³)
Base duty 163.8 kW × 1.2 = 196.6 kW design
+25% fault uplift = +49.2 kW
49.2 kW × 24 h × 365 ÷ 1.8 ≈ 239,440 kWh/yr extra
Result
Required duty 245.8 kW (838,670 BTU/h · 69.9 TR) at -22 °C, ~853 m² floor. The fault alone accounts for 49.2 kW and ~239,440 kWh of electricity a year.
What to do next
• Size replacement capacity on today's intake, not the original nameplate.
• Check compressor selection against the new duty with the compressor sizing calculator.
Chilled warehouse in a hot climate tripping on high pressure
A distribution warehouse holds 600 pallets at +2 °C. On days above 40 °C ambient the condensers cannot reject heat and the plant trips on high pressure.
What the operator sees
• High-pressure trips in the afternoon
• Condenser surrounded by hot recirculated air
• Normal operation at night
Diagnosed fault: Condenser struggles on hot days
Calculation
600 pallets × 3.2 = 1,920 m³ (67,804 ft³)
Base duty 42.2 kW × 1.2 = 50.6 kW design
+10% fault uplift = +5.2 kW
5.2 kW × 8 h × 365 ÷ 3 ≈ 5,061 kWh/yr extra
Result
Required duty 55.8 kW (190,390 BTU/h · 15.9 TR) at 2 °C, ~320 m² floor. The fault alone accounts for 5.2 kW and ~5,061 kWh of electricity a year.
What to do next
• Oversize the condenser for the design ambient and fix siting so hot air is not recirculated.
• Use the troubleshooting tool to rule out dirty coils or refrigerant charge first.
A pharma distributor stores 300 pallets at +2…+8 °C. The plant is 14 years old, excursion alarms are rising and spare parts are getting harder to source.
What the operator sees
• Rising number of temperature excursions
• Long recovery after door openings
• Repeated compressor repairs
Diagnosed fault: Plant older than 12 years
Calculation
300 pallets × 3.2 = 960 m³ (33,902 ft³)
Base duty 21.1 kW × 1.2 = 25.3 kW design
+20% fault uplift = +5.1 kW
5.1 kW × 24 h × 365 ÷ 3 ≈ 14,892 kWh/yr extra
Result
Required duty 30.4 kW (103,725 BTU/h · 8.6 TR) at 2 °C, ~160 m² floor. The fault alone accounts for 5.1 kW and ~14,892 kWh of electricity a year.
What to do next
• Plan replacement capacity with N+1 redundancy rather than another top-up.
• Include mapping, alarmed monitoring and backup power in the quote request scope.
