1. 1 Importance of ESP, Gas Pressure, and Voltage for Gas-Fired Units Presented by Bruce Standerwick

2. 2 Importance of ESP, Gas Pressure, and Voltage for Gas-Fired Units Part 1: The Importance of ESP on Gas-Fired Units

3. Two Cases When Actual ESP not Equal to Design ESP Case A: Actual ESP > Design ESP Case B: Actual ESP < Design ESP 3

4. 4 4,100 cfm 2.1 ” TSP – “ W.C. CFM in 1000 ’ s Design Point

5. 5 4,100 cfm 2.1 ” TSP – “ W.C. CFM in 1000 ’ s Actual Operation: Case A 2.6 ” 3,780 cfm

6. 6 Case A: Actual ESP > Design ESP Solutions: 1.Adjust sheave if possible 2.Change sheave and possibly belts

7. 7 4,100 cfm 2.1 ” TSP – “ W.C. CFM in 1000 ’ s Actual Operation: Case A 2.6 ” 3,780 cfm 3.0 BHP 2.6 BHP

8. 8 Case A: Actual ESP >Design ESP Solutions: 1.Adjust sheave if possible 2.Change sheave and possibly belts 3.Need (1), (2) and possibly larger motor size with new motor controls -- Will motor fit?

9. 9 Motor Compartment of DFC

10. 10 Case A: Actual ESP > Design ESP Solutions: 1.Adjust sheave if possible 2.Change sheave and possibly belts 3.Need (1), (2) and possibly larger motor size with new motor controls -- Will motor fit? 4.Shaft deflection may require larger shaft and bearings

11. 11 Fan Assembly Under Construction

12. 12 Motor Compartment of DFC

13. 13 3,900 cfm TSP – “ W.C. CFM in 1000 ’ s Operating Point Design Point New Operating Point

14. 14 Fan Assembly Under Construction This dimension is smaller on a fan with a narrow housing

15. 15 Case A: Actual ESP > Design ESP Solutions: 1.Need sheave change 2.Need (1) and larger motor and controls 3.Need (1), (2) and possibly larger motor size with new motor controls -- Will motor fit? 4.Shaft deflection may require larger shaft and bearings 5.Different fan because new cfm/TSP point is not in operating range of fan in unit

16. 16 4,100 cfm 2.1 ” TSP – “ W.C. CFM in 1000 ’ s Actual Operation: Case B 4,550 cfm 1.6”

17. 17 Case B: Actual ESP < Design ESP Solutions: 1.Adjust sheave if possible 2.Change sheave and possibly belts

18. 18 When Actual ESP is Different From Design ESP Conclusions: ● It’s easier to slow a fan down than to speed it up ● It’s safer to overestimate the ESP than to underestimate it!

19. 19 Importance of ESP, Gas Pressure, and Voltage for Gas-Fired Units Part 2: The Importance of Gas Pressure for Gas-Fired Units

20. Typical Gas-Fired Pipe Train in Piping Compartment 20

21. Typical Direct Gas-Fired Pipe Train 21 Main Gas Pressure Regulator Main Gas Valve Auxiliary Gas Valve Maxitrol Modulating Gas Valve Test Port Pilot Gas Shutoff Valve Pilot Gas Pressure Regulator Pilot Gas Valve Orificed Needle Valve Pilot Gas manifold; start of factory furnished and piped components Main Gas Shutoff Valve

22. Direct Gas-Fired Burner in Burner Compartment 22

23. Direct Gas-Fired Burner at Full Fire 23

24. Typical Direct Gas-Fired Heater Rating Plate 24 Max. Gas Inlet Pressure Min. Gas Inlet Pressure

25. Two Cases Where Actual Gas Pressure not Equal to Design Gas Pressure Case A: Actual Gas Pressure > Design Gas pressure Case B: Actual Gas Pressure < Design Gas pressure 25

26. Case A: Actual Gas Pressure > Design Gas Pressure 26 Main Gas Pressure Regulator Main Gas Valve Auxiliary Gas Valve Maxitrol Modulating Gas Valve Test Port Pilot Gas Shutoff Valve Pilot Gas Pressure Regulator Pilot Gas Valve Orificed Needle Valve Pilot ¾” I.P.S. gas manifold; 5 psig actual gas pressure instead of 10-14” w.c. per design Main Gas Shutoff Valve

27. Solution for Case A:Actual Gas Pressure > Design Gas Pressure Install a High Gas Pressure Regulator 27

28. Case B: Actual Gas Pressure < Design Gas Pressure 28 Main Gas Pressure Regulator Main Gas Valve Auxiliary Gas Valve Maxitrol Modulating Gas Valve Test Port Pilot Gas Shutoff Valve Pilot Gas Pressure Regulator Pilot Gas Valve Orificed Needle Valve Pilot 2” I.P.S. manifold; 10” w.c. gas pressure instead of 1- 2 psig per design Main Gas Shutoff Valve

29. Case B: Actual Gas Pressure < Design Gas Pressure Solutions: 1.Add section to burner 2.Modify sheet metal in burner section 29

30. When Actual Gas Pressure is Different From Design Gas Pressure Conclusions: ● It’s much easier in the field to add a high gas pressure regulator than to rebuild a gas train/burner ● It’s safer to underestimate the gas pressure than to overestimate it! 30

31. 31 Importance of ESP, Gas Pressure, and Voltage for Gas-Fired Units Part 3: The Importance of Voltage on Gas-Fired Units

32. 32 Motor Compartment of DFC

33. Components That Could be Affected by a Voltage Change Disconnect Switch and/or Distribution Block Fuses and Fuse Blocks Circuit Breaker Transformers Starter and Overload Contactors Motor(s) Wiring and conduit to motor(s) Wiring diagram 33

34. Relationship Between Volts and Amps HP is proportional to volts times amps If : HP 1 = HP 2 then: (volts x amps) 1 = (volts x amps) 2 or (volts 1 /volts 2 ) = (amps 2 /amps 1 ) Amps are inversely proportional to volts at constant horsepower. 34

35. Two Cases Where Actual Voltage not Equal to Design Voltage Case A: Actual Voltage > Design Voltage Case B: Actual Voltage < Design Voltage 35

36. Case A: Actual Voltage > Design Voltage 36 Disconnect Switch and/or Distribution Blocks No change Fuses and Fuse BlocksFuses probably change; fuse blocks also if different fuse type required Circuit BreakerProbably need to change so it will trip when necessary. TransformersMust change unless original transformer is tri-voltage (208/230/460). StartersNo change Overload ContactorsProbably need to change so it will trip when necessary. Motor(s)Must change unless original motor is tri- voltage (208/230/460). Wiring and ConduitNo change

37. Case B: Actual Voltage < Design Voltage 37 Disconnect Switch and/or Distribution Blocks Non-fused disconnect may change; fused disconnect will change Fuses and Fuse BlocksFuses probably change; fuse blocks also if different fuse type required Circuit BreakerDoesn’t change because it’s downstream of transformer TransformersMust change unless original transformer is tri-voltage (208/230/460) StartersMust change Overload ContactorsMust change Motor(s)Must change unless original transformer is tri-voltage (208/230/460). Wiring and ConduitMay change depending on original amp rating

38. When Actual Voltage is Different From Design Voltage Conclusions: ● Fewer components are likely to need changing if the voltage goes up (amps go down) rather than if the voltage going down (amps go up) ● It’s safer to underestimate the voltage than to overestimate it! Wiring diagram, specification sheet and rating plate must be replaced if the voltage changes 38

39. 39 Importance of ESP, Gas Pressure, and Voltage for Gas-Fired Units The End Thank You!