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Gas Main Installation

Gas Main Installation

We have been designing and installing gas main at PW Maintenance for a number of years using lots of different materials such as copper, stainless steel, iron and also fully welded solutions.

When an enquiry for a gas main lands we generally need to consider various factors before we can even begin to quote.

  • Fuel type – Natural Gas or LPG
  • How long will the gas main be
  • What load in Kw will be drawing from the main
  • Suitability of existing gas meter
  • Gas main run including direction changes
  • Connection types – Flanges, Screwed
  • Pressures involved within the final main

Late last year we were contracted to design and install a gas main to provide gas to a large CHP (Combined Heat And Power) Plant provided by Clarke Energy and two Gas Fired thermal oil boilers supplied by Wanson Babcock. The total combined gas use already equalled the amount of gas available on site, and all of that was being used. It quickly became apparent that a gas main upgrade was needed.

The CHP Engine alone required 645 m3/h at full operation and each oil boiler needed 325 m3/h, giving a new additional load of 1,295 m3/h of Natural Gas. Our first stop is normally to the Network where an application for additional gas is completed, then the wait begins. Almost immediately we get an independent energy company involved, Energy Assets who are able to lease with the Network on our behalf to try and speed up the paperwork and design side of things. Gas main upgrades wont happen overnight and often not in the same year.

Our worst nightmare came back for this job, where the Network wanted to run a feasibility study for 12 months, to see how this additional load might affect the existing network. A feasibility study is normally bad news, but that’s where Energy Assets comes in handy. ¬†Straight over to them and get them to work on the network. On this particular job we needed 650 m of IP (Intermediate Pressure) main installing, straight down the main road to the very end and into the IP main at the end of the estate. The final plan was to effectively parallel up the existing main to provide twice the amount of capacity to the single stream station on site. The LP network on site could already handle the demand. Energy Assets handled the network for us and designed and supplied the new gas meter. They also arranged the parallel IP main installation and the connections to the LP main on site.

We followed the proposed CAD drawings of the new plant and effectively designed the pipe run first, together with the necessary steelworks to hold the gas main in place.
The main was designed by simply working out the correct pipe size for the volume of gas then assessing pressure drop to be within 1 mBar for this particular job.

Energy Assets provided us a new gas meter with a 12″ take off and this was located in a purpose built meter room on site. The meter was craned in in sections and assembled and fixed in place. We added a 12″ cut off valve wired to the building fire alarm system, straight on the end of the meter.

The pipe continued through the wall in 12″ to a Tee, where a valve was installed and further 12″ pipework to support the CHP. You will see on the drawing how the pipe size reduces immediately on the connection flange at the CHP engine. During calculations it worked out better to increase the size of this small section of main to effectively reduce the pressure drop to almost nothing, giving a little more give for the other run to the Gas thermal oil boilers.

The feed around to the Gas thermal oil boilers worked out in 8″ with a half mBar drop. This was installed from another isolation valve on the 12″ Tee and installed around to a gas booster supplied by Wanson Babcock. Again the 8″ pipe was reduced to 4″ before connecting to the booster. Secondary pipe was completed in 4″ from the booster to each boiler.

The materials arrived on site and our coded welders fabricated most of the sections before they were installed using a crane, then bolted together when in place. Some final welds had to be completed in location with large fittings being installed using a Genie Super lift to hold them in position whilst welded. Our Gas Engineers then carried out the required Strength Test and Tightness Test before purging the main over to Gas using the appropriate equipment and handing over a bunch of certificates.

An operative then cleaned and painted the main in a coating of protective oxide then a standard coat of yellow ochre paint and finally some gas tape afterwards.

When the appliances were commissioned we had a much lower pressure drop than calculated and all the appliances functioned perfectly.

If you are looking to have a new gas main installed or need modifications carried out to an existing gas main, then please contact us to help you with your project.
We will consider any project using most material types from a small copper main all the way to a fully welded solution!

Meter Sections Being Craned InAssembled Gas MeterCHP Gas MainCHP ConnectionBooster Pipe WorkGas Meter Room Under Construction

Digital Destratification – Wi-Fi Solution

Introducing Digital Destratification

Some time ago we began to investigate a remote control system to control a destratification fan.

Its a well known fact that to adjust the temperature a destrat fan activates at, you need to access the unit. In most cases they are installed high in the roof of the building. This means you probably need a scissor lift or boom lift at worst case. Either way it costs you money.

So many sites simply leave the fans turned off because they are not happy with how they work, missing out on massive fuel savings and not getting the full benefit of destratification.

Back in 2015 we began designing a system to control the fans remotely. We made a couple of prototype systems that worked really well, the first using Infra Red and the second using radio technology. The fundamentals were great, but the remote control worked out far to expensive, especially if you only owned one fan.

Remember when the first smart lighting for warehouses was released? The T5 technology was fantastic, lux sensors and motion detection and all fully programmable from the ground level. Then you came to buy a remote control and the cost was close to a thousand pounds. For our fan controller to be commercially viable, the remote needed to be really cheap or even free.

Back in 2016 we came across a fantastic device, a Wi-Fi SoC (system on a chip) integrated with a Tensilica Xtensa LX106 Core processor. We ordered a few demo models and the power and abilities of the device were absolutely amazing.

The capabilities we now had in a footprint the size of a cigarette lighter took us straight back to the drawing board. Not only could we control temperature but we could deliver the entire control procedure straight over Wi-Fi to any compatible device and web browser with ease.

Our final Beta version worked straight from the box, did what it said on the tin and to be frank, it turned heads for those few people lucky enough to see the initial work and testing going on.

We are proud to announce that the first batch of controllers is currently under way, and we will be able to offer this controller on our own brand of destratification fans within the next few weeks. At the same time they will be commercially available for other manufacturers or for retro fit applications.

Installation is simple, attach the control unit to the side of the fan and connect a flex from the PCB to the fan motor. A simple set of screw terminals provides the mains power to the fan.

The mains feed to the controller is similar, drop a flex to the fan and terminate at the terminals on board. To comply with wiring regulations you should install a spur in the roof but you should be doing that now anyway.

We supply a digital sensor with each unit that simply cable ties to the wire guard on the back end of the fan and again terminates to a set of terminals on the PCB. The sensor contains a single chip sensing element that responds to temperature changes much faster than a thermostat or thermocouple. Its simply digital all the way.

We sample the sensor thousands of times a second and take an average reading over a period of time for a much more stabilised temperature reading. We added a time delay to prevent the fan cycling on and off quickly.

When power is applied to the fan, you can find it on your smart phone under Wi-Fi settings. Log in with the supplied password then open a web browser and you have complete control.

You are then able to select four operating modes and given temperature information from the fan.

Fan Off
Turns the fan off, it stays off.

Fan On
Turns the fan on, it stays on continuously.

Automatic
With the click of a button, you set the required temperature for the fan to activate and it runs like a normal destratification fan. Simple to adjust the operating temperature within seconds. No need to get to the fan.

Frost Mode
When entering frost mode, select the operating temperature. When the temperature drops below the selected temperature the fan will come on. Even during the winter the heat will stay at the top of the building. Using frost mode can help reduce freezing issues within your building when its vacant during holidays for example. Frost mode is normally only found on expensive BMS controlled systems.

The user interface is so simple, its all controlled at the click of a button without cumbersome text entry boxes or drop down menus.

For further information please contact us and we will be happy to assist.

 

Philip Hamer
Director.

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February Update

With the 2015 to 2016 season looking to draw to a close we are happy to report another very successful year for heating sales, installations and breakdowns. Our thanks go out to all our customers who have supported us again, new and old for another great year.

With such mild temperatures business has been difficult at times. We have again noticed a trend directly comparing how busy the office phones are to outside temperatures with medium sales during the warmer days and heavy phone traffic during the cold mornings.

We are extremely pleased overall with our sales for the period and are happy to report despite the mild weather we have increased our turnover and sold much more equipment in comparison to the prior year. Warmairheaters.com has enjoyed record sales and on the back of the supply chain we have enjoyed installing much of the equipment supplied to customers.

Our service and breakdown engineers have also been very busy keeping existing equipment running and we have grown our client base to surprising new levels this winter yet again.

Orders are still being received for heating equipment nationwide with some large interesting projects in the pipeline which we are starting to close now ready for installation.

In a couple of weeks time we start one of the largest installation projects we have ever taken on board, a 4 Mega Watt Natural Gas fired power plant and various industrial coatings lines. We have nearly 870M of stainless steel pipe to supply and install over the summer period!

We have supplied primarily Powrmatic heaters again for a third year and are happy to report that equipment failure is at a record low, mainly issues with sticking fan and limit thermostats that Powrmatic are solving with the manufacturer. Powrmatic have attended any sites very promptly and carried out warranty repair works quickly. We truly believe that the figures show just how reliable Powrmatic equipment is and we look forward to another year selling and installing Powrmatic kit. Powrmatic are 100% behind us just as we are supporting them with increased sales. We cant wait to be told our final order values and are hoping to reach the top three suppliers for this year increasing us from the top five last year, still a record achievement we are proud to have!

With the Summer fast approaching, we are starting to look at service and maintenance works and to pick up those businesses which upgrade or change heating during the summer rather than waiting for the winter to approach before making a decision.

One has to remember we are still only in March and often in the UK climate, we can experience cold mornings and even snow and ice through until April. We have therefore decided to keep our winter Powrmatic pricing structure in place until at least April. We hope our reduced costs will inspire those still looking at exchanging or installing new equipment to take the plunge and take advantage of the cost saving.

If we can be of any assistance to you in future projects, small or large then please contact us we are sure we will be able to help you out and in the mean time, keep an eye on our social network for updates and offers through the year.

Philip Hamer

Director.