Powrmatic TE Air Rotation Heater
Powrmatic TE Heater Installation. We were asked to quote to heat a large warehouse a few months back at Magna Park, Lutterworth. The building was on a short term lease of 18 months, while the clients new property was being built for them on the same estate. The client requested frost protection only and asked us to offer some ideas. They asked us to quote for heating the warehouse with Powrmatic NVx Gas Fired Unit Heaters and Destratification Fans. Ideally the final solution would be movable to the new premises when complete.
We calculated a heat load of around 550 kW for the building but due to the size, twelve heaters would have been required. With a building size of 150M x 120M, it would have taken a lot of Gas Pipework and Destratification Fans to effectively service the area.
We submitted a price but also decided to introduce them to the Powrmatic TE, Air Rotation Heater.
The Powrmatic TE warehouse heater range of gas and oil-fired air rotation heaters are specifically designed for the efficient heating of large areas and are especially suitable for open plan warehousing and manufacturing facilities.
Powrmatic TE air rotation units utilise high efficiency axial fans to move large volumes of air. These heaters achieve a uniformity in the distribution of heated air that cannot be matched by conventional units that treat low volumes of air at high temperature.
The principle of air rotation is to move large volumes of air at low velocity and controlled temperature. Cooler low level air is constantly drawn through the heater with a high level discharge effectively de-stratifying the building and, in turn, lowering the temperature gradient within the heated area. For the majority of applications a single heater can provide uniform warmth wall to wall and floor to ceiling without the need for costly duct work. Flexibility is a key benefit of Powrmatic air rotation systems.
The cost of the Powrmatic TE heater is higher than the equivalent in unit heaters, but once you consider the amount of gas main, destratification fans and labour, overall the final solution is far more cost effective. The problem with unit heaters, warehouses and racking is when the building is moved around. Heaters become obstructed by racking and stock and eventually the scheme will fail as airflow is reduced. This is one solution the Powrmatic TE overcomes. Heat is evenly distributed even with racking and stock because of the inherent design of the unit.
Powrmatic normally carry out the design calculations to confirm heat input but more importantly, to specify the fan duty inside the units. Every building is different and will require a different air volume to be effective. Because of the size of this warehouse, Powrmatic confirmed we would also require a destratification fan at the opposite side of the building.
The customer received our quotation and after taking some time to investigate the Powrmatic TE heater range, they placed an order with us.
Following a meeting on site, we were informed that the floor finish inside the building must be protected and we could make no tyre marks or cause damage to the floor in any way. We went back to the office to think over this and come up with a solution on how to proceed.
Gas Main Installation And Modifications
We had already calculated that the building has a sufficient gas supply to add the new unit. As always, we contacted the gas transported and informed them that an additional load of 550 kW was planned for the service pipe. We were told that sufficient gas was available and we could proceed. We always check that capacity is available during quoting stage, to avoid embarrassment later on should a restriction be in force.
Whilst the Powrmatic TE heater was being manufactured down at Powrmatic, we began to install the gas pipework to the building.
We had a small section of gas pipe work welded up in our fabrication shop which was taken to site alongside the materials required to install a new gas main.
Our engineers attended site and first carried out some basic gas safety tests. We made sure the existing gas main had no leaks, that the isolation valves all worked and the gas solenoid cut off worked. They then purged the whole main to Nitrogen so the header could be worked on safely.
They carefully removed the section from the header and installed out new fabricated branch. They fitted a Gas approved butterfly valve, press flange and immediately spaded off the new leg. A test was carried out to prove the modifications were safe then the site was purged back to gas. The existing plant was then recommissioned, tested and put back into service.
From our previous calculations, we had to install a gas main of at least DN100 (4″) to minimise pressure drop over the whole system. Accurately calculating and designing gas mains is very important as it can cause problems with gas flow and pressures that can make appliances dangerous.
We chose to use large Scissor Lifts with non marking tyres, fitted with internal pipe racks supplied by the hire company. Classed as a construction site, working practises were strictly monitored to ensure the Health and Safety of everyone working on site.
We chose to use a stainless steel pipe system supplied by Geberit. Brackets were fitted to the roof and 136m of pipework was safely installed in two days by four operatives. We then carried out a Strength Test to IGE/UP/1 to confirm our new installation was safe.
Powrmatic TE Heater Delivery And Assembly
We were scheduled to receive the Heater and Destratification Fan which was due to arrive to the site on two separate articulated vehicles. We just had to think how to get the equipment inside without taking these lorries in or marking the floor. Our preferred lifting contractor David Stanley also provided a large Hi Ab crane, capable of the lift. David Stanley have done a lot of heavy lifts for us in the past and have very experienced drivers.
The Powrmatic TE heaters are delivered on trailers with a special sliding roof, which enables all the modules to be lifted vertically off the trailer by crane.
We unloaded all the parts of the Powrmatic TE heaters from the delivery vehicles, to an assigned area of the car park outside. After identifying the sections, the Destratification fan modules was loaded onto the Hi Ab vehicle, ready to drive inside the building.
We had arranged to be delivered to site some large rolls of heavy duty plastic sheeting, which we could lay over the concrete floor so the Hi Ab made to tyre marks when driven around inside the building. We had to comply with this request as there were severe penalties for damaging the floor. With careful driving from Vince, we successfully got the Hi Ab inside the building without damaging the floor or making any marks.
Our engineers then assembled the destratification fan first. Each module is craned into position on top of the last and secured with special plates to lock the unit into place. Air seals are applied to each module during assembly and then further modules are stacked on top of the last, until the unit is built.
Once all the sections were assembled, post brackets were fully locked up and the assembly was complete. The overall height of the Destratification Fan module was 6.5 m. Its a large unit as you can appreciate from the photograph.
Next we had to reverse the Hi Ab crane back out of the building, move the plastic sheet around and form a new runway to the location of where the Powrmatic TE heater would be built up. Modules were loaded onto the Hi Ab and it was again expertly driven back into the building by Vince.
Final Gas Connections, Flue, Condensate And Power
Final gas connections were made by our engineers and we installed an inline Gas Meter, so the consumption could be monitored by the BMS system in the building. After carrying out a final test of the gas supply, it was purged safely to Gas using one of our burn off rigs.
The SFL Twin wall flue system was supplied by Powrmatic which was fitted to the heater, with a long vertical stack to the outside of the building. Various flue support sections were added to ensure the flue stack was well supported. As the roof already had a man safe system fitted (roof safety working lines) two of our operatives made safe access from the roof hatch on the plant deck to install the flue. Our roof workers are trained line workers and Gotcha trained and can carry out an emergency recovery of an operative, should an accident happen that requires rapid recovery. We own our own safety equipment for easy roof working under these conditions.
Condensate pipe work was installed to flow through a neutraliser (to pH adjust the condense water) which then discharged into a high volume boiler condensate pump. The pump then discharges a build up of condense through simple 1/4″ braided hose to a suitable disposal point. Traps were formed into the condensate pipe work to ensure no passing of combustion gases during operation. Because of the high volume of air that passed over the Powrmatic TE heater’s heat exchanger, a large amount of condense is created.
Site electricians provided us with a rotary isolator for each of the units and a separate switch fused spur to power the condense pump. Our electricians installed the final connections and carried out safety tests to the electrical circuits.
Once the equipment was ready to be commissioned, a full set of safety inspections was carried out and then the unit was commissioned by Martin and Trent, two of our commercial engineers. A full flue gas analysis was carried out and the burner fully adjusted as required.
The internal Powrmatic MC200 controller was fully programmed for Frost Mode Only, and a separate Heatmiser IQ+ with remote sensor was programmed on the Destratification fan.
The heater and fan were demonstrated as working and signed off by the visiting site hand over engineer. We will re attend once the customer has moved in and provide half a day free training on how to best use the equipment.
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