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HomeMy WebLinkAboutChevak Waste Heat Correspondence & Memo 1991Alaska Village Electric Cooperative, Inc. 4831 Eagle Street Anch , Alaska 9950897] worse RECEIVED (907) 561-2388 FAX JUN 2 € 1992 June 24, 1992.0 ey auinory, ity Mr. Gary Smith Rural Projects Manager Alaska Energy Authority P.O. Box 190869 Anchorage, AK 99519-0869 Subject: Chevak Waste Heat Utilization Dear Gary: Alaska Village Electric Cooperative has just recently completed a project to connect the two remaining diesel electric sets at Chevak to a remote radiator. So currently all three diesel electric sets are connected to one of two different remote radiators. This should simplify the installation of a waste heat utilization system especially for the school which is located in relatively close proximity to the AVEC power plant. Sincerely, Dt 6. Lb Mark E. Teitzel Assistant General Manager MET/sm letters.101 Alaska Village Electric Cooperative, Inc. og «MAR 10 N4:33 4831 Eagle Street 7 cr Anchorage, Alaska 99503-7497 (907) 561-1818 March 9, 1989 Mr. Peter N. Hansen, P.E. Project Manager Alaska Power Authority P.O. Box 190869 Anchorage, Alaska 99517-0869 RE: Response to Letter of February 27, 1989 Received March 1, 1989, Regarding Chevak Waste Heat Design Dear Mr. Hansen: In respect to your comments in the first paragraph of your letter, I am enclosing a copy of a letter of January 6, 1983, from Joseph Schneider to Mr. Don Bassler. In that letter Mr. Schneider comments on the design completed by Raj Bhargava Associates. As you remember, Raj Bhargava Associates was hired by the APA to complete the design of the Rural Waste Heat Capture & District Heating project for a number of villages. It is clear that Raj Bhargava Associates selected and specified many items of the design including the "series/2-pass" radiator configuration and the use of a step controller. It is assumed that these selections were based upon their "professional" engineering experience. It is also clear that they rejected a number of the recommendations made by Mr. Schneider. On your comments regarding reliability, it is agreed that one method of increasing reliability is to simplify the system. Unfortunately, it is doubtful that a simple system can be designed that will function effectively with the multitude of varying conditions that must be contended with but we are certainly interested in trying to attain such a design. Your comments regarding operations personnel involvement and maintenance personnel involvement is accepted. Your proposal to start over on the Chevak design is heartily supported. We agree that elevating the radiators has the advantage of reducing the impact of wind blown surface snow but also introduces the problems of initial installation difficulty, future maintenance difficulty, liquid level monitoring and filling difficulty among others. If these problems can be overcome then this will be a wise design decision. Mr. Peter N. Hansen, P. March 9, 1989 Page 2 It is agreed that there are two choices regarding snow. One is to accept the condition that the actual radiators will be operating in a snow environment. The other is to design a system that will prevent snow from entering the operating regime of the radiator but without decreasing the cooling efficiency of the radiator. Comments regarding the specific points of your proposal: 1. The peak 15 minute average demand recorded at Chevak is currently 313 KW. It is generally assumed that the 5 second peak demand that the generator set had to meet is 10% greater than this or 344 kw. The Caterpillar 3412 1200 RPM engine currently being installed in the module carries a rating of 530 HP which equates to 364 KW. We are forecasting a 2.5% growth rate in electrical demand at Chevak. Under this forecast, the peak loads at Chevak will be exceeding the capacity of the Caterpillar 3412 1200 RPM in approximately three years. Our current standard is to install a Cummins KTA 38 when the load exceeds the capacity of the 3412. A Cummins KTA 38 will not fit very well inside a Hussman module so one procedure is to install a larger module in place of the existing module and to relocate the existing module to a location that currently does not have a module. This is in accordance with our goal to have at least one module at all locations. Therefore, we question the proposal to install the radiators on top of the module if it might be relocated in three years. We have no plans to relocate the butler building but the sidewalls and roof may require reinforcement to support the additional weight. aa Initially the use of multiple circular core radiators appear to be an excellent choice. These units would appear to be less prone to icing problems and snow packing. The individual small fan motors will have a reduced in rush on the system and should reduce cycling. We would like to see data on the heat rejection of the D353 and the heat rejection capability of the selected radiators as a function of ambient temperature. 3s Same comment as #1 except that there is not adequate room inside the Butler building for the heat exchanger. 4. The installation of three radiators for just the Butler building units with adequate cooling capacity provided by just two of the radiators will meet or exceed the current reliability level where each unit has its own separate radiator. This would be acceptable. ow We are very hesitant to rely on the secondary loop of the main heat exchanger for obtaining heat for the interior of the power plant. With the substantially reduced pressure drop of the proposed radiators and the reduced length of piping as a result of keeping two completely independent systems, it is not clear why the two existing shell and tube heat exchangers cannot continue to be utilized. Mr. Peter N. Hansen, P. March 9, 1989 Page 3 Again the proposed use of the circular core radiators appears to be an excellent idea and we will be awaiting further design and engineering data regarding their specific selection and plumbing. Sincerely, Pad ¢ Lhd Mark E. Teitzel Manager, Engineering * 4831 EAGLE STREET, ANCHORAGE, ALASKA 99503 TELEPHONE: (907) 561-1818 January 6, 1983 Mr. Don Bassler Raj Bhargava Associates 301 East Fireweed Anchorage, Alaska 99503 Dear Don: After reviewing the Rural Waste heat Capture & District heating Project for Ambler, Elim, Goodnews Bay, Grayling, Kaltag, Kiana, Savoonga and Shungnak, I would like to make the following comments: 1. With respect to the engine coolant loop outside the heat recovery module, do not allow welded fittings, specify Victaulic (or Gustin- Bacon) Style 77 standard couplings, series 700 butterfly valves, long radius elbows where ever possible, and style 72 outlet for reduced bypass and thermometer well connections. Specify green stripe grade "E" EPDM seals for the above couplers and valves. 2. Do not boil out the engine coolant system with sodium hydroxide and sodium tripolyphosphate; simply flush with clean water. Do not allow the engines to be pressure tested. 3. Connection to engines should be made with Aeroquip flexmaster pipe joints. 4, With respect to the engine coolant loop, the use of 25% DOW SR-1 and 75% water will give freeze protection down to only 9°F, If an engine were to shut down in -50°F weather with a 50 MPH wind, the entire system would freeze up. Please specify the use of 50/50 mixture of Prestone ethylene glycol and clean water. I am also concerned with the use of pure water in the district heating loop for the reasons noted above. Do not expect 100% reliability of electric service to the main pumps. If antifreeze is used, shouldn't it be a potable type to prevent danger of cross contamination? 5. As previously discussed, please install the AMOT valves in a "mixing" position and not a diverting position as shown on the prints. The equipment lists should specify 175°F elements for the valves. 2 Mr. Don Bassler January 6, 1983 Raj Bhargava Ass ates Page 2 10. The Ambler, Elim, Kaltag and Shungnak AMOT valves should be re- sized; use a 2" BFOC-175-01 valve. The Goodnews Bay and Grayling valves should be resized; use a 14" BOC-175-01 valve. The Kiana and Savoonga AMOT valves should be resized; use a 23" BOC-175-01 valve. Lacking the energy balance calculations for the various villages, a concern of mine is that the heat exchangers on the engine coolant loop could remove more heat from the coolant water than desirable. In no case should water be returning to the engine at less than 170°F. I am curious if the heat exchangers have been sized to eliminate this problem. If not, some method must be used to ensure that district heating water is maintained at your design tempera- ture. Possible solutions are: a. A three way valve located on the district heating loop just after the pump(s) discharge could recirculate water through the heat exchanger. b. Variable speed motor controls for the pumps could be used to maintain correct heat exchanger discharge temperatures. c. Installation of pumps with different capacities, i.e. #1 pump rated at 100% flow, #2 pump rated at 75% flow, and #3 pump rated at 50% flow. An automatic switch could monitor temperature and switch to pump #2 or #3 if the heat exchanger discharge temperature dropped below approximately 175°F. A manual switch used in conjunction with the above could save power during summer months when only 50% flow is required. The 4" pipe size engine coolant connections specified on the prints for Kaltag, Elim, Kiana and Shungnak are oversized of that required for approximately 40-120 GPM flow; it is suggested that the connection size be reviewed. Since the main engine coolant loop at Kiana runs between engines, it should be run underfloor or overhead. Please add a note to that effect on sheet M-2 for the Kiana drawings. The use of type "K" heavy wall copper pipe for the Ambler modules glycol heating loop is requested. It is also requested that a PVC jacket around the fiberglass insulation inside the Butler building and an aluminum jacket between the buildings be used. It is requested that a 3/4" victaulic outlet coupler, style 72 , be used in front of all the engines on supply and return pipes. Mr. Don Bassler January 6, 1983 Raj Bhargava Aswcciates Page 3 11. 12. 13. 14, 15. Simply cap or plug the outlet coupler for future connection by AVEC. This will allow an off-line engine to be heated with coolant thus eliminating electric block heaters. Delete the use of a ventilation fan in the specifications for Ambler. The ventilation fans in the Butler buildings should be installed in front of the #1 engine position to provide ventilation control to the switchgear and engine control panels. These electrical systems have ventilation control priority. The ventilation fans should be specified with two speed motors, two stage thermostats and two speed motor starters. Use of two speed controls will increase efficiency and reduce cycling, although specifications call for thermostats, ‘the prints only call for a manual control switch; this is inadequate since Plant Operators only inspect the plant a maximum of three times a day. A motor control box must be supplied with an auto, low speed manual, high speed manual, and off position control. There must also be separ- ate lights to indicate low and high speed operation. Switches and lights should be clearly labeled. The thermostat should be mounted in an area representative of the switchgear temperature. Ventilation fan motor starters are undersized; NEMA size 00 is only rated for 1/3 HP. The ventilation fans should have exhaust hoods designed to operate with high winds and not fill with snow. Please include with the existing note to remove radiators, fans, pullies, etc., that these items shall be carefully crated, protect- ed from damage and shipped to AVEC headquarters in Anchorage. The remote radiators at Ambler, However, should be left in place and intact. Connect to the engines with tees and isolation valves on the engine inlet and outlet. This would allow operation of any of the AVEC engines should the new proposed system go down. It is requested that three phase radiator and pump motors be used at Ambler, Kaltag, Kiana, Savoonga and Shungnak. The three phase motors will cost less, are more efficient and provide better generator load balance. AVEC has issued requests for bids for one new generator module at Kiana and two new generator modules at Shungnak. Current schedules would result in their arrival at the plant sites by mid to late summer, and complete field connection by the first part of fall. Therefore, a hydronic heating system will be required at these villages, and actual field work involving your installations may differ greatly than currently planned. Connection to these new modules should be simple, however, due to planned installation of wr. Raj 16. 17. 18. 19. 20. von bassier Jvanuary 0, 1LY&3 Bhargava As. ‘ates Page 4 wall penetrations and tees with bypass valves on engine coolant piping. ; In the event AVEC should install modules at any of the other villages, provision must be made to allow installation of a hydron- ic heating system. Please provide tees on the district heating loop for this purpose. The use of Q series quiet radiators is requested to decrease noise level. The radiators should be equipped with discharge hoods to prevent ice build up. The prints show no mounting details for the radiators; a referenced detail M/2 is nonexistent. The radiator aquastat and step controller are described for Angoon but not for any of the other villages. Complete part numbers and ratings should be given. A wiring diagram for the connection of these items needs to be included on the drawings. Radiators should be supplied with a motor control] box with auto, low speed, high speed and off position control unless the step controller can provide this manual override feature. A detail should be added for the protection of the power cables between the Butler building and the new module. Where will the power source to the new module be picked up from? A detail should be added for penetration of the pipes through the walls. The use of braided stainless steel hose, approximately 36" long, between the buildings for use as a flex joint is requested. Sincerely, ' Joseph Schneider Project Engineer JS/mv + . ° . 6 February 27, 1989 Mr. Mark E. Teitzel Assistant General Hanager Alaska Village Electric Cooperative 4831 Eagle Street Anchorage, Alaska 99503-7497 Subject: Chevak Waste Heat Design Dear Mr. Teftzel: I have received your letter of 2/16/89 concerning Chevak, and I am at this time somewhat discouraged by what appears to be history repeating itself. Every time we get into the mode of design review, a relatively simple design is repeatedly modified with additional layers of complex- ity, until the original design philosophy has been lost. The unfortu- nate Alaska Vil Tage Electric Cooperative (AVEC) specified, Power Author- ity installed “series/2-pass" configuration of two SrRGHieaetl core radiators with a step controller is a clear example of this. It is my firm belfef that in order to get these systems to work reliably with little maintenance needed over an extended period, they must be kept very simple and basic. Operator involvement must be avoided or kept to an absolute minimum, and if such involvement becomes necessary, the complexity must match the capability of the ever-changing local operations personnel. Once installed on an existing facility, the big picture must still appear simple and straight forward to the operator and to the maintenance personnel, and in this area I feel that previous installations have failed miserably. After reading your letter and after reviewing recent operational prob- lems in Savoonga and Chevak with Mr. John Lyons, I hereby propose that we start all over in Chevak and develop a reliable and yet very simple design. It appears obvious that the snow problems encountered in Savoonga warrant a complete reevaluation of the way we design cooling systems for intermittent service in areas with blowing snow. Evidently, the radiators have to be mounted as high as possible, and it would also be helpful, if the radiator design was well suited for operation in snow. As illustrated in Chevak, we cannot rely on the operator to clear snow away from the radiator. What I will be proposing to you will be a design, which may seem'unusual to you; yet it is a design which, due to its simplicity, has proven itself in some of the Teast maintenance capable communities in Alaska. 5110/944(1) My proposal is as follows: 1. All radiators in Chevak be located on a steel framework on top of the module. 2. 3 ea. circular core radiators in up-blast configuration be used for engines #1 and #2, and the existing MWC-86 or alternatively 3 ea. additional circular core radiators be used for engine #4. The circular core radiators will have 1 or 1-1/2 hp, single speed, 3-phase motors with completely independent controls on three different circuit breakers. These radiators will be sized to provide adequate cooling for a Cat 353 at full load on a 40 degree day with only two radiators in service. The radiators will have a "hat" to reduce the a mount of snow, which accumulates on the radiator. 3. The heat exchanger be located in the radiator plenum in the module, thereby completely eliminating the need for a platform on the Butler building. 4. The two systems be kept completely independent, thereby eliminating the need for several by-pass valves and additional expansion tank components, which the local operator will be unable to utilize anyway. 5. The existing shell and tube heat exchangers be removed and the existing AVEC heating system be connected to the new flat plate heat exchanger with appropriate provisions to allow for stand- alone operation of AVEC's heating system in case of a line break on the line to the high school. I can mention to you that very similar cooling systems are working with little or no maintenance in Atka, Diomede, White Mountain, Golovin, Koyukuk, Birch Creek, and Nikolai. I am attaching a spec. sheet on the radiators, which in reality are down blast unit heaters. Please note that these unit heaters are sold as radiators by Young; a phone call to Young confirmed my suspicion that they are identical to Young's unit heaters. I have used other manufacturers such as Dunham-Busch and Coil Company, and my preference is for Coil Company because of the lower pressure drop in their design. . We have to date not experienced a single motor failure, and due to the circular, brazed tube design of the core, I certainly do not expect to see any core failures. Another obvious advantage is that these radia- tors weigh approximately 200 Ibs. including the motor and will fit nicely in a Cessna 207. With the motor, fan and other components removed, they can be handled by one man (I have tried it, and even though it 1s a chore, it certainly is no comparison to handling a core from a horizontal or vertical core radiator!). The motor is a standard (quiet, 78 db(A)) 1140 rpm 3-phase motor costing about $200 and weighing in at less than 50 Ibs. - 5110/944(2) Please dfscuss this proposal with your Operations Department and feel free to contact me at 261 7221 if you have any questions or comments. Sincerely, Peter N. Hansen, P.E. Project Manager PNH: it Attachments as stated 5110/944(3) CATALOG 14 1982 Supersedes Cat. No. 14-81 Young AV COOLERS for Compressed Air Aftercooling and General Purpose Water Cooling Patented U.S. Patent 2,504,798 2825 Four Mile Road @ Racine, Wisconsin 53404 Plants at: Racine, WI, Mattoon, IL and Centerville, 1A ® Copvriaht 1982 YOUNG RADIATOR COMPANY Yy? YOUNG RADIATOR COMPANY | AV Coolers are designed to perform efficiently and economically with minimum maintenance. Patented construction permits cool atmospheric air to circulate around the motor protecting it from radiant heat damage thereby insuring longer motor life (see Fig 3). Corrosion resistant materials, permanent high temperature bonding of tubes to manifolds and circular core design minimize stresses and guarantee dependable cooler performance. Fig. 4 The circular heat transfer core (See Fig. 2) is contained between steel covers of slightly larger diameter than the core, providing space for free expansion and con- traction without stress or strain. The fan shroud is venturi-shaped to allow maximum fan efficiency. Welded steel, cadmium or zinc plated fan guards which provide necessary protection for vulnerable Parts of the unit and workmen in close proximity to the cooler are standard equipment. NEMA frame motors are used. All motors are Totally Enclosed Fan-On-Shaft Air-Over type specifically designed for these units. ° Fig. 3 AV Coolers function efficiently whether mounted horizontally or vertically. Coolers may: be mounted Morizontally for vertical air discharge either upward or downward. Four 1/2 in. holes with mount- ing nuts (13 NC thrd) welded in place are furnished in the steel cover opposite the fan shroud. Fig. 4 and Fig. 5 are close-up views of the fins, tubes and manifolds used in the core. The tubes are high temper- ature brazed to the manifolds for long life. Aluminum fins are per- manently bonded by mechanical means to corrosion resistant copper/ copper alloy tubes, insuring maximum heat transfer. Fig. 5 | - AV technical data/piping diagram Coane TABLE 1 AV TECHNICAL DESCRIPTION ~~ Motor Sound Level Water Shipping Model Flow Power, hp Rotation, rpm dB (A) @7 ft Volume Weight ctm 10 30 10 30 | 10 | 30 gal. r AV-60S 815 1/6 1/6 1075 1140 55 57 0.4 67 AV-80S 1185 1/6 1/6 1075 1140 55 57 0.6 80 AV-105S 1620 1/6 1/6 1075 1140 60 62 0.6 87 AV-140S 2030 1/6 1/6 1075 1140 63 | 65 0.8 95 AV-165S 2335 1/6 1/6 1075 1140 68 70 T 0.9 120 [ AV-210S 3085 1/4 1/4 i 1075 1140 68 70 | 1.2 130 av-2608 | 3500 | 1/4 v4 | 1075 | 1140 | 69 | 71 13 180 AV-350S 4710 1/2 1/2 1075 | 1140 71 73 2.0 237 AV-480S 6470 3/4 3/4 1075 1140 74 76 300 AV-600S 9600 _ 1% _ 1140 _ 78 NOTEA: Standard motors are totally enclosed air-over type. NOTE B: To estimate sound level at distances other than 7 Totally enclosed explosion-proof motors are avail- feet from cooler, add 6 dB (A) for each halving able at additional cost. of distance or subtract 6 dB (A) for each doubling of distance. Sound levels shown are an average of several measurement points. AV Coolers for compressed air aftercooling can be be used as shown and moisture traps and blow off valves mounted in any of the positions shown. Separators should to eliminate condensate are recommended as required. . NOT LESS THAN !2 COOLING PROM AIR FLOW FROM CEILING COMPRESSOR , \ COomPRESSOR 7 TO RECEIVER TO RECEIVER COOLING SEPARATOR SEPARATOR AIR FLOW oo — COOLING AiR FLOW —-_ FROM COMPRESSOR Yo N.P.T —_— To RECEIVER Fig. 6 BALL FLOAT TRAP SEPARATOR “ A274 Young AV water cooling capacity AV Coolers are superior for low water flow conditions in situations requiring air cooling. The units are suit- able for small engines which cannot use large radiators. we as moun} al or hrzotal the AV Coolers to be ‘positions. The design allows for ceiling mounting which provides more room for vital equipment on the floor and also increased potential for heat recovery to maintain room air temperature. TABLE 3 - [ AV CAPACITY FACTOR Water Flow | Av-60S | AV-80S Av-165s | Av-210s | av-260s | av-350s | Av-4s0s | AVv-600S TLEG [EG | Water] EG | ACTORY WHEN SELECTIONS FALL IN THIS AREA | 12 15 [12] 14 [13] 17 21 24 [as[ is [aa[ 19 [ra[ 23 | [27 [13] 16 [15] 20 [19] 25 [23] 30 [14[ 18 [16] 22 [21| 28 [26] 34 [31 15| 19 [17| 24 [22] 30 | 28] 37 [34 12 19 [20] 26 [24] 33 [30] 40 | 37 17| 21 [20] 27 [25] 35 [32] 43 | 40 ve[ 22 [21] 29 [27[ a7 [as] 46 [49 19] 23 [22|{ 30 |28| 39 |36| 49 | 45 20| 24 |22| 31 |29| 41 [ae] 51 | 48 20| 25 |23| 32 |30] 42 [39] 53 [50 21{ 25 [23] 33 [31] 43 | 40] 55 [51 |e 34 _[s2[ 45 [42] 58 [54 60 | FLOW RATES IN THIS AREA 47 | 44] 60 | 56 79 | EXCEED MAXIMUM ALLOWED 163 Tar NOTE F: In TABLES 3 and 4 column heading EG refers to a solution of 50% water and ethylene glycol. TABLE 4 wale! AV WATER PRESSURE LOSS psi Flow | Av-60S | Av-s0s | AVv-105S | AV-140S [ Av-165S | AVv-210S | av-260s | Av-asos | Av-4sos | Av-600S 3PM | Water |EG | Water |EG | Water | EG | Water |EG | Water |EG [eEs| EG Water| EG | Water |EG | Water |EG 0.1 CONSUET FACTORY WHEN or loal on [os 01 T0171 01 o1 SELECTIONS FALL IN THIS AREA 0.1 [o1{ 01 [01] 01 [or] 04 01 [ot orf 0.1 0.1 01 fo1{ o1 for] oa for] or fort on fort on fort on fort on 0.1 0.1 02 fo2| o1 fo2{ or fo2] o1 [orl o1 [on a to 0.1 foi[ 01 foi] 01 04 0.2 [o3| o1 fos] o2 [o2] o1 fo2] or Jo2] o1 for] o1 for{ o1 for] o1 for] o1 o4 fos] 02 [o4{ 03 foal o2 [os| o2 [os] o1 for{ o1 fo2] or [or] o1 for] o1 [or 06 |0.8| 03 |06| 05 |06| 03 |04| 03 |04| 02 [o2| 02 fos| o1 La 0.1 [01| 01 [01 10 [1.3] 04 [o8| o7 [1.0| 04 [oe] o4 [oe] o2 [o3| 03 fo4[ 02 [oz] o1 |o2| o1 [02 14 [19{ 06 [1.2] 11 [14[ 06 fos! o6 Jos| o3 [os] os fos! o3 Jos o2 fo2] o2 [os 09 [18] 16 [21| 09 [12] 09 [12] 05 [o7| 06 foal o4 fos] 03 [os] 03 [oa 14 [48[ 14 [18] 08 [10] 09 [12] 06 fos] o4 [os] o4 [os] 19 [25] 1.1 [1.4] 1.3 [1.7] 09 [1.1] 05 [07] 06 [07 {14/18 17 [22] 12 ]15| 07 [o9| o7 |10 18 [23] 21 [27/15 [20] 09 [12] 09 [12 23 [3.1| 14 |18| 14 [18] FLOW RATES IN THIS AREA 19 [25] 19 [24 EXCEED MAXIMUM ALLOWED 24 132 pert) AV dimension/water selection Young J K 875 All dimensions are in inches. Certitied D dimension drawings are available for —— : B MAX installation. Fan guard screen conforms to OSHA. eames FAN GUARD | J Finish is gray semi-gloss enamel. | 4 MTG HOLES -—F—t_- FE —4 SSNS Tae Maximum Operating J | Temperature 365F | Maximum Operating Pressure 150 psi pt Test Pressure 300 psi Fig. 11 _BM7604 TABLE 5 AV-80S AV-105S Av-1408_ | 32.75 AV-165S AV-210S AV-260S AV-350S AV-480S AV-600S AV water selection example 1. Calculate CAPACITY FACTOR required: Select AV to remove 900 Btu/min from 20 gpm of 50% eth- heat load ylene glycol entering at 170F in an ambient air temperature CAPACITY FACTOR ="FmaxcTamb of 110F. 900 1. CAPACITY FACTOR = =15 heat load = Btu/min 170-110 _ Tmax = maximum water temperature, F 2. Select AV-210S rated 18 at 20 gpm for EG (50% water Tamb = ambient air temperature, F and ethylene glycol) from TABLE 3. 2. Select AV model with an adequate CAPACITY FACTOR 3. Determine WATER PRESSURE LOSS of .7 psi from for WATER FLOW from TABLE 3. TABLE 4. 3. Determine WATER PRESSURE LOSS from TABLE 4. NOTE G: Ethylene glycol solutions at Tmax less than 170F may result in unreliable CAPACITY FACTORS. Refer such applications to Factory. NOTE H: If the value of Tmax-Tamb is less than SOF, selec- tion may not be reliable. In this case, consult Young Radiator Company Representative or Factory. Form No. 1301H | Unit Heaters For Steam and Hot Water Applications Horizontal and Vertical Discharge COMMERCIAL PRODUCTS DIVISION Products That Perform...By People Who Care H model C, CA OPTIONS é SOLID STATE SPEED CONTROL Adjustable solid state speed controllers are available for unit sizes 100 through 850. Speed controllers are shipped loose and feature adjustable trimpot for minimum speed selection. Speed controllers are shipped in a 2” x 4” J-box with face plate. MOTOR OPTIONS UNIT EXPLOSION PROOF (1) TOTALLY ENCLOSED (2) EXPLOSION PROOF (2) SIZE VOLTAGE HP RPM. AMP. VOLTAGE HP RPM AMP VOLTAGE HP RPM AMP. 100 115/1-60 ‘he 1725 3.0 Consult Factory _ N/A 175 115/1-60 ‘te 1725 3.0 Consult Factory N/A 250 115/1-60 ‘he 1725 3.0 Consult Factory “N/A 300 115/1-60 Ve 1140 3.0 200/230/460-3-60 ‘4 1140 1.7/1.6/.8 _200/230/460-3-60__'s 1140 __1.7/1.6/.8 400 115/1-60 Me 1140 3.0 200/230/460-3-60 1140 1.7/1.6/.8 _200/230/460-3-60 1140 1.7/1.6/.8 500 115/1-60 ‘a 1140 3.0 200/230/460-3-60 1140 1.7/1.6/.8 _200/230/460-3-60_ 1140 1.7/1.6/.8 600 115/1-60 Ye 1140 3.0 200/230/460-3-60 1140 1.7/1.6/.8 _200/230/460-3-60_ ‘4 1140 1.7/1.6/.8 700 115/1-60 Me 1140 3.0 200/230/460-3-60 ‘4 1140 1.7/1.6/.8 _200/230/460-3-60_ ‘4 1140 1.7/1.6/.8 850 115/1-60 Ye 1140 3.0 200/230/460-3-60 1140 1.7/1.6/.8 _200/230/460-3-60__/ 1140 __1.7/1.6/.8 1100 _115/230-1-60 ‘kh 1140 8.0/4.0 _200/230/460-3-60_ ‘2 1140 _2.2/2.0/1.0 _200/230/460-3-60 ‘2 1140 2.5/2.4/1.2 1350__115/230-1-60 ‘hh 1140 8.0/4.0 _200/230/460-3-60__‘/z 1140 2.2/2.0/1.0 _200/230/460-3-60 ‘kz 1140 2.5/2.4/1.2 1500__115/230-1-60 ‘a 1140 8.0/4.0 _200/230/460-3-60__/z 1140 2.2/2.0/1.0 _200/230/460-3-60 ‘2 1140 2.5/2.4/1.2 (1) Class 1, Group D; Class !!, Group E, F, &G. (2) Totally Enclosed, Fan Cooled. (3) Class 1, Group D; Class !!, Group F & G. ( Consult factory for 575/3/60 applications. VERTICAL LOUVERS Four way air deflection can be attained with the addition of optional vertical louvers. All Horizontal Discharge Unit Heaters have individually adjustable horizontal louvers as standard. Vertical louvers are shipped loose for field installation. Removal of the top panel and installation of the vertical louvers is easily accomplished. Instructions are included. SPECIAL COILS For high temperature, high pressure systems coils may be constructed of .049” wall 90/10 cupro-nickel tubing and red brass headers for supply and return. Operating pressures up to 300 psi at 350° F may be accomplished with this option. PROTECTIVE COATINGS Waste water treatment facilities, paint booths, and many other such applications posea particular threat to air moving equipment. Corrosive atmospheres are responsible for much premature failure of coils and sheet metal parts. Coils, fan propellers, and/or entire units may be ordered with a3 mil. thick “Libcote 7” baked.phenolic coating for additional protection against these hazardous environments. DISCONNECT SWITCH Single phase units may be ordered with factory installed disconnect switch mounted in a 2” x 4” junction box on the back of the unit. THERMOSTATS (shipped loose for wall mounting) PART NUMBER CONTROL RANGE ELEC. RATINGS FUNCTION 009632A1 40° F-90°F 1.5A, 3.5A inrush at Low voltage SPOT makes contact for heating and/or ( 30 VAC cooling. .- 009634A1 56° F-94°F 6.0/3.0 amps at Line voltage contacts make on temperature fall. 120V/240V VERTICAL DISCHARGE UNIT HEATERS FEATURES Spun Steel 2 Top & Bottom “Rapid Action!» Heating Element: Dunham-Bush Vertical Discharge Unit Heaters are available in ten sizes tor steam or hot water heating, with capacities ranging from 133 EDR to 2490 EDR (based on 2 Ibs. steam pressure and 60°F entering air). They are designed for working pressures up to 150 psi. Entering hot water temperatures of up to 340°F may be used with hot water heating systems. Based on 200°F entering water 20°F drop, capacities ranging from 19 MBH to 427 MBH may be obtained. VERTICAL DISCHARGE UNIT DESIGN FEATURES MOTORS Standard motors are open frame and flange mounted. Motors on Models C175 thru C525 have permanently oiled sleeve bearings while motors on Models C650 thru C2400 have grease packed bail bearings. Motors 1/3 HP and smaller can be operated at reduced speeds by the addition of aspeed controller. All motors can be removed from the bottom of the unit, permitting installation close to the ceiling. — CONSTRUCTION The sturdy motor support cone and the spun steel top and bottom direct the air from the heating element to the fan, furnishing improved air flow and quiet operation while protecting the motor from excessive heat, dust and other impurities. HEATING ELEMENT Supply and return lines are located on top and bottom of the unit, approximately in line with each other, for ease of installation. All units are finished in beige baked enamel. ELEMENT 7 The heating element fins are aluminum. Tubes are heavy copper expanded into fins to provide a positive and per- manent mechanical bond. The complete assembly is tested with air pressure under water and hydrostatically at 400 Ibs. psi. The C Model G is recommended for pressures up to 75 psi and temperatures up to 325°F. The C Model GA is recommended for pressures up to 150 psi and temperatures up to 340°F. GENERAL The double duty hanger support provides strong support for the units. There is no support strain on the piping. mciavaiientci st, MOTOR AND FAN DATA (:15-1-60) UNIT SIZE TYPE HP RPM AMP. FAN DIA (in) 175 ooP "ho 1550 1.14 10 300 OOP ‘ho 1550 1.11 14 400 ODP ‘ho 1550 1.14 16 525 ODP “ 1550 4.0 16 650 OOP te 1075 3.5 20 900 OOP vA) 1140 3.8 20 Optional motors are 1250 OOP ‘k 1140 7.8 26 . ; : 1650 TEFC (1) Me 1140 a 26 palele with Explosion C Model G, GA 2000 TEFC(1) 1% 1140 11.0 30 ulebionii ine olales 2400 ODP (2) 1 1140 14.7 30 : See page 12. All motors are UL approved. (1) 115/230-1-60 (2) 115/208/230-1-60 AIR DELIVERY (Approximate-ft.) C Model G -_C Model GA MOUNTING HEAT SPREAD MOUNTING | HEAT SPREAD WEIGHT UNIT SIZE HEIGHT DIAMETER UNIT SIZE HEIGHT OIAMETER Lb. 175 W 20 175 14 26 175 44 300 12 30 300 14 38 300 37 400 12 33 400 15 42 400 67 525 13 35 $25 18 46 525 73 650 18 44 650 22 51 650 105 900 20 46 900 24 59 900 115 1250 24 56 1250 29 72 1250 197 1650 26 60 1650 35 74 1650 250 2000 31 69 2000 38 91 2000 350 2400 35 67 2400 41 93 2400 403 SUPPLY H—+-—H TOP VIEW BOTTOM VIEW UNIT DIMENSIONS IN INCHES SIZE A B c o E F G H ~ J K C175 26%s 9% Tithe 10%6 he S/ea 1% Ths 6% 11%6 C300 27% 10% gNhs 14% 36 8/4 1% The 6% 12 C400 31% WW g"he 1646 he S\/ea 1% 8°56 Bh 13/6 C525 31% 13 Vi"he 16%6 he S\/ea 1% 8/6 Bit/h6 13/6 C650 35% 13% 116 20% he he 2 10'/6 Whe 15% C900 35% 17% 15/6 20% he Whe 2 10'%/6 QVhe 15% C1250 41% 17% 15% 2676 % 16 2 12%hs 11% 18%6 C1650 41% 21% 19% 2676 % 16 2. 1256 11% 18%6 C2000 52% 23% 20% 30% 1% Vhe 2% 16% 15 23% C2400 S2% 25% 22% 30% Wn Whe 2% 16% 15 23% Supply and return labeled for steam. Reverse for hot water applications. C model G HOT WATER CAPACITIES ENTERING WATER TEMPERATURE NIT TEMP. No. DROP 180°F 200°F 220°F 240°F MBH GPM_LAT WPD| MBH GPM _ LAT WPD| MBH GPM LAT WPD|MBH GPM LAT WPD 10° 27.7 5.65 106 85] 34.0 7.28. 110 1.17] 405 858 127 1.57] 466 9.50 137 1.85 C175G 20° 23.7 2.41 99 17] 29.7 3.02 109 .26| 363 3.69 120 36} 42.6 430 131 48 1/40 HP 30° 19.9 135 93 .03} 25.7) 183 103 .11] 32.2 230 113 -15] 38.7 263 124 22 1550 RPM 40° 15.6 .80 86 02} 21.4 1.14 96 .05} 28.0 1.40 107 07} 34.8 1.77 118 -10 557 CFM 50° 12.1 50 80 01} 17.3 74 89 .02| 24.0 -96 100 04] 30.8 1.25 111 .05 10° 485 9.90 105 1.05] 52.0 11.1 108 1.31} 70.4 14.9 125 2.12} 81.0 16.4 135 2.5 C300G 20° 40.9 4.16 98 23] 464 472 103 .29] 624 634 118 -49} 73.0 7.42 128 64 1/20 HP 30° 33.8 230 91 08} 41.9 2.99 99.14) 55.2 3.94 111 26} 65.9 4.48 121 28 1550 RPM 40° 26.5 1.35 85 02} 37.2 1.99 94 .07| 47.6 2.55 104 +12] 58.9 3.00 115 15 1000 CFM__50° 19.3 .79 78 -01| 326 1.4 go. -.04| 401 1.72 97 05] 51.8 2.10 108 07 10° 63.0 12.8 102 1.9) 76.2 16.3 111 2.9] 88.6 185 119 3.60/1021 20.6 128 4.05 C400G 20° 53.0 539 95 -37| 66.7 678 105 .64}) 80.1 814 114 86} 93.3 9.48 122 1.13 1/12 HP 30° 43.4 2.95 89 -10| 57.4 4.10 98 .26) 71.5 5.10 108 -40} 84.8 5.77 117 -50 1550 RPM 40° 33.9 1.73 83 03} 47.9 2.56 92 .12] 62.9 3.36 102 20} 75.9 3.87 111 25 1382 CFM ___50° 24.2, .99 = 76 .01| 38.4 1.65 86.06 |_ 54.4 2.33 102 -11] 67.4 2.73 105 13 10° 77.8 15.9 103 1.65} 95.2 20.4 113° 2.53] 113.0 23.7 123 3.30/140.0 283 138 4.22 C525G 20° 66.6 677 97 -38} 83.9 853 107 .57] 101.5 10.3 117 -80/117.0 11.9 125 1.05 1/8 HP 30° 55.9 3.80 91 -18] 72.7 5.19 100 .24] 903 643 110 +35] 106.4 7.24 119 45 1550 RPM 40° 44.5 2.27 85 09} 61.3 3.28 94 12] 78.6 4.21 104 -17} 95.5 487 113 22 1658 CFM___50° 33.8 1.38 79 .03 | 50.3 2.15 88.06] 67.5 289 99 .09| 845 3.42 107 WU 10° | 111.3 23.0 103 3.60) 130.5 27.9 111 4.90] 154.4 32.4 120 6.40/179.3 36.2 130 7.80 C650G 20° 94.0 955 97 -791 114.9 11.7 105 1.15] 138.7 14.1. 114 1.55]161.2 16.4 123 2.10 1/4 HP 30° 77.6 5.28 90 +30} 100.1 7.15 99 .49/ 123.5 881 108 -70}145.8 9.91 117 -98 1075 RPM 40° 60.6 3.10 84 -10} 84.5 4.53 93 .22] 107.3 5.76 102 -30}130.0 663 111 -50 2370 CFM ___50° 44.2 1.80 77 05 | 68.9 2.95 93.10} 92.4 3.99 96 :251114.6 4.64 105 28 10° | 145.0 296 102 2.35] 175.7 37.6 111 4.20} 206.0 43.1 120 5.22|237.0 47.9 129 6.50 C900G 20° | 124.8 12.7 97 -64 | 155.4 15.8 106 «=.92| 186.1 18.9 115 1.25}2164 22.0 123 1.60 1/3 HP 30° |105.2 7.16 91 -32]} 135.9 968 100 .30| 1665 11.3 109 -511197.0 13.4 118 -70 6. 4. 0. 1. 2. 1140 RPM 40° 85.4 435 85 -15 | 115.3 16 94 .12]145.8 7.80 103 -23/176.9 9.02 112 -38 3160 CFM __ 50° 66.1 2.70 79 .06 | 96.0 un 88 09/1268 5.43 97 -101156.2 6.33 106 20 10° | 194.0 39.6 94 §.43 | 234.0 50.1 101 8.20] 273.0 58.0 108 10.8/310.0 62.6 115 123 C1250G 20° | 168.4 17.1 90 1.27 | 206.9 21.0 96 1.85] 246.4 25.0 103 2.50/284.7 289 110 3.17 1/2 HP 30° | 143.0 9.72 85 -51 | 181.1 12.9 92.70} 221.0 15.8 99 1.15}260.0 17.7 106 1.38 1140 RPM 40° [117.0 5.97 81 -23:} 154.1 7.71 87 .30} 195.6 10.5 94 -54/235.0 11.9 101 75 5250 CFM ___ 50° 91.6 3.74 76 -13 1128.0 5.48 83.25 168.0 7.19 90 -241/210.0 8.51 97 42 10° | 261.0 53.6 100 5.65 |320.0 68.5 110 8.30 | 368.0 78.9 117 11.7/432.0 87.3 127 13.9 C1650G 20° | 227.0 23.0 95 1.28 | 282.0 28.7 104 1.90} 334.0 33.9 112 250/385.8 39.2 120 3.25 3/4 HP 30° | 193.0 13.1 90 -53 | 246.0 17.5 98 80} 300.0 21.3 112 1.15/349.0 23.7 114 1.22 1140 RPM 40° | 157.8 8.03 84 -23 | 207.0 11.1 93.37] 264.5 14.2 101 -58/311.0 15.9 108 -68 5980 CFM__50° |123.8 5.04 79 -10 | 170.8 7.30 87 _—«.19 | 231.0 9.91 97 °30[274.0 11.1 103 -40 10° | 362.0 73.8 102 12.3) 409.0 87.5 107 16.4} 496.0 106.0 117 23.0/544.0 109.9 123 27.6 C2000G 20° | 318.2 323 97 3.00 | 370.3 37.6 103 3.90 | 452.7 46.0 112 5.45}5083 515 119 6.50 3/4 HP 30° | 272.0 18.5 91 1.20 | 336.0 24. 99 1.67} 411.0 29.3 107 2.60/472.0 32.1 114 3.5 1140 RPM 40° | 226.0 11.5 86 -60 | 296.0 15.8 94 .75/366.0 196 102 1.30/439.0 22.4 111 1.9 8040 CFM __50° _|181.3 7.41 81 -30 | 258.0 11.1 90.40 | 327.0 14.0 98 -60/405.0 16.4 107 1.20 10° | 398.0 81.2 102 12.6 | 478.0 102.3 111° 17.3: | 548.0117.0 118 23.5}/582.0 1196 122 23.0 C2400G 20° | 351.2 35.7 97 2.95 | 426.6 43.4 105. 3.85}500.9 50.9 113 5.40/556.8 57.6 119 6.90 1 HP 30° {302.0 20.5 92 1.35 | 378.0 27.0 100 1.60] 453.0 30.8 108 2.40/5220 35.5 115 3.00 1140RPM 40° | 250.0 12.7 86 -69 | 326.5 20.2 95 .98/ 406.0 222 103 1.40/485.0 24.7 111 1.70 8750 CFM__50° |204.0 8.32 82 38 | 277.0 11.9 89 43 | 360.0 14.7 98 -60|451.0 18.3 108 1.0 Conversion factors can be found on page 15. Based on 60° entering air temperature. 10 C model G q OPTIONS SOLID STATE SPEED CONTROL Adjustable solid state speed controllers are available for unit sizes 175 through 900. Speed controllers are shipped loose and feature adjustable trim pot for minimum speed selection. Speed controllers are shipped in a 2” x 4” J-box with face plate. : we MOTOR OPTIONS UNIT TOTALLY ENCLOSED EXPLOSION PROOF (1) T TOTALLY ENCLOSED (2) EXPLOSION PROOF (1) SIZE VOLTAGE TYPE HP RPM AMP | VOLTAGE HP RPM AMP VOLTAGE HP RPM AMP VOLTAGE HP RPM AMP 175 115/230-1-60 TENV i“ 1625 2.0/1.0 115-1-60 ‘he 1725 3.0 Consult Factory Not Available 300 115/230-1-60 TENV % 1625 2.0/1.0 115-1-60 ‘he 1725 3.0 Consult Factory Not Available 400 115/230-1-60 TENV % 1625 2.0/1.0 115-1-60 ua 1725 3.0 Consult Factory Not Available 525 115/230-1-60 TENV '& 1625 2.0/1.0 115-1-60 he 1725 3.0 Consult Factory Not Available 650 115/230-1-60 TENV % 1140 4.0/2.0 |_115-1-60 Me 1140 3.0 200/230/460-3-60 ‘hs 31140 1.7/1.6/.8 200/230/460-3-60 ‘hb 1140, 2.5 900 115/230-1-60 TENV ‘4 1140 4.8/2.4 115-1-60 Me 1140 3.0 200/230/460-3-60 ‘hs 1140 1.7/1.6/.8 200/230/460-3-60 ‘4 1140, 2.4 1250 115/230-1-60 TEFC % 1140 8.0/4.0 115-1-60 Me 1140 3.0 200/230/460-3-60 * 1140 2.2/2.0/1.0 200/230/460-3-60 ” 1140, 1.2 1650 115/230-1-60 TEFC % 1140 _10.0/5.0 |115-230-1-60 & 1140 __11.0/5.5 | 200/230/460-3-60 % 1150 3.3/3.1/1.6 200/230/460-3-60 % 1150 3.0 2000 115/230-1-60 TEFC % 1140 _10.0/5.0 |115-230-1-60 1140 _11.0/5.5 | 200/230/460-3-60 % 1150 3.4/3.1/1.6 200/230/460-3-60 % 1150 2.8 2400 115/230-1-60 TEFC 1 1140 _14.0/7.0 |115-230-1-60_ 1 1140 __14.0/7.0 | 200/230/460-3-60 1 1140 4.0/3.8/1.9 200/230/460-3-60 1 1140 3.0 (1) Class |, Group D; Class l!, Group F & G. (2) Totally Enclosed, Fan Cooled. Consult factory for 575/3/60 applications. DIFFUSERS, ANEMOSTATS A variety of options are available to attain desired air delivery with Vertical Discharge Unit Heaters. These include adjustable cone diffuser, radial louver diffuser, and 3 or 4 cone anemostats. All are shipped loose with complete instructions for installation. See page 13 for dimensions. SPECIAL COILS Special coils for use with high temperature, high pressure systems are available. Tubes will be .049” wall 90/10 cupro-nickel and supply and return header will be constructed of red brass pipe nipples suitable for pressures up to 300 psi at temperatures up to 350°F. PROTECTIVE COATINGS Waste water treatment facilities, paint booths, and many other such applications posea particular threat to air moving equipment. Corrosive atmospheres are responsible for much premature failure of coils and sheet metal parts. Coils, fan propellers, and/or entire units may be ordered with a3 mil. thick “Libcote 7” baked phenolic coating for additional protection against these hazardous environments. THERMOSTATS (shipped loose for wall mounting) PART NUMBER CONTROL RANGE ELEC. RATINGS FUNCTION . 009632A1 40° F-90°F 1.5A, 3.5A inrush at Low voltage SPDT makes contact for heating and/or 30 VAC cooling. 009634A1 56°F-94°F 6.0/3.0 amps at Line voltage contacts make on temperature fall. 120V/240V 12 COM UN MIEATERS FOR SPACE HEATING EFFECTIVE TEMPERATURE CONTROL INITIAL COST SAVINGS -~ OPERATING SAVINGS WIDE RANGE OF SIZES ¢ HIGH EFFICIENCY RELIABLE PERFORMANCE FOR USE WITH : ry HEAT TRANSFER FLUIDS e GLYCOL SOLUTIONS ¢ HOT WATER e STEAM COIL COMPANY INC. TERRA, Inc. 1900 W. 125 South Front Street, Colwyn (Darby), PA (USA) 19023 P.O, os orag oY TOLL FREE 800-523-7590 Anchorage, Alaska 99502 COIL UNIT HEATERS INTRODUCTION Horizontal Blow or Vertical Blow units are ideal for economically heating commercial, institutional storage, service, manufacturing and industrial building areas. The design, function and arrangement of the building structure and areas should be considered for optimum selections, operation and maintenance. Where variable space temperatures and air distribution are considered satisfactory, a fewer larger sized units may be applicable. Spaces where temperature and air distribution are critical, fewer smaller units should be considered. Horizontal Blow Heaters are ideal for suspended mountings where air distribution is not impeded. Generally, horizontal flow heaters should be arranged to satisfy the inside periphery of spaces with exposed walls. Vertical Blow Heaters for variable height mountings are ideal where space obstructions interfere with horizontal air flow patterns. Heat Transfer Coils COIL Heat Transfer Surfaces have been selected for the most efficient and rugged duty ranges. Standard Construction utilize heavy wall copper tubes expanded into rugged aluminum plate fin stock for a tight bond of the primary to secondary surfaces. Tubes are brazed to steel or iron manifold steel headers. Standard surfaces are ideal for low pressure steam of hot water systems. Copper tube surfaces are considered up to 365°F and 150 PSIG steam. Where steam pressures exceed 25 PSIG supply, heavier duty and high pressure designs are recommended for extended service. For elevated steam pressures and steam or water temperatures, optional materials are available. © Copper © Carbon Steel © Cupro-Nickle © Stainless Steel ¢ Brass Enclosure Cabinets Horizontal Blow of the wrap design casing of carbon steel with venturi fan ring mountings are rib formed to the core configuration and size. Venturi panels are used for the efficient movement of air by the propeller fans through the element surfaces. Motors are mounted to removable motor brackets. Fan inlet guards are available for protection and safety requirements. The air discharges are standard with single individually adjustable air deflectors for downward and angular flows. Double deflection features are available upon request. Vertical Blow are of the two piece carbon steel design for the top inlet air and bottom outlet air opening. Air enters the coil around the periphery of the circular units. Motors are anchored to removable motor brackets. The round bottom outlet ring is suitable for mounting various down flow deflectors, louvers, cone diffusers and multi cone air distribution devices. Fans All propeller type fans of aluminum or carbon steel are statically balanced and carefully mounted to the motor shaft extensions. Fans of special materials are available in many sizes but may need a modification to the motor horsepower requirements. Totally enclosed motors are standard from recognized sources which provide protection for air-borne particles, reliability and motor life. Single phase - Sixty Cycle at 115 volts are considered standard for all fractional horsepower motors. Single phase at 230 volts is available available as standard for integral horsepower frames. Explosion Proof Motors, designed for fan duty and hazardous conditions are available such as class 1 Group D, Class 2 Group E, F, G. Due to the limited frames available, it may be necessary to consider alternate groups and horsepowers. Coil Factory Testing All cores factory tested wit air while submerged under water. Other test measures available upon request. Pana? STEAM - WATER -) OWER CG-02 GLOSSARY: MBH BTUH in Thousands BTUH British Thermal Unit Per Hour PSIG Pounds Per Square Inch SLH Latent Heat of Steam in BTU/LB CLBS/HR Condensate per hour CFM Cubic Feet Per Minute at free discharge air TRA Temperature Rise of Air FT Final Temperature of air at discharge (°F) EA Entering Air Temperature (°F) wTD Water (LIQUID) Temperature Drop ENT Water (LIQUID) Temperature entering Unit GPM Gallons per Minute P.O. Pressure Drop in Feet of Water HP Horsepower w Watts (Approx.) RPM Revolutions per Minute USEFUL FORMULAS & DATA CG-03 460° + 70°F 460 + FT BTUH = CFM at 70°F X 1.085 x TRA CFM (70°F) = 7a = BTUH 1.085 X CFM @ 70°F C Las/HR = ———BTUH_ Latent Heat of System GPM = BTUH 500 X Water Drop (°F) Water: 8.34 LBS/GALLON 8.34 LBS/Min/GPM 500 LBS/HR/GPM Boiler HP: 33480 BTUH PER BOILER HP Kilowatts: 3413 BTUH PER KW HEAT TRANSFER DATA CG-04 GLOSSARY: A Heat Transfer Surtace, Ft? GPM Fluid Flow Rate, gal/min Q Heat Transterred, BTU/hr U Overall Heat Transfer Rate, BTU/hr Ft? °F Cp. Specific Heat @ t., BTU/Ib °F d Density @ ts, Ibs/gal h Film Coefficient @ ta. BTU/hr Ft? °F s Specific Gravity @ ta. = d + 8.3453 t Temperature, °F at tt orte—t USEFUL FORMULAS: Q = GPM X cy Xd X At X 60 Q GPM = . Xd X At X 60 = See : at= GPM X c, Xd X 60 psi = Feet of Fluid Column x s 2.307 Feet of Fluid PSX 2307 s VISCOSITY CONVERSION: Centipoise Kinematic (Centistokes) = ; Absolute (Ib/hr Ft} = Centipoise X 2.42 Absolute (Ib/sec Ft) = Senmperee sn mare danenentchene dsleinads: | { | HOT WATER COIL VERTICAL BLOW CONDITION WATER 200°F ENTERING —_ sn = fs MODEL # EA WTD MBH CFM FT GPM P.D. | 10 434.1 7176 99 86.8 40° 20 379.0 7095 91 37.9 /ATER3180°F: 42-WV 30 341.1 7004 86 22.7 10 372.6 7310 110 74.5 15. 60° 2059324.0 °.72355°104 = 32.4.7 2.62 30 291.6 7181 100 19.5” to peed 10 506.5 9540 90 101.3 24.7 asad 40° 20 442.2 9513 88 44.2 6.0 °378.029338) 49-wv 30 398.0 9365 80 26.5 18 '340.2>9264 10 434.7 9770 103 87.0 185 365.4% 60° 20 378.0 = 9660 3 98. =37.8 233.72 30 340.2 9614 94 227 1.3 1285.73595138 10 305.5 5340 95 61.1 5.0 (262.2%5263 40° 20 266.7 5288 90 267 9 zen 2seey HWV 30 240.1 5243 85 16.0 4 205: 6 290 10 262.2 5442 107 524 3.5 & 60° REOREEE28 05398 101228 30_205.2 5355 97 10 357.7 5902 99 0°20: 312.4 5818 91 HWV 30 281.1 5768 86 340 10 307.0 6020 110 60° ERORNe67,0391595839 043 0) 40.; 902 99 10 444.8 6521 107 40° 20 388.4 6405 98 HWV 30 349.6 6362 93 420 10 381.8 6637 117 60° 2OMEES 3209655) oy 30 298.8 6387 95 10. 517.2 9662 91 40° 20 «451.6 9616 88 HWV 30 404.4 9467 80 490 10 443.9 9895 104 60° 20 SUG; Omen (OSMEESO geo. 5 30 347.4 9718 94 23.2 4 Oe 54 gee. 434 278.5 TWV-400 TERING®S4 WATER 160°F ENTERING MOTOR @ baie a AIR CFM FT GPM P.D. HP RPM 6977 84 65.6 11.0 6902 78 285 20 6847 74 17.1 8 i 1140 2 7031 88 142 4 9338 78 765 143 9246 73 333 27 ~ ~ t 1140 63.4 10.3 9494 87 276 19 9457 85 166 8 5166 77 40.7 22 5156 76 200 5 511572 120 3 3 1140 5329 94 382 19 4 45288 90 166 4 } 5263 87 100 2 5690 84 540 39 5684 78 234 7 5650 75 141 93 3 1140 5880 97 448 27 4 5824 92 195 5 5802 89 117 2 6325 90 672 26 6258 84 292 5 621080 175 4 yay 6466 102 557 19 @ 5242.3 6399 96 24.2 4 ) BHi218.0 6362 93 145 2 $440 390.6 9440 78 78.1 35 339.6 9346 73 340 6 f9H305.7 9300 70 204 3,1 1140 9323.8 9672 92 647 24 2 281.7 9616 88 282 5 253.6 9570 85 169 3 For Other Conditions of Entering Water Temperatures, Water Temperature Drops (T.D.) and Entering Air Conditions, refer to Chart |CW-96. THE WATER SIDE s Recirculating system pressures represent an accumulation of the friction losses through the piping plus the head loss through the coil of the unit heater and system components. System pressures will vary depending Upon the. speed or velocity of the water through small or large pipe areas, length and circuiting of the system, type of pipe, boiler circuiting and the circuiting of the hot water coil in the unit heater. _ Diversity load factors should be considered- where room internal heat gains or external solar exposures require individual unit heaters to have reduced load demand and correspondingly less water flow. Careful consideration should be given size of the pump and piping for reduced flow conditions. Recirculating water systems to unit heaters should have feeds from the supply main to match the heater coil sepentine circuiting connection locations and corresponding exit connections to the return main. Each heater piping should be properly air vented, equipped with water flow balancing cocks and shut off gate valves in each supply and return connection leg to the main. Provide adequate balancing cock to each heater water supply connection plus shut-off valving for each supply and return pipe connection in case of repair or emergency protection of the heater. a Page 10 Farts The following GPM values are charted against drops of 5 feet and 10 feet, per 100 feet of line size. Schedule 40 Pipe SIZE 5 ft(GPM) 10 ft(GPM) % 3 % 1 1% 1% 2k 3% V1 2.0 4.4 85 17.5 27 50 83 145 210 290 1.6 3.0 6.5 12.5 26.0 39 73 120 220 300 430 oe Copper Tubing TUBE OD 5 ft(GPM) % ” 1.0 ’* % 12 % % 45 1 1% 9.0 1% 1% 16.0 1% 1% 24 2 2h 50 2k 2% 91 3 3% 160 3% 3% 225 4 320 4h pipe sizes at pressure 10 ft(GPM) 1.4 26 6.8 14.0 24.0 36 75 135 230 330 : 475 C GLYCOL SOLUTIONS & HEAT TRA 2R FLUIDS Glycols mixed with water are frequently applied to unit heater systems for freeze protection of the systems piping and components. The water/glycol solution may be varied in Percentages for the desired freeze point. Slightly higher viscosities combined with some change in specific heat and specific gravity of the water/glycol solution may require the system to handle a small increase in flow or minor adjustment in heat transfer surface area. High Temperature Heat Transfer Fluids that are not miscible with water are available up to at least 600°F. Special consideration should be given to the fluid temperature limits from waste heat or hot stack recovery applications when circuited directly to copper surfaces and standard unit heaters. TYPICAL SPECIFICATIONS Unit heaters shall be of the propeller fan types based on standard tests and rating procedures as recommended by ASHRAE and Air Moving and Conditioning Association. Each unit heater shall be capable of providing the air volume (CFM), air temperature rise (°F) load capacities in BTUH or MBH, motor characteristics and air throw distribution as so indicated by the project plans and specifications. The motor and fan assembly resiliently mounted shall be designed for on-off cycling or continuous duty. Motor and fan assembly to be removable for ease in heater maintenance. Heater coils to be of the extended fin surface with minimum of .030” copper tube wall thickness with maleable iron or steel manifold headers. Coils are to be factory tested prior to assembly to unit. Horizontal blow units to have multiple and individually adjustable air discharge louvers. Vertical blow shall have discharge openings and optional cone nozzles as specified. Unit heaters shall be as those by the Coil Company, Colwyn, Pennsylvania 19023. PRODUCT WAR ‘'Y & INFORMATION Heater coils are warranted for one year from date of shipment against mechanical defects that originated during manufacture. Motors and miscellaneous products that are sold with unit heaters have their respective manufacturers warranty. No warranty may exist on any product or part, unless all invoices are paid within 30 days from date of shipment. The product and system description and all information is presented in good faith, but because we cannot control or anticipate the many conditions under which this information and product may be applied, no warranty is expressed or implied. HEATER CONTROLS Motors are standard for single speed control or reduced speed control for varying space temperature conditions. Wiring should be in accordance with the best practices for one of the following installation options. 1. Single Phase: Manual on-off starter 2. Single’ Phase: Manual on-off starter with room thermostatic control 3. Single Phase: Manual on-off starter with room thermostat and reverse acting controller 4; Single Phase: Manual on-off starter with three position selector switch or thermostatic control 5. Single Phase: Manual on-off starter, speed control and thermostatic control 6. Three Phase: Manual on-off starter 7. Three Phase: Manual on-off starter with thermostatic control and limit controller 8. Magnetic starter control with thermostatic control for operating several heaters. 9. Overload protection recommended for each motor. Where thermostatic control is applied, the wiring harness and control should be adequate for the system load characteristics. THE STEAM SIDE The two pipe system, one for steam supply connection to the heater coil plus the second connections from the coil to the condensate return are recommended and widely applied for unit heaters and steam coils. Piping arrangements should utilize swing joint steam supply and condensate return connections to the unit heater thus avoiding thermal and flow stresses to each heater coil element. To avoid drip from the steam main through the heater element, connections should be made from the top of the main. Condensate lines should be positioned vertically downward at least 12 inches, prior to lateral pitch to strainers and traps plus another 6 inches vertical dirt leg or a total vertical leg of 18 inches. Avoid reducing piping size from unit heater element connection through strainers, check valves, traps, gate valve and hardware. ‘ Modulating steam control valves which vary the temperature and pressure of the steam and the output of the coil are not recommended for single tube unit heater cores. Steam modulating valves are applicable with double tube, non freeze or inner distributing coils. Provide shut-off valves on the steam supply side and-in the condensate path downstream of the trap. Steam traps function on pressure differentials when the steam has released its latent heat for the purpose of maintaining temperature of the heat user. Condensate is prevalent when the steam has released its heat, therefore in unit heater applications the steam trap should have a capacity of at least three times the accumulated loads of the heat transfer coil, line and hardware losses related to temperature, BUH and pounds condensate per hour. ___ APPROXIMATE FLOWS (LBS/HR) TWO PIPE STEAM SYSTEMS sc4 PIPE LOW PRESSURE VACUUM MEDIUM PRESSURE HIGH PRESSURE SIZE MAX 15 PSIG STEAM MAX 30 PSIG STEAM MAX 150 PSIG STEAM INCHES STEAM CONDENSATE STEAM CONDENSATE STEAM CONDENSATE SUPPLY RETURN SUPPLY RETURN SUPPLY RETURN % 30 280 65 365 300 900 1 55 490 125 730 550 1750 1% 110 850 280 1530 1230 3700 1% 175 1350 435 2500 1700 6100 2 335 2800 880 5000 3400 12300 2% 540 4700 1460 8400 -__5200 20000 3 960 7500 2650 15300 9400 37000 3% 1400 11300 4000 22700 13100 55000 4 2000 15500 5600 32200 19200 75000 LINE LOSS Ss 5 2.0’ 1.0° 5.0° : 2.0° PER 100° (FEET OF WATER) . SYSTEM MAX LOSS 1.0° 1.0° 10.0° 5.0° 25.0° 20.0' Page 11 WORIZONTAL BLOW NOTES: (HORIZONTAL BLOW) (1) Coil connection sizes female thread (2) Steam supply at top, hot water supply at bottom HORIZONTAL BLOW COIL CONNECTIONS FREE BLOW (ft) __ APPROX. MODEL # H w oD TOP _ BOTTOM HEIGHT THROW _WT.LB. 12 "1 12 10 1 1 8 18 15 19 13 16 13 1% 1% 8 18 28 29 13 16 13 1% 1% 8 20 28 38 15 18 14 1% 1% 8 20 34 39 17 20 14 1% VW 10 30 . 45 46 15 18 14 1% 1% 9 22 34 53 19 22 16 1% 1% 12 35 50 59 17 20 14 1% 1% 9 22 45 — eS 66 21 24 18 1% 1% 14 36 70 69 17 20 15 1% 1% 12 30 52 80 23 26 18 1% % 16 40 77 92 19 22 16 1% 1% 12 40 54 101 21 24 18 1% 1% 12 35 72 112 27 31 20 2 2 16 35 130 140 23 26 18 1% 1% 13 50 80 165 23 26 18 1% 1% 14 50 80 172 31 35 23 2 2 18 60 154 207 27 31 23 2 2 14 70 140 270 31 35 26 - 2 2 15 65 168 300 31 35 26 2 2 16 75 168 342 35 35 26 2 2 15 60 168 382 35 35 26 2 2 18 70 230 Free blow louvres . T= Three cone NOTES: (VERTICAL BLOW) (1) M = Mounting heights (feet approx.) (2) S = Air spread (feet approx.) (3) Coil connection sizes male thread (4) Steam supply at top, hot water supply at bottom VERTICAL BLOW. COIL ADJUSTABLE SINGLE THREE CONE FOUR APPROX CONNECTIONS FREEBLOW — LOUVERS CONE CONE ; CONE wT. MODEL# HD TOP BOT‘OM MS CV _ M __S CV M S$ -C¥V-M Se CV MS LBS) 4 8 25 1% M 10 20 8 12 #15 #10 10 2 ..4 10 2-* 7 8 28 40 6 12 25 % M 1125 868 «615 18 10 10 30 7 11 «28 7 8 30 50 she, 9 14 25 % 1M 11 300 9 «©6170 «20011 100s: 380 8 11 30% 8 9 40 56 1 1535 1% 1 14 35 9 22 2 11 «112 ~«35 6 12 38 8 9 45 82 13 15 38 1% 1 18 40 10 26 30 13 «14 «445 9 14:45 9 11 45 82 15 15 35 1% 1 20 45 #10 2 30 13 #20) «45 9 16 50 9 13 6 90 20 16 35 1% 1 20 45-4 27 30 15 20 45 9 1 55 9 13 65 100 26 1635 2 1% 24,55 13, 324018 = S55 10 S17 SS 10S 13S 70122 29 17 44 2% 1% 22 40 #13 30 35 #18 #420 40 #10 #16 «655 )=«©610 13 60° 162 29H 21 44 2% 1% 175 34 21 44 2% 1% 30 60 13 40 50 18 28 60 10 18 70 10 13 85 162 34H 44 2% 1% 175 42 21 44 2% 1% 35 70 13 40 60 18 2 70 10 18 80 10 13 90 184 42H 44 2% 1% . 210 49 21 44 2% 1% 35 70 13 45 60 18 35 70 10 19 80 10 16 90 200 49H 44 2% 1% 210 Above dimensions are approximate. Contact factory for specific data, demensions, & special duty coil & heater applications. Page 12 COIL COMPANY INC. 125 South Front Street, Colwyn (Darby), PA (USA) 19023 215-461-6100 TOLL FREE 800-5: 23-7590 tl SIN rN aah: at a nn eatin es sasili bbb dace bbbiedastainnstibath sisainsestiilitnenen. State of Alaska N Steve Cowper, Governor Alaska Energy Authority A Public Corporation November 7, 1989 Mr. Alex Tatum, Superintendent Kashunamiut School District 985 KSD Way Chevak, Alaska 99653 Dear Mr. Tatum: ui Enclosed for your signature is a revised copy of the Chevak Waste Heat Agreement. We have incorporated the changes in the document requested by the school district and by AVEC. Please sign notarize and return all three copies of the agreement. We will solicit a signature from AVEC and return a copy of the agreement with original signatures for your files. If you have any questions about this matter, please call me at 561-7877. Thank you. i I. ki Ceupif (Aun David “a My Maes f Director of Rural Projects Enclosures as stated. cc: Gary Smith, Alaska Energy Authority Sue White, Alaska ka Ene caer PO. Box AM Juneau. Alaska 99814 (907) 465-3575 x PO. Box 190869 701 East Tudor Road Anchorage, Alaska 99519-0869 (907) 561-7877 Ow yh February 27, 1989 Mr. Mark E. Teitzel Assistant General Manager Alaska Village Electric Cooperative 4831 Eagle Street Anchorage, Alaska 99503-7497 Subject: Chevak Waste Heat Design Dear Mr. Teitzel: I have received your letter of 2/16/89 concerning Chevak, and I am at this time somewhat discouraged by what appears to be history repeating itself. Every time we get into the mode of design review, a relatively simple design is repeatedly modified with additional layers of complex- ity, until the original design philosophy has been lost. The unfortu- nate Alaska Village Electric Cooperative (AVEC) specified, Power Author- ity installed "series/2-pass" configuration of two horizontal core radiators with a step controller is a clear example of this. It is my firm belief that in order to get these systems to work reliably with little maintenance needed over an extended period, they must be kept very simple and basic. Operator involvement must be avoided or kept to an absolute minimum, and if such involvement becomes necessary, the complexity must match the capability of the ever-changing local operations personnel. Once installed on an existing facility, the big picture must still appear simple and straight forward to the operator and to the maintenance personnel, and in this area I feel that previous installations have failed miserably. After reading your letter and after reviewing recent operational prob- lems in Savoonga and Chevak with Mr. John Lyons, I hereby propose that we start all over in Chevak and develop a reliable and yet very simple design. It appears obvious that the snow problems encountered in Savoonga warrant a complete reevaluation of the way we design cooling systems for intermittent service in areas with blowing snow. Evidently, the radiators have to be mounted as high as possible, and it would also be helpful, if the radiator design was well suited for operation in snow. As illustrated in Chevak, we cannot rely on the operator to clear snow away from the radiator. What I will be proposing to you will be a design, which may seem unusual to you; yet it is a design which, due to its simplicity, has proven itself in some of the least maintenance capable communities in Alaska. 5110/944(1) My proposal is as follows: 1. All radiators in Chevak be located on a steel framework on top of the module, 2. 3 ea. circular core radiators in up-blast configuration be used for engines #1 and #2, and the existing MWC-86 or a ternatively 3 ea. additional circular core radiators be used for engine #4. The circular core radiators will have 1 or 1-1/2 hp, single speed, 3-phase motors with completely independent controls on three different circuit breakers. These radiators will be sized to provide adequate cooling for a Cat 353 at full load on a 40 degree day with only two radiators in service. The radiators will have a "hat" to reduce the a mount of snow, which accumulates on the radiator. 3. The heat exchanger be located in the radiator plenum in the module, thereby completely eliminating the need for a platform on the Butler building. 4. The two systems be kept completely independent, thereby eliminating the need for several by-pass valves and additional expansion tank components, which the local operator will be unable to utilize anyway. 5. The existing shell and tube heat exchangers be removed and the existing AVEC heating system be connected to the new flat plate heat exchanger with appropriate provisions to allow for stand- alone operation of AVEC's heating system in case of a line break on the line to the high school. I can mention to you that very similar cooling systems are working with little or no maintenance in Atka, Diomede, White Mountain, Golovin, Koyukuk, Birch Creek, and Nikolai. I am attaching a spec. sheet on the radiators, which in reality are down blast unit heaters. Please note that these unit heaters are sold as radiators by Young; a phone call to Young confirmed my suspicion that they are identical to Young's unit heaters. I have used other manufacturers such as Dunham-Busch and Coil Company, and my preference is for Coil Company because of the lower pressure drop in their design. We have to date not experienced a single motor failure, and due to the circular, brazed tube design of the core, I certainly do not expect to see any core failures. Another obvious advantage is that these radia- tors weigh approximately 200 Ibs. including the motor and will fit nicely in a Cessna 207, With the motor, fan and other components removed, they can be handled by one man (I have tried it, and even though it is a chore, it certainly is no comparison to handling a core from a horizontal or vertical core radiator!). The motor is a standard (quiet, 78 db(A)) 1140 rpm 3-phase motor costing about $200 and weighing in at less than 50 Ibs. 5110/944(2) Page 3 Please discuss this proposal with your Operations Department and feel free to contact me at 261 7221 if you have any questions or comments. Sincerely, (bere Peter N. Hansen, P.E. Project Manager PNH: it Attachments as stated 5110/944(3) February 27, 1989 Mr. Mark E. Teitzel Assistant General Manager Alaska Village Electric Cooperative 4831 Eagle Street Anchorage, Alaska 99503-7497 Subject: Chevak Waste Heat Design Dear Mr. Teitzel: I have received your letter of 2/16/89 concerning Chevak, and I am at this time somewhat discouraged by what appears to be history repeating itself. Every time we get into the mode of design review, a relatively simple design is repeatedly modified with additional layers of complex- ity, until the original design philosophy has been lost. The unfortu- nate Alaska Village Electric Cooperative (AVEC) specified, Power Author- ity installed “series/2-pass” configuration of am horizontal core radiators with a step controller is a clear example of this. It is my firm belfef that in order to get these systems to work reliably with little maintenance needed over an extended period, they must be kept very simple and basic. Operator involvement must be avoided or kept to an absolute minimum, and if such involvement becomes necessary, the complexity must match the capability of the ever-changing local operations personnel. Once installed on an existing facility, the big picture must still appear simple and straight forward to the operator and to the maintenance personnel, and in this area I feel that previous installations have failed miserably. After reading your letter and after reviewing recent operational prob- lems in Savoonga and Chevak with Mr. John Lyons, I hereby propose that we start all over in Chevak and develop a reliable and yet very simple design. It appears obvious that the snow problems encountered in Savoonga warrant a complete reevaluation of the way we design cooling systems for intermittent service in areas with blowing snow. Evidently, the radiators have to be mounted as high as possible, and it would also be helpful, if the radiator design was well suited for operation in snow. As illustrated in Chevak, we cannot rely on the operator to clear snow away from the radiator. What I will be proposing to you will be a design, which may seem unusual to you; yet it is a design which, due to its simplicity, has proven itself in some of the vanst 2 Rowe capable communities in Alaska. 5110/944(1) My proposal is as follows: 1. All radiators in Chevak be located on a steel framework on top of the module, 2. 3 ea. circular core radiators in up-blast configuration be used for_ engines #1 and #2, and the existing MWC-86 or alternatively 3 ea. additional circular core radiators be used for engine #4. The circular core radiators will have 1 or 1-1/2 hp, Single speed, 3-phase motors with completely independent controls on three different circuit breakers. These radiators will be sized to provide adequate cooling for a Cat 353 at full load on a 40 degree day with only two radiators in service. The radiators will have a "hat" to reduce the a mount of snow, which accumulates on the radiator. 3. The heat exchanger be located in the radiator plenum in the module, thereby completely eliminating the need for a platform on the Butler building. 4. The two systems be kept completely independent, thereby eliminating the need for several by-pass valves and additional expansion tank components, which the local operator will be unable to utilize anyway. 5. The existing shell and tube heat exchangers be removed and the existing AVEC heating system be connected to the new flat plate heat exchanger with appropriate provisions to allow for stand- alone operation of AVEC's heating system in case of a line break on the lfne to the high school. I can mention to you that very similar cooling systems are working with little or no maintenance in Atka, Diomede, White Mountain, Golovin, Koyukuk, Birch Creek, and Nikolai. I am attaching a spec. sheet on the radiators, which in reality are down blast unit heaters. Please note that these unit heaters are sold as radiators by Young; a phone call to Young confirmed my suspicion that they are identical to Young's unit heaters. I have used other manufacturers such as Dunham-Busch and Coil Company, and my preference is for Coil Company because of the lower pressure drop in their design. We have to date not experienced a single motor failure, and due to the circular, brazed tube design of the core, I certainly do not expect to see any core failures. Another obvious advantage {s that these radia- tors weigh approximately 200 lbs. including the motor and will fit nicely in a Cessna 207, With the motor, fan and other components removed, they can be handled by one man (I have tried it, and even though it is a chore, it certainly is no comparison to handling a core from a horizontal or vertical core radiator!). The motor is a standard (quiet, 78 db(A)) 1140 rpm 3-phase motor costing about $200 and weighing in at less than 50 Ibs. 5110/944(2) Please discuss this proposal with your Operations Department and feel free to contact me at 261 7221 if you have any questions or comments. Sincerely, Peter N. Hansen, P.E. Project Manager PNH: it Attachments as stated 5110/944(3) CATALOG 14 1982 Supersedes Cat. No. 14-81 Young AV COOLERS for Compressed Air Aftercooling and General Purpose Water Cooling Patented U.S. Patent 2,504,798 2825 Four Mile Road @ Racine, Wisconsin 53404 Plants at: Racine, WI, Mattoon, IL and Centerville. IA ® Copyright 1982 YOUNG RADIATOR COMPANY YOUNG RADIATOR COMPANY ey Yo ung AV construction features AV Coolers are designed to perform efficiently and economically with minimum maintenance. Patented construction permits cool atmospheric air to circulate around the motor protecting it from radiant heat damage thereby insuring longer motor life (see Fig 3). Corrosion resistant materials, permanent high temperature bonding of tubes to manifolds and circular core design minimize stresses and guarantee dependable cooler performance. The circular heat transfer core (See Fig. 2) is contained between steel covers of slightly larger diameter than the core, providing space for free expansion and con- traction without stress or strain. The fan shroud is venturi-shaped to allow maximum fan efficiency. Welded steel, cadmium or zinc plated fan guards which provide necessary protection for vulnerable Parts of the unit and workmen in close proximity to the cooler are standard equipment. NEMA frame motors are used. All motors are Totally Enclosed Fan-On-Shaft Air-Over type specifically designed for these units. : Fig. 3 AV Coolers function efficiently whether mounted horizontally or vertically. Coolers may: be mounted horizontally for vertical air discharge either upward or downward. Four 1/2 in. holes with mount- ing nuts (13 NC thrd) welded in place are furnished in the steel cover opposite the fan shroud. Fig. 4 and Fig. 5 are close-up views of the fins, tubes and manifolds used in the core. The tubes are high temper- ature brazed to the manifolds for long life. Aluminum fins are per- manently bonded by mechanical means to corrosion resistant copper/ copper alloy tubes, insuring maximum heat transfer. AV tecnnical data/piping diagram Young TABLE 1 AV TECHNICAL DESCRIPTION = Motor Sound Level Water Shipping Model Flow Power, hp Rotation, rpm dB (A) @7 ft Volume Weight |__efm 10 30 | 10 30 | 10 | 30 gal. Ib. AV-60S 815 1/6 1/6 1075 1140 55 57 0.4 67 AV-80S 1185 1/6 1/6 | 1075 1140 55 57 0.6 80 AV-105S 1620 1/6 1/6 1075 1140 60 62 0.6 87 AV-140S 2030 1/6 1/6 1075 1140 63 65 0.8 95 AV-165S 2335 1/6 1/6 1075 1140 68 70 0.9 120 AV-210S 3085 1/4 1/4 1075 1140 68 70 1.2 130 AV-260S 3500 1/4 1/4 1075 1140 69 71 1.3 180 AV-350S 4710 1/2 1/2 1075 1140 71 73 2.0 237 AV-480S 6470 3/4 3/4 1075 1140 74 76 3.0 300 AV-600S 9600 = 1% _ 1140 _- 78 3.4 375 NOTE A: Standard motors are totally enclosed air-over type. Totally enclosed explosion-proof motors are avail- able at additional cost. AV Coolers for compressed air aftercooling can be mounted in any of the positions shown. Separators should COOLING AIR FLOW tif FROM COMPRESSOR TO RECEIVER SEPARATOR FROM COMPRESSOR Yoner. BALL FLOAT TRAP SEPARATOR NOTE B: To estimate sound level at distances other than 7 feet from cooler, add 6 dB (A) for each halving of distance or subtract 6 dB (A) for each doubling of distance. Sound levels shown are an average of several measurement points. be used as shown and moisture traps and blow off valves to eliminate condensate are recommended as required. NOT LESS THAN "| CEILING FROM COMPRESSOR TO RECEIVER COOLING AIR FLOW COOLING AIR FLOW To RECEIVER > SEPARATOR Fig. 6 A2NTI4 | Yo ung AV water cooling capacity | | AV Coolers are superior for low water flow conditions allows for ceiling mounting which provides more room | in situations requiring air cooling. The units are suit- for vital equipment on the floor and also increased | able for small engines which cannot use large radiators. potential for heat recovery to maintain room air Multiple mounting points allow the AV Coolers to be temperature. placed in vertical or horizontal positions. The design TABLE 3 | oe AV CAPACITY FACTOR | Flow | AV-60S | AV-80S | AV-105s | Av-140s | av-165s | av-210s | Av-260s | av-350s | Av-asos | Av-600S | oo Water |EG | Water | EG Water | EG | Water | EG | W: EG | Water| EG | Water | EG| Water |EG| Water| EG | Water | EG a |oa2 CONSULT FACTORY WHEN 2 140 137) 54 157] 63 1581 75 a3 SELECTIONS FALL IN THIS AREA 3 | 44 [41| 61 [61| 71 | 66] 87 97 [eay a 12 15 4 | 47 [44] 65 [64] 77 [7.1] 95 | 88] 10 | 98] 13 [12] 14 [43] 17 21 24 5 | 49 |[46| 69 |a7| 82 [77[10_ [93/41 [10 [14-43] 15 [14[ 19 [ae| 23 27 6 | 51 |4e[ 72 [71] 85 | 79[10 | 98[ 1 [11 | 15 [13] 16 [15] 20 [19] 25 | 23[ 30 8 | 5.4 [5.1] 76 [74] 91 [985/11 [10 [12 [11 | 16 [14[ 18 [16] 22 [21] 28 [26] 34 | 31 1o | 56 [5.3] 7.9 |78| 95] 89/11 [11 [13 [12 [| 17 [15] 19 [a7| 24 [22] 30 | 28] 37 | aa 13 | 59 [55| 83 [a1{10 [93/12 |11 | 14 |13 | 18 | 16{ 19 |20| 26 [24] 33 | 30] 40 | 37 16 | 60 [5.7[ 86 [a4[10 [97/13 [12 [14 [43 | 19 [17[ 21 [20] 27 [25] 35 [32] 43 | 40 20 89 [a7{10 [10 [13 |12 [15 [14 | 20 [1s] 22 [21] 29 [27| 37 |34| 46 | 43 25 14/13 [ 16 [15 | 20 [19| 23 [22] 30 [28] 39 | 36] 49 | 45 30 16 [15 [ 21 [20] 24 [22] 31 [29] 41 | 38] 51 | 48 35 22 [20] 25 |23] 32 [30] 42 [39] 53 | 50 40 22°21 iz 23| 33 [a1] 43 [40] 55 [51 50 34 [32] 45 | 42] 58 st] _ 60 | FLOW RATES IN THIS AREA a7 | 44] 60 |56 79 | EXCEED MAXIMUM ALLOWED 61157 NOTE F: In TABLES 3 and 4 column heading EG refers to a solution of 50% water and ethylene glycol. TABLE 4 Water AV WATER PRESSURE LOSS psi Flow | AV-60S AV-80S AV-105S | AV-140S AV-165S | AV-210S | AV-260S | AV-350S | AV-480S | AV-600S Ent Water | EG | Water | EG | Water | EG | Water | EG | Water | EG | Water| EG | Water | EG | Water| EG | Water | EG | Water |EG 1 0.1 CONSULT FACTORY WHEN 2 0.1 10.1] 01 Jo1] 01 Jo1] 01 0.1 SELECTIONS FALL IN THIS AREA | 3 0.1 {0.1} 0.1 [0.1] 0.1 [0.1] 0.1 0.1 [0.1] 01 0.1 0.1 4 0.1 [0.1] 0.1 [0.1] 0.1 [01] O01 [O41] 01 [O01] O14 [0.1] 0.1 [0.1] 0.1 0.1 0.1 | 5 0.2 {0.2| 0.1 {0.2} 0.1 [0.2] 0.1 [0.1] 0.1 |0.1) 014 [0.1] 0.1 [0.1] 0.1 [0.1] 0.1 0.1 6 0.2 {0.3{ 0.1 [03] 02 102] 01 [02] 01 102] 01 10.1] 0.1 [0.1] 0.1 [0.1] 0.1 O01} 01 8 0.4 [0.5] 0.2 {0.4) 03 [04] 02 {03} 0.2 |03] 0.1 [0.1] 0.1 [0.2} 0.1 [0.1] 0.1 $0.1] 0.1 [0.1 10 0.6 {0.8} 0.3 |0.6] 05 {06] 03 [04] 03 |04] 0.2 10.2] 0.2 |0.3] 0.1 [0.1] 0.1 {0.1} 0.4 [0.1 13 1.0 [1.3] 0.4 |0.8] 07 [10] 04 |06] 04 [06] 0.2 |0.3} 0.3 [0.4] 0.2 |0.2] 0.1 |0.2] 0.1 |0.2 16 1.4 11.9] 06 [1.2] 1.1 [14] 06 |08/ 06 [0.8] 0.3 10.5] 0.4 |0.6] 0.3 |0.3] 0.2 |0.2| 0.2 |03 20 0.9 }1.8} 16 [21] 09 {1.2] 09 | 1.2] 05 |0.7] 06 [0.8] 0.4 |0.5| 0.3 [0.3] 0.3 [0.4 25 1.4 11.8] 1.4 [ 1.8} 08 [1.0] 09 |1.2] 0.6 {08} 0.4 |05] 04 |05 r 30 1.9 [25] 1.1 41.4) 1.3 11.7] 0.9 [1.1] 05 10.7} 06 [0.7 | 35 4.4 $VOt 1.7% [22 t.2-11.54:-67 (OS O7 11.0 40 V8 |23} 23 $2.7}: 1.5 [2.04.09 [1.21°-0:9. |.1.2 50 i 2.3/3.1] 1.4 11.8] 1.4 11.8 60 _| FLOW RATES IN THIS AREA 1.9 25] 19 [24 79 | EXCEED MAXIMUM ALLOWED 24 132 AV dimension/water selection Young FAN GUARD 4 MTG HOLES | .5-13 NC THRD All dimensions are in inches. Certitied dimension drawings are available for installation. Fan guard screen conforms to OSHA. Finish is gray semi-gloss enamel. Maximum Operating Temperature 365F Maximum Operating Pressure 150 psi Test Pressure 300 psi TABLE 5 AV-60S 25.88 11.75 AV-80S 25.88 14.50 6.50 14;75 AV-105S | 29.88 15.00 6.50 13.50 1.00 AV-140S | 32.75 |. 14.25 6.75 2.50 8.00 | 15.00 1.00 2.13 1.50 | AV-165S_ | 37.25 T 14.38 6.75 3.38 8.00 17.13 1.25 2.13 2.00 | AVv-210S | 37:25 | 16.00 9.38 3.38 9.00 17.13 1.25 2.13 AV-260S | 41.75 16.00 9.38 3.75 9.00 19.25 1.25 2.13 Ee | 43.25 17.63 12.00 3.88 12.00 19.75 1.50 2.38 | AV-480S | 47.38 19.13 14.63 4.50 11.50 21.50 1.75 2.50 | AV-600S 51.88 21.13 15.88 5.25 14.00 23.75 1.75 2.50 AV water selection example 1. Calculate CAPACITY FACTOR required: heat load CAPACITY FACTOR =“Tmactamb heat load = Btu/min Tmax = maximum water temperature, F Tamb = ambient air temperature, F . Select AV model with an adequate CAPACITY FACTOR for WATER FLOW from TABLE 3. 3. Determine WATER PRESSURE LOSS from TABLE 4. Select AV to remove 900 Btu/min from 20 gpm of 50% eth- ylene glycol entering at 170F in an ambient air temperature of 110F. 1. a 900__ i70-110 > Select AV-210S rated 18 at 20 gpm for EG (50% water and ethylene glycol) from TABLE 3. CAPACITY FACTOR = Determine WATER PRESSURE LOSS of .7 psi from TABLE 4. NOTE G: Ethylene glycol solutions at Tmax less than 170F may result in unreliable CAPACITY FACTORS. Refer such applications to Factory. NOTE H: If the value of Tmax-Tamb is less than SOF, selec- tion may not be reliable. In this case, consult Young Radiator Company Representative or Factory. Form No. 1301H Unit Heaters For Steam and Hot Water Applications Horizontal and Vertical Discharge Weems Wwes e2=wwe oe COMMERCIAL PRODUCTS DIVISION Products That Perform...By People W/ho Care AED ae we AD Be Dee H model C, CA SOLID STATE SPEED CONTROL OPTIONS Adjustable solid state speed controllers are available for unit sizes 100 through 850. Speed controllers are shipped loose and feature adjustable trimpot for minimum speed selection. Speed controllers are shipped in a 2” x 4” J-box with face plate. MOTOR OPTIONS UNIT EXPLOSION PROOF (1) TOTALLY ENCLOSED (2) EXPLOSION PROOF (2) SIZE VOLTAGE HP RPM AMP VOLTAGE HP RPM AMP VOLTAGE HP RPM AMP 100 115/1-60 Ye 1725 3.0 Consult Factory N/A 175 115/1-60 Ys 1725 3.0 Consult Factory N/A 250 115/1-60 Ye 1725 3.0 Consult Factory “N/A 300 115/1-60 Me 1140 3.0 ___ 200/230/460-3-60 1140 1.7/1.6/.8 _200/230/460-3-60 1140 ___1.7/1.6/.8 400 115/1-60 Ww) 1140 3.0 __ 200/230/460-3-60 1140 1.7/1.6/.8 _200/230/460-3-60 1140 __1.7/1.6/.8 500 115/1-60 Ve 1140 3.0 _ 200/230/460-3-60_ 1140 1.7/1.6/.8 _200/230/460-3-60__‘/ 1140 __1.7/1.6/.8 600 115/1-60 Me 1140 3.0 _ 200/230/460-3-60 1140 1.7/1.6/.8 _200/230/460-3-60 1140 __1.7/1.6/.8 700 115/1-60 Ve 1140 3.0 _ 200/230/460-3-60 1140 1.7/1.6/.8 _200/230/460-3-60 1140 __1.7/1.6/.8 850 115/1-60 Ve 1140 3.0 _ 200/230/460-3-60 _' 1140 1.7/1.6/.8 _200/230/460-3-60 1140 ___1.7/1.6/.8 1100 __115/230-1-60 ‘h 1140 8.0/4.0 _200/230/460-3-60__‘2 1140 2.2/2.0/1.0 _200/230/460-3-60 v2 1140 _2.5/2.4/1.2 1350__115/230-1-60 a 1140 8.0/4.0 _200/230/460-3-60_ _‘z 1140 2.2/2.0/1.0 _200/230/460-3-60 ‘2 1140 _2.5/2.4/1.2 1500 __115/230-1-60 ‘kh 1140 _ 8.0/4.0 _200/230/460-3-60_ 1140 ___2.2/2.0/1.0 _200/230/460-3-60__* 1140 __2.5/2.4/1.2 (1) Class 1, Group D; Class II, Group E, F, & G. (2) Totally Enclosed, Fan Cooled. (3) Class 1, Group D; Class Il, Group F & G. Consult factory for 575/3/60 applications. included. VERTICAL LOUVERS Four way air deflection can be attained with the addition of optional vertical louvers. All Horizontal Discharge Unit Heaters have individually adjustable horizontal louvers as standard. Vertical louvers are shipped loose for field installation. Removal of the top panel and installation of the vertical louvers is easily accomplished. Instructions are SPECIAL COILS For high temperature, high pressure systems coils may be constructed of .049” wall 90/10 cupro-nickel tubing and red brass headers for supply and return. Operating pressures up to 300 psi at 350° F may be accomplished with this option. PROTECTIVE COATINGS Waste water treatment facilities, paint booths, and many other such applications pose a particular threat to air moving equipment. Corrosive atmospheres are responsible for much premature failure of coils and sheet metal parts. Coils, fan propellers, and/or entire units may be ordered with a3 mil. thick “Libcote 7” baked phenolic coating for additional protection against these hazardous environments. DISCONNECT SWITCH Single phase units may be ordered with factory installed disconnect switch mounted in a 2” x 4” junction box on the back of the unit. THERMOSTATS (shipped loose for wall mounting) PART NUMBER CONTROL RANGE ELEC. RATINGS FUNCTION 009632A1 40°F-90°F 1.5A, 3.5A inrush at Low voltage SPDT makes contact for heating and/or 30 VAC cooling. 009634A1 56°F-94°F 6.0/3.0 amps at Line voltage contacts make on temperature fall. 120V/240V VERTICAL DISCHARGE UNIT HEATERS FEATURES Dunham-Bush Vertical Discharge Unit Heaters are available in ten sizes for steam or hot water heating, with capacities ranging from 133 EDR to 2490 EDR (based on 2 Ibs. steam pressure and 60°F entering air). They are designed for working pressures up to 150 psi. Entering hot water temperatures of up to 340°F may be used with hot water heating systems. Based on 200°F entering water 20°F drop, capacities ranging from 19 MBH to 427 MBH may be obtained. VERTICAL DISCHARGE UNIT DESIGN FEATURES MOTORS Standard motors are open frame and flange mounted. Motors on Models C175 thru C525 have permanently oiled sleeve bearings while motors on Models C650 thru C2400 have grease packed ball bearings. Motors 1/3 HP and smaller can be operated at reduced speeds by the addition of aspeed controller. All motors can be removed from the bottom of the unit, permitting installation close to the ceiling. — CONSTRUCTION The sturdy motor support cone and the spun steel top and bottom direct the air from the heating element to the fan, furnishing improved air flow and quiet operation while protecting the motor from excessive heat, dust and other impurities. HEATING ELEMENT Supply and return lines are located on top and bottom of the unit, approximately in line with each other, for ease of installation. All units are finished in beige baked enamel. ELEMENT The heating element fins are aluminum. Tubes are heavy copper expanded into fins to provide a positive and per- manent mechanical bond. The complete assembly is tested with air pressure under water and hydrostatically at 400 Ibs. psi. The C Model G is recommended for pressures up to 75 psi and temperatures up to 325°F. The C Model GA is recommended for pressures up to 150 psi and temperatures up to 340°F. GENERAL The double duty hanger support provides strong support for the units. There is no support strain on the piping. = MOTOR AND FAN DATA ,..5-1-60) UNIT SIZE TYPE HP RPM AMP FAN DIA (in) | 175 oop “Yeo 1550 1.14 10 300 oop ‘Yeo 1550 1.41 14 400 ODP "feo 1550 4.11 16 525 oop “Ye 1550 4.0 16 650 ODP “ 1075 3.5 20 900 Oop “s 1140 3.8 20 Optional motors are 1250 OoP Ye 1140 7.8 26 js ‘ : 1680 TEFC (1) Pi bape 11.0 26 — with Explosion C Model G, GA zoo | Tero) Mona go | oe mutation 2400 ODP (2) 1 1140 14.7 30 * See page 12. All motors are UL approved. (1) 115/230-1-60 (2) 115/208/230-1-60 AIR DELIVERY (Approximate-ft.) C Model G C Model GA MOUNTING HEAT SPREAD MOUNTING HEAT SPREAD WEIGHT UNIT SIZE HEIGHT DIAMETER UNIT SIZE HEIGHT DIAMETER Lb. 175 1 20 175 14 26 175 44 300 12 30 300 14 38 300 37 400 12 33 400 15 42 400 67 525 13 35 525 18 46 525 73 650 18 44 650 22 51 650 105 900 20 46 900 24 59 900 115 1250 24 56 1250 29 72 1250 197 1650 26 60 1650 35 74 1650 250 2000 31 69 2000 38 91 2000 350 2400 35 67 2400 41 93 2400 403 = 8B ot SUPPLY . | G ies as rE %e” DIA. MOUNTING HOLES Nee SECTION TOP VIEW BOTTOM VIEW Oar DIMENSIONS IN INCHES SIZE A B c D E F G H a) K C175 26%s 9% The 10%6 “he ea 1% Ths 6% 11%s C300 27% 10% os 14% Me Yeu 1% The 6% 12 C400 31% i Othe 1654s he S/o 1% 8% Bie 13"%he C525 31% 13 11"he 16% he on 1% B's Bie 13'%6 cés0 35% 13% 11s 20% he 1s 2 10'%6 Whe 15% C900 35% 17% 15"hs 20% he 1%s 2 10"hs Whe 15% C1250 [fs 41% 17% 15% 2676 % 1s 2 1256 11% 18% C1650 41% 21% 19% 2676 % 1s 2 12%hs 11% 18%/6 C2000 52% 23% 20% 30% 1% Vhs 2% 16% 15 23% 2400 52% 25% 22% 30% 1% the 2% 16% 15 23% Supply and return labeled for steam. Reverse for hot water applications. HOT WATER CAPACITIES ENTERING WATER TEMPERATURE UNIT = TEMP. NO. DROP 180°F 200°F 220°F 240°F MBH GPM _ LAT WPD| MBH GPM _ LAT WPD| MBH GPM LAT WPD|MBH GPM LAT WPD 10° 27.7 5.65 106 85] 34.0 7.28. 110 1.17]. 405 858 127 1.57] 466 9.50 137 1.85 C175G 20° 23.7 2.41 99 -17] 29.7 3.02 109 .26] 363 3.69 120 36} 426 4.30 131 48 1/40 HP 30° 19.9 135 93 03] 25.7. 1.83 103 .11] 32.2 230 113 -15} 38.7 2.63 124 22 1550 RPM 40° 15.6 .80 86 02} 21.4. 1.14 96 .05] 28.0 1.40 107 07} 34.8 1.77 118 10 557 CFM 50° 12.1 50 80 .01| 17.3 74 89.02] 24.0 -96 100 04} 30.8 1.25 111 .05 10° 485 9.90 105 1.05} 52.0 11.1 108 1.31] 70.4 149 125 2.12] 81.0 16.4 135 2.5 C300G 20° 40.9 416 98 -23} 464 4.72 103 .29] 62.4 634 118 49) 73.0 7.42 128 -64 1/20 HP 30° 33.8 230 91 08} 41.9 2.99 99 .14} 55.2 3.94 111 26} 65.9 4.48 121 -28 1550 RPM 40° 265 1.35 85 02} 37.2 1.99 94 .07} 47.6 255 104 +12} 58.9 3.00 115 15 1000 CFM___50° 19.3 79 78 .01| 326 1.4 90.04] 401 1.72 97 OS] 51.8 2.10 108 07 10° 63.0 12.8 102 1.9) 76.2 16.3 111, 2.9} 88.6 185 119 3.60]1021 20.6 128 4.05 C400G 20° 53.0 5.39 95 -37] 66.7 6.78 105 64] 80.1 814 114 86) 93.3 9.48 122 1.13 1/12 HP 30° 43.4 295 89 -10] 57.4 4.10 98 .26] 71.5 5.10 108 40) 84.8 5.77 117 -50 1550 RPM = 40° 33.9 1.73 83 03] 47.9 2.56 92.12} 62.9 3.36 102 -20} 75.9 3.87 111 25 1382 CFM___50° Ba? 9.76 .01| 38.4 1.65 86.06 | 54.4 2.33 102 11] 67.4 2.73 105 13 10° 77.8 15.9 103 1.65] 95.2 20.4 113° 2.53] 113.0 23.7 123 3.30/140.0 283 138 4.22 C525G 20° 66.6 677 97 -38] 83.9 853 107 .57/ 101.5 10.3 117 -80} 117.0 11.9 125 1.05 1/8 HP 30° 55.9 3.80 91 -18| 72.7 5.19 100 .24] 90.3 643 110 35] 106.4 7.24 119 45 1550 RPM 40° 445 2.27 85 09} 61.3 3.28 94 12] 78.6 4.21 104 -17} 95.5 4.87 113 22 1658 CFM __50° 33.81.38 79 .03] 503 2.15 88 .06| 67.5 289 99 .09| 845 3.42 107 11 10° | 111.3 23.0 103 3.60] 130.5 27.9 111 4.90] 154.4 32.4 120 640/179.3 36.2 130 ‘7.80 C650G 20° 94.0 955 97 -79| 114.9 11.7 105 1.15] 138.7 14.1 114 1.55]161.2 16.4 123 2.10 1/4 HP 30° 77.6 5.28 90 +30] 100.1 7.15 99.49} 123.5 881 108 -70}145.8 9.91 117 -98 1075 RPM 40° 60.6 3.10 84 -10] 84.5 4.53 93 .22]107.3 5.76 102 +30] 130.0 663 111 -50 2370 CFM __50° 44.21.80 77 05 | 68.9 2.95 93.10] 92.4 3.99 96 2511146 4.64 105 28 10° | 145.0 29.6 102 2.35] 175.7 37.6 111 4.20] 206.0 43.1 120 5.22/237.0 47.9 129 6.50 C900G 20° | 124.8 12.7 97 -64) 155.4 15.8 106.92] 186.1 18.9 115 1.25}2164 22.0 123 1.60 1/3 HP 30° |105.2 7.16 91 -32] 135.9 968 100 .30| 166.5 11.3 109 -51/197.0 13.4 118 -70 1140 RPM 40° 85.4 435 85 -15] 115.3 6.16 94 .12]145.8 7.80 103 -23]176.9 9.02 112 38 3160 CFM___50° 66.1 2.70 79 106 | 96.0 4.11 88.09 | 126.8 543 97 10|156.2 6.33 106 20 10° | 194.0 39.6 94 5.43 | 234.0 50.1 101 8.20] 273.0 58.0 108 10.8/3100 626 115 123 C1250G 20° | 168.4 17.1 90 1.27 | 206.9 21.0 96 1.85] 246.4 25.0 103 2.50]284.7 289 110 3.17 1/2 HP 30° |143.0 9.72 85 -51 | 181.1 12.9 92.70} 221.0 15.8 99 1.15]260.0 17.7 106 1.38 1140 RPM 40° {117.0 5.97 81 -23:} 154.1 7.71 87 =.30] 195.6 10.5 94 -54] 235.0 11.9 101 75 5250 CFM___50° 91.6 3.74 76 -13 | 128.0 5.48 83.251 168.0 7.19 90 24/210.0 8.51 97 42 10° | 261.0 53.6 100 5.65 | 320.0 68.5 110 8.30 | 368.0 78.9 117 11.7/432.0 87.3 127 13.9 C1650G 20° | 227.0 23.0 95 1.28 | 282.0 28.7 104 1.90 | 334.0 33.9 112 2.50/385.8 39.2 120 3.25 3/4 HP. 30° | 193.0 13.1 90 -53 | 246.0 17.5 98 .80} 300.0 21.3 112 1.15]349.0 23.7 114 1.22 1140 RPM 40° {157.8 8.03 84 -23 | 207.0 11.1 93.37 | 264.5 14.2 101 -58/311.0 15.9 108 -68 5980 CFM __50° |123.8 5.04 79 10 1170.8 7.30 87.19 | 231.0 9.91 97 30/274.0 11.1 103 40 10° | 362.0 73.8 102 12.3 | 409.0 87.5 107 16.4 | 496.0 106.0 117 23.0/544.0 109.9 123 27.6 C2000G 20° | 318.2 32.3 97 3.00 | 370.3 37.6 103 3.90] 452.7 46.0 112 5.45/5083 51.5 119 6.50 3/4 HP. 30° | 272.0 18.5 91 1.20 | 336.0 24.0 99 1.67] 411.0 29.3 107 2.60}472.0 32.1 114 3.5 1140 RPM 40° | 226.0 11.5 86 -60 | 296.0 15.8 94 .75|366.0 19.6 102 1.30]439.0 22.4 111 1.9 8040 CFM__50° {181.3 7.41 81 -30 | 258.0 11.1 90.40 | 327.0 14.0 98 60|405.0 16.4 107 1.20 10° {398.0 81.2 102 = 12.6 | 478.0 102.3 111° 17.3 | 548.0117.0 118 23.5/582.0 119.6 122 23.0 C2400G 20° {351.2 35.7 97 295 | 426.6 43.4 105 3.85) 500.9 50.9 113 5.40/556.8 57.6 119 6.90 1 HP 30° |302.0 20.5 92 1.35 | 378.0 27.0 100 1.60 | 453.0 30.8 108 2.40/522.0 35.5 115 3.00 1140 RPM 40° | 250.0 12.7 86 -69 | 326.5 20.2 95 .98| 406.0 22.2 103 1.40}485.0 24.7 111 1.70 8750 CFM __50° {204.0 8.32 82 38 | 277.0 11.9 89.43 | 360.0 14.7 98 -60|451.0 18.3 108 1.0 Conversion factors can be found on page 15. Based on 60° entering air temperature. 10 C model G é OPTIONS SOLID STATE SPEED CONTROL Adjustable solid state speed controllers are available for unit sizes 175 through 900. Speed controllers are shipped loose and feature adjustable trim pot for minimum speed selection. Speed controllers are shipped in a 2” x 4" J-box with face plate. g MOTOR OPTIONS UNIT TOTALLY ENCLOSED EXPLOSION PROOF (1) TOTALLY ENCLOSED (2) EXPLOSION PROOF (1) SIZE VOLTAGE TYPE HP RPM AMP | VOLTAGE HP RPM AMP VOLTAGE HP RPM AMP. VOLTAGE HP RPM_ AMP 175, 115/230-1-60 TENV % 1625 2.0/1.0 115-1-60 Me 1725 3.0 Consult Factory Not Available 300 115/230-1-60 TENV % 1625 2.0/1.0 115-1-60 ‘e 1725 3.0 Consult Factory Not Available 400 115/230-1-60 TENV % 1625 2.0/1.0 115-1-60 ‘te 1725 3.0 Consult Factory Not Available 525 115/230-1-60 TENV 1625 2.0/1.0 115-1-60 “ 1725 3.0 Consult Factory Not Available 650 115/230-1-60 TENV % 1140 4.0/2.0 115-1-60 % 1140 3.0 200/230/460-3-60 * 1140 1.7/1.6/.8 200/230/460-3-60 ‘ 1140, 2.5 900 115/230-1-60 TENV. ‘4 1140 4.8/2.4 115-1-60 % 1140 3.0 200/230/460-3-60 “ 1140 -1.7/1.6/.8 200/230/460-3-60 “ 1140 2.4 1250 115/230-1-60 TEFC % 1140 8.0/4.0 115-1-60 “ 1140 3.0 200/230/460-3-60 ” 1140 2.2/2.0/1.0 200/230/460-3-60 ’ 1140, 1.2 1650 115/230-1-60 TEFC % 1140 _10.0/5.0|115-230-1-60 1140 _11.0/5.5 | 200/230/460-3-60 % 1150 3.3/3.1/1.6 200/230/460-3-60 % 1150 3.0 2000 115/230-1-60 TEFC % 1140 _10.0/5.0|115-230-1-60 % 1140 _11.0/5.5 | 200/230/460-3-60 % 1150 3.3/3.1/1.6 200/230/460-3-60 % 1150, 2.8 2400 115/230-1-60 TEFC 1 1140 __14.0/7.0 |115-230-1-60 1 1140 __14.0/7.0 | 200/230/460-3-60 1 1140 4.0/3.8/1.9 200/230/460-3-60 1 1140 3.0 (1) Class 1, Group D; Class I, Group F & G. (2) Totally Enclosed, Fan Cooled. Consult factory for 575/3/60 applications. é DIFFUSERS, ANEMOSTATS A variety of options are available to attain desired air delivery with Vertical Discharge Unit Heaters. These include adjustable cone diffuser, radial louver diffuser, and 3 or 4 cone anemostats. All are shipped loose with complete instructions for installation. See page 13 for dimensions. SPECIAL COILS Special coils for use with high temperature, high pressure systems are available. Tubes will be .049” wall 90/10 cupro-nickel and supply and return header will be constructed of red brass pipe nipples suitable for pressures up to 300 psi at temperatures up to 350°F. PROTECTIVE COATINGS Waste water treatment facilities, paint booths, and many other such applications pose a particular threat to air moving equipment. Corrosive atmospheres are responsible for much premature failure of coils and sheet metal parts. Coils, fan propellers, and/or entire units may be ordered with a3 mil. thick “Libcote 7” baked phenolic coating for additional protection against these hazardous environments. THERMOSTATS (shipped loose for wall mounting) PART NUMBER CONTROL RANGE ELEC. RATINGS FUNCTION : 009632A1 40°F-90°F 1.5A, 3.5A inrush at Low voltage SPDT makes contact for heating and/or 30 VAC cooling. 009634A1 56° F-94°F 6.0/3.0 amps at Line voltage contacts make on temperature fall. 120V/240V 12 “20,000 to 950,000 BTUH COM URI? LIEATERS FOR SPACE HEATING EFFECTIVE TEMPERATURE CONTROL INITIAL COST SAVINGS OPERATING SAVINGS WIDE RANGE OF SIZES e HIGH EFFICIENCY RELIABLE PERFORMANCE FOR USE WITH © HEAT TRANSFER FLUIDS e GLYCOL SOLUTIONS e HOT WATER e STEAM COIL COMPANY INC. TERRA, Inc. 1900 W. 125 South Front Street, Colwyn (Darby), PA (USA) 19023 P. 0. ‘Hor sag. 4” TOLL FREE 800-523-7590 Anchorage, Alaska 99502 COIL UNIT HEATERS INTRODUCTION Horizontal Blow or Vertical Blow units are ideal for economically heating commercial, institutional storage, service, manufacturing and industrial building areas. The design, function and arrangement of the building structure and areas should be considered for optimum selections, operation and maintenance. Where variable space temperatures and air distribution are considered satisfactory, a fewer larger sized units may be applicable. Spaces where temperature and air distribution are critical, fewer smaller units should be considered. Horizontal Blow Heaters are ideal for suspended mountings where air distribution is not impeded. Generally, horizontal flow heaters should be arranged to satisfy the inside periphery of spaces with exposed walls. Vertical Blow Heaters for variable height mountings are ideal where space obstructions interfere with horizontal air flow patterns. Heat Transfer Coils COIL Heat Transfer Surfaces have been selected for the most efficient and rugged duty ranges. Standard Construction utilize heavy wall copper tubes expanded into rugged aluminum plate fin stock for a tight bond of the primary to secondary surfaces. Tubes are brazed to steel or iron manifold steel headers. Standard surfaces are ideal for low pressure steam of hot water systems. Copper tube surfaces are considered up to 365°F and 150 PSIG steam. Where steam pressures exceed 25 PSIG supply, heavier duty and high pressure designs are recommended for extended service. For elevated steam pressures and steam or water temperatures, optional materials are available. ¢ Copper © Carbon Steel © Cupro-Nickle © Stainless Steel © Brass Enclosure Cabinets Horizontal Blow of the wrap design casing of carbon steel with venturi fan ring mountings are rib formed to the core configuration and size. Venturi panels are used for the efficient movement of air by the propeller fans through the element surfaces. Motors are mounted to removable motor brackets. Fan inlet guards are available for protection and safety requirements. The air discharges are standard with single individually adjustable air deflectors for downward and angular flows. Double deflection features are available upon request. Vertical Blow are of the two piece carbon steel design for the top inlet air and bottom outlet air opening. Air enters the coil around the periphery of the circular units. Motors are anchored to removable motor brackets. The round bottom outlet ring is suitable for mounting various down flow deflectors, louvers, cone diffusers and multi cone air distribution devices. Fans All propeller type fans of aluminum or carbon steel are statically balanced and carefully mounted to the motor shaft extensions. Fans of special materials are available in many sizes but may need a modification to the motor horsepower requirements. Motors Totally enclosed motors are standard from recognized sources which provide protection for air-borne particles, reliability and motor life. Single phase - Sixty Cycle at 115 volts are considered standard for all fractional horsepower motors. Single phase at 230 volts is available upon request. Three phase - Sixty Cycle at 230 volt, 460 volt or other voltages are available as standard for integral horsepower frames. Explosion Proof Motors, designed for fan duty and hazardous conditions are available such as class 1 Group D, Class 2 Group E, F, G. Due to the limited frames available, it may be necessary to consider alternate groups and horsepowers. Coil Factory Testing All cores factory tested with 200 PSIG air while submerged under water. Other test measures available upon request. Paae 2 STEAM - WATER - A WER CG-02 GLOSSARY: MBH BTUH in Thousands BTUH British Thermal Unit Per Hour PSIG Pounds Per Square Inch SLH Latent Heat of Steam in BTU/LB CLBS/HR Condensate per hour CFM Cubic Feet Per Minute at free discharge air TRA Temperature Rise of Air fT Final Temperature of air at discharge (°F) EA Entering Air Temperature (°F) wTD Water (LIQUID) Temperature Drop ENT Water (LIQUID) Temperature entering Unit GPM Gallons per Minute P.O. Pressure Drop in Feet of Water HP Horsepower w Watts (Approx.) RPM Revolutions per Minute USEFUL FORMULAS & DATA CG-03 460° + 70°F 460 + FT BTUH = CFM at 70°F X 1.085 X TRA CFM (70°F) = TRA = BTUH 1.085 X CFM @ 70°F CLssHR = ———STUH Latent Heat of System cee BTUH 500 X Water Drop (°F) Water: 8.34 LBS/GALLON 8.34 LBS/Min/GPM 500 LBS/HR/GPM Boiler HP: 33480 BTUH PER BOILER HP Kilowatts: 3413 BTUH PER KW HEAT TRANSFER DATA CG-04 GLOSSARY: A___ Heat Transfer Surface, Ft? GPM Fluid Flow Rate, gal/min Q Heat Transferred, BTU/hr U Overall Heat Transfer Rate, BTU/hr Ft? °F Cp Specific Heat @ ta, BTU/Ib °F d Density @ ts, Ibs/gal Film Coefficient @ ta, BTU/hr Ft? °F h s Specific Gravity @ t., = d + 8.3453 t Temperature, °F At th—torte—t USEFUL FORMULAS: Q=GPM Xc, Xd X At X 60 Q = e Cp Xd X At X 60 At= 2. GPM X cp Xd X 60 psi = Feet of Fluid Column x's 2.307 psi X 2.307 s Feet of Fluid * VISCOSITY CONVERSION: Centipoise s Absolute (Ib/hr Ft) = Centipoise x 2.42 Absolute (Ib/sec Ft) = Cece Kinematic (Centistokes) = | _' COIL VERTICAL BLOW | ‘ ‘4 { | HOT WATER TWV-400 CONDITION WATER 200°F ENTERING ae: 160°F ENTERING MOTOR AIR MODEL # EA __WTD MBH CFM FT GPM P.D. HP RPM 10 434.1 7176 99 868 6977 84 65.6 11.0 40° 20 379.0 7095 91 37.9 6902 78 285 2.0 42-WV 30 341.1 7004 86 227 6847 74 #17.1 8 1 1140 10 372.6 7310 110 74.5 7140 97 544 9.1 2 60° 205%324.0:723591049'32.4 7072 92 237 1.4 30 291.6 7181 100 195 7031 88 142 4 10 506.5 9540 90 101.3 9338 78 76.5 14.3 40° 20 442.2 9513 88 44.2 9246 73 333 2.7 49-WV 30 398.0 9365 80 265 9200 70 200 1.0 t 1140 10 434.7 9770 103 87.0 9559 91 63.4 103 60° 20555 = 98°23 9494 87 276 19 - 945785 166 8 10 305.5 5340 95 61.1 5166 77 40.7 2.2 40° 20 266.7 5288 90 26.7 5156 76 20.0 5 HWV 30 240.1 5243 85 16.0 .5 5115 72 12.0 3 3 1140 290 10 262.2 5442 107 524 3: 191.3 5329 94 382 1.9 60° R20GF4228.055395 91012722.8 5288 4 30 205.2 5355 97 13.7 ‘ 5263 ‘2 10 357.7 5902 99 715 65 9 wor 20 3124 5818 91 31.2 12 - a HWV 30 281.1 5768 86 18.7 211.4 5650 75 14.1 3 340 10 307.0 6020 110 614 50 224.0 5880 97 448 2.7 60° EpogEe6 70° 8/5958 1 0458 26;7: ae 194.9 5824 92 19.5 5 40.3. 5902 99 16.0 3 175.4 5802 89 11.7 2 10 444.8 6521 107 889 45 336.0 6325 90 672 26 40° 20 388.4 6405 98 388 9 292.1 6258 84 29.2 5 HWV 30 3496 6362 93 23.3 4 262.9 6210 80 17.5 4 420 10 381.8 6637 117 763 3.5 278.5 6466 102 55.7 1.9 60° 20388332:03 5742110 833,2 Sa! 242.3 6399 96 24.2 4 30 298.8 6387 95 20.0 3 218.0 6362 93 145 2 10. 517.2 9662 91 103.4 62 390.6 9440 78 78.1 3.5 40° 20 451.6 9616 88 452 1.2 339.6 9346 73 34.0 6 HWV 30 404.4 9467 80 27.1 5 305.7 9300 70 204 3 490 10 443.9 9895 104 888 323.8 9672 92 64.7 2.4 60° f20MES86:0=9765SN9S8 mise 281.7 9616 88 28.2 5 30 347.4 9718 94 23.2 53.6 9570 85 16.9 3 For Other Conditions of Entering Water Temperatures, Water Temperature Drops (T.D.) and Entering Air Conditions, refer to Chart CW-96. THE WATER SIDE Recirculating system pressures represent an accumulation of the friction losses through the piping plus the head loss through the coil of the unit heater and system components. System pressures will vary depending upon the speed or velocity of the water through small or large pipe areas, length and circuiting of the system, type of pipe, boiler circuiting and the circuiting of the hot water coil in the unit heater. er Diversity load factors should be considered-where room internal heat gains or external solar exposures require individual unit heaters to have reduced load demand and correspondingly less water flow. Careful consideration should be given size of the pump and piping for reduced flow conditions. Recirculating water systems to unit heaters should have feeds from the supply main to match the heater coil sepentine circuiting connection locations and corresponding exit connections to the return main. Each heater piping should be properly air vented, equipped with water flow balancing cocks and shut off gate valves in each supply and return connection leg to the main. Provide adequate balancing cock to each heater water supply connection plus shut-off valving for each supply and return pipe connection in case of repair or emergency protection of the heater. Page 10 The following GPM values are charted against pipe sizes at pressure drops of 5 feet and 10 feet, per 100 feet of line size. Schedule 40 Pipe Copper Tubing SIZE 5 ft(GPM) 10 ft(GPM) TUBE OD % 14 1.6 % ke % 2.0 3.0 ke % % 44 6.5 % va 1 8.5 12.5 1 1% 1% 17.5 26.0 1% 1% 1% 27 39 1% 1% 2 50 73 2 2% 2% 83 120 2k 2% 3 145 220 3 3% 3% 210 300 3% 3% 4 290 430 4 4% 1.0 1.7 45 9.0 16.0 24 50 91 160 225 320 1.4 2.6 6.8 14.0 24.0 36 75 135 230 330 475 5 ft(GPM) 10 ft(GPM) . GLYCOL SOLUTIONS & HEAT TRA! R FLUIDS Glycols mixed with water are frequently applied to unit heater systems for freeze protection of the systems piping and components. The water/glycol solution may be varied in percentages for the desired freeze point. Slightly higher viscosities combined with some change in specific heat and specific gravity of the water/glycol solution may require the system to handle a small increase in flow or minor adjustment in heat transfer surface area. High Temperature Heat Transfer Fluids that are not miscible with water are available up to at least 600°F. Special consideration should be given to the fluid temperature limits from waste heat or hot stack recovery applications when circuited directly to copper surfaces and standard unit heaters. TYPICAL SPECIFICATIONS Unit heaters shall be of the propeller fan types based on standard tests and rating procedures as recommended by ASHRAE and Air Moving and Conditioning Association. Each unit heater shall be capable of providing the air volume (CFM), air temperature rise (°F) load capacities in BTUH or MBH, motor characteristics and air throw distribution as so indicated by the project plans and specifications. The motor and fan assembly resiliently mounted shall be designed for on-off cycling or continuous duty. Motor and fan assembly to be removable for ease in heater maintenance. Heater coils to be of the extended fin surface with minimum of -030" copper tube wall thickness with maleable iron or steel manifold headers. Coils are to be factory tested prior to assembly to unit. Horizontal blow units to have multiple and individually adjustable air discharge louvers. Vertical blow shall have discharge openings and optional cone nozzles as specified. Unit heaters shall be as those by the Coil Company, Colwyn, Pennsylvania 19023. THE STEAM SIDE The two pipe system, one for steam supply connection to the heater coil plus the second connections from the coil to the condensate return are recommended and widely applied for unit heaters and steam coils. Piping arrangements should utilize swing joint steam supply and condensate return connections to the unit heater thus avoiding thermal and flow stresses to each heater coil element. To avoid drip from the steam main through the heater element, connections should be made from the top of the main. Condensate lines should be positioned vertically downward at least 12 inches, prior to lateral pitch to strainers and traps plus another 6 inches vertical dirt leg or a total vertical leg of 18 inches. Avoid reducing piping size from unit heater element connection through strainers, check valves, traps, gate valve and PRODUCT WARR Y & INFORMATION Heater coils are warranted for one year from date of shipment against mechanical defects that originated during manufacture. Motors and miscellaneous products that are sold with unit heaters have their respective manufacturers warranty. No warranty may exist on any product or part, unless all invoices are paid within 30 days from date of shipment. The product and system description and all information is Presented in good faith, but because we cannot control or anticipate the many conditions under which this information and product may be applied, no warranty is expressed or implied. HEATER CONTROLS Motors are standard for single speed control or reduced speed control for varying space temperature conditions. Wiring should be in accordance with the best practices for one of the following installation options. 1. Single Phase: Manual on-off starter 2. Single Phase: Manual on-off starter with room thermostatic control 3. Single Phase: Manual on-off starter with room thermostat and reverse acting controller 4. Single Phase: Manual on-off starter with three position selector switch or thermostatic control 5. Single Phase: Manual on-off starter, speed control and thermostatic control 6. Three Phase: Manual on-off starter 7. Three Phase: Manual on-off starter with thermostatic control and limit controller 8. Magnetic starter control with thermostatic control for operating several heaters. 9. Overload protection recommended for each motor. Where thermostatic control is applied, the wiring harness and control should be adequate for the system load characteristics. Modulating steam control valves which vary the temperature and pressure of the steam and the output of the coil are not recommended for single tube unit heater cores. Steam modulating valves are applicable with double tube, non freeze or inner distributing coils. Provide shut-off valves on the steam supply side and_in the condensate path downstream of the trap. Steam traps function on pressure differentials when the steam has released its latent heat for the purpose of maintaining temperature of the heat user. Condensate is prevalent when the steam has released its heat, therefore in unit heater applications the steam trap should have a capacity of at least three times the accumulated loads of the heat transfer coil, line and hardware loSses related to temperature, BTUH and pounds condensate per hour. hardware. APPROXIMATE FLOWS (LBS/HR) TWO PIPE STEAM SYSTEMS sc4 PIPE LOW PRESSURE VACUUM MEDIUM PRESSURE HIGH PRESSURE SIZE MAX 15 PSIG STEAM MAX 30 PSIG STEAM MAX 150 PSIG STEAM INCHES STEAM CONDENSATE STEAM CONDENSATE STEAM CONDENSATE SUPPLY RETURN SUPPLY RETURN SUPPLY RETURN % 30 280 65 365 300 900 1 55 490 125 730 550 1750 1% 110 850 280 1530 1230 3700 1% 175 1350 435 2500 1700 6100 2 335 2800 880 5000 3400 12300 2% 540 4700 1460 8400 5200 20000 3 960 7500 2650 15300 9400 37000 3% 1400 11300 4000 22700 13100 55000 4 2000 15500 5600 32200 19200 75000 LINE LOSS 5 5 2.0' 1.0° 5,0° 2.0' PER 100’ (FEET OF WATER) SYSTEM MAX LOSS 1.0’ 1.0° 10.0° 5.0° 25.0° 20.0° Page 11 NOTES: (HORIZONTAL BLOW) (1) Coil connection sizes female thread (2) Steam supply at top, hot water supply at bottom TAT “SLR A HORIZONTAL BLOW HORIZONTAL BLOW COIL CONNECTIONS FREE BLOW (ft) APPROX. MODEL # H Ww Do TOP BOTTOM HEIGHT THROW WT. LB. 12 1 12 10 1 1 8 15 15 19 13 16 13 1% 1% 8 18 28 29 13 16 13 1% 1% 8 20 28 38 15 18 14 1% 1% 8 20 34 39 17 20 14 1% 1% 10 30 - 45 46 15 18 14 1% 1% 9 22 34 53 19 22 16 1% 1% 12 35 SO 59 17 20 14 1% 1% 9 22 45 66 21 24 18 1% 1% 14 35 70 69 17 20 15 1% 1% 12 30 52 80 23 26 18 1% 1% 16 40 77 92 19 22 16 1% 1% 12 40 54 101 21 24 18 1% 1% 12 35 72 112 27 31 20 2 2 16 35 130 140 23 26 18 1% 1% 13 50 80 165 23 26 18 1% 1% 14 50 80 172 31 35 23 2 2 18 60 _ 184 207 27 31 23 2 2 14 70 140 270 31 35 26 - 2 2 15 65 168 300 31 35 26 2 2 16 75 168 342 35 35 26 2 ie 15 60 168 382 35 35 26 2 2 18 70 230 NOTES: (VERTICAL BLOW) (1) M = Mounting heights (feet approx.) (2) S = Air spread (feet approx.) (3) Coil connection sizes male thread (4) Steam supply at top, hot water supply at bottom 4 d — ce Free blow VERTICAL BLOW. COIL ADJUSTABLE SINGLE THREE CONE FOUR APPROX CONNECTIONS FREEBLOW - LOUVERS CONE CONE CONE wT. MODEL# H D TOP BOT*OM M s cv M s Cv M S _CV-= M Ss CV M s (LBS) 4 8 25 1% 1% 10 20 8 12 15 10 10. 25 4 10... 25 7 8 28 40 t 6 12. 25 1% 1% 11 25 8 18 18 10 10. 30 7 aides 28 7 8 30 50 Shan Q 14. 25 1% % 1 30 9 7220 11 10° 30 Bxor14 30° 8 9 40 56 11 1535 1% 1 14. 35 9. 43.22-5. 26 11 12. 35 6 12. 38. 8 9 45 82 13 15 38 1% 1 18° 40 *10.., 426 - +30 13 14. 45 9-14 xedGs Ore Tt 45 82 15 15 35 1% 1 20. 45 10° 28: 30 13°20). -45 9 16 -50 9 13 60 90 20 16 35 1% 1 20 45-1 20.30 15 20 45 9 16°" 55 9. 43°.” 65 2100 26 16 35 2 1% 24. = 55 13 32 40 18 24 55 102.17: 86002 510); 13 ~. 70.122 29 17 44 2% 1% 22.2 40 ABE 280s. °S5 18 225.20 -< -40%25 10 16 55 10%. 13°-: 60: 162 29H 21 44 2k 1% 175 34 21 44 2% 1% 30 60 13 40 50 18 <<5,28.:-60 10 16°. 70-10. 13 . 85 162 34H 44 2h 1% 175 42 21 44 2k 1% 35 70 13 40 = 60 18. 28:70 10 18 80 10 13 90 184 42H 44 2k 1% : 210 49 21 44 2k 1% 35 70 13 #45 ~~ 60 18% 35 =: -90-* 10_<. 19 55:80 10 16 90 200 49H 44 2k 1% 210 Above dimensions are approximate. Contact factory for specific data, demensions, & special duty coil & heater applications. COIL COMPANY INC. .- 125 South Front Street, Colwyn (Darby), PA (USA) 19023 Page 12 215-461-6100 TOLL FREE 800-523-7590 Alaska Village Electric Cooperative, Inc. 4831 Eagle Street Anchorage, Alaska 99503-7497 (907) 561-1818 February 16, 1989 SLASK Mr. Peter N. Hansen, P.E. Project Manager Alaska Power Authority P.O. Box 190869 Anchorage, Alaska 99519-0869 RE: Chevak Waste Heat Design Dear Peter: We have reviewed your letter and set of three blueprints received February 9, 1989, on the above-referenced project and have the following comments in their original order: 1 2s 3s A valve opposite #17 should be added on the inlet end of the relocated Butler building heat exchanger to allow for complete isolation of the unit. Accepted. Substantial evidence and calculations show that two expansion tanks at different points on the same system will never be at the same level when an engine is running, and will fluctuate depending on which engine is running, i.e., when Position #1 or Position #2 engine is using Position #4 radiator, Position #1 expansion tank level will go down, Position #4 expansion tank level will go up, possibly overflowing, causing low coolant shut down on the engine in Position #1 or Position #2. This is caused by dynamic pressure differences. If the cap on Position #1 expansion tank is removed, then the static pressure in the system causes the level in the Position #1 expansion tank to come up abruptly and overflow. Solution #1: Plumb both expansion tanks together at the same point. Disadvantage: Valves must be added and then set each time a change is made from the engine in Position #1 or Position #2 to the engine in Position #4. Solution #2: Use design as is since this problem would occur only during "emergency" configuration of cooling system, i.e., when the engine in Position #1 or Position #2 uses the Position #4 radiator. Solution #3: Add full expansion capacity at one end of system with valves on other expansion tank connections so that in an "emergency" only the single expansion tank would be valved off. Mr. Peter N. Hansen, P.c. February 16, 1989 Page 2 We prefer Solution #3. The sheet titled "Piping Schematic Alternate #1" identifies the unit in the Hussman module as #3. AVEC's standard engine numbering convention would identify this unit as Position #4. Possibly for additional clarity the word position should be added ahead of each number and Position #3 in the butler building could be added and shown as currently empty. Please provide catalog cut and recommended length. Enclosed are copies of prints (Drawing 3-00-6020) and/or parts numbers (Req. 89-00181, Req. 89-00182) for AVEC's standard ventilation system including controls, fan assembly and hood. Alaska Village Electric Cooperative currently has 49 horizontal core radiators located in ambient air with fans driven by variable speed drives in service. Our records indicate three core failures. Sixteen additional horizontal core radiators located in ambient air and driven by two speed motors were installed as part of the waste heat recovery program. Our records indicate fourteen core failures. This is a failure rate fourteen times higher than similar installations with the only difference being the manner in which the radiator fan is driven. AVEC's first and only instal- lation of two horizontal core remote radiators with two speed radiator fan motors in ambient air at Mt. Village has resulted in two core failures for a 100% failure rate. Again, based upon the information received, it is our belief that cold shocking a radiator core that is carrying 185°F fluid with a sudden and rapid cool down in -30°F or colder ambient air can and will cause struc- tural failure and resultant leaks. Only time will tell if the single pass, parallel reconnection will result in a reduction in core failures, however, if the theory of cold shocking the radiators is correct, then we will expect the number of core failures to actually increase after this change. With only one-half the flow of coolant entering each radiator core, the rate of cool down should nearly double resulting in even greater shock forces on the radiator core. We would like to see this problem avoided completely by the installation of a variable speed drive. The variable speed drive also controls the level of cooling much better than the two speed motor arrangement and therefore increases the amount of heat avail- able for recovery. This should be to the advantage of the APA and the School District at Chevak. For these reasons, it is not clear why the APA/Chevak school district should not be willing to cover the cost of the variable speed drive since it would be recovered over time through additional waste heat recovery. Reports from some of the windier locations seem to indicate that snow is not only being blown horizontally but is also being blown vertically upward into the horizontal core of the HC radiator. If this is correct, then it is difficult to see why the problem would not even be worse with a vertical core radiator where the blown snow would not even have to overcome the force of gravity but would merely have to be blown into the motor fan assembly and the core. The legs which elevate the HC core would appear to allow most of the snow to blow past the horizontal core and only the snow that is blown against the motor could be forced upwards. The vertical core Mr. Peter N. Hansen, P.c. February 16, 1989 Page 3 10. 11. radiator would appear to present a much larger area to horizontally blown snow or ice and could be expected to accumulate more snow. And any accumu- lation of snow at the base of the core would start to interfere with the fan on the vertical core radiator almost immediately. For these reasons, I have grave reservations regarding the selection of a vertical core radiator. However, if you decide to proceed, the higher capacities of the 86 series would be preferred over the 66 series. Accepted. Flow schematics are needed as soon as possible to complete the review of the design. Some of the flow schematics specifically needed are: 1) Engine in Position #1 or Position #2 operating AMOT Working New Heat Exchanger Working New Radiator Working 2) Engine in Position #4 operating Position #4 Radiator Working New Heat Exchanger Working Position #4 AMOT Working No. 1) and No. 2) are normal conditions. 3) Engine in Position #1 or Position #2 operating AMOT removed for repair or 4) New Heat Exchanger Removed for Repair New Radiator Working 5) Engine in Position #1 or Position #2 operating New Radiator Removed for Repair Position #4 Radiator Working 6) Engine in Position #4 operating Position #4 Radiator Removed for Repair New Radiator Working From indepth calculations on previous waste heat recovery systems, we have found that even 4" pipe and components in these arrangements are barely large enough to adequately cool a Cummins 1150 at peak loads. For this reason, someone needs to look closely at the number and type of valves, elbows, tees (both run and branch flow), reducers, expanders, etc., which are incorporated into this system as well as length of pipe runs, heat exchangers, and thermostatic valves. Although not initially stated there has been some consideration of installing a Cummins KTA 1150 at Chevak and therefore consideration should be given to designing the system for this alternative. It is agreed that actual measurements to verify pressure drops and flow restrictions are the best means of determining that all operating para- meters are within the manufacturer's recommendations. However, it would be very expensive to discover that the 3 inch system is too restrictive and Mr. Peter N. Hansen, P... February 16, 1989 Page 4 12. 13. 14. 15.. that all of the piping needs to be replaced with 4" after the 3" system was intalled. Accepted. We will be awaiting figures on coolant capacity and expected expansion volume after the final component selection has been completed. Our concerns regarding the use of a vertical core radiator equipped with a two speed fan motor has been stated earlier. AVEC has encountered failures of similar radiator cores at Hooper Bay, Chevak, and Noorvik. Motor burnouts on two-speed installations has been much higher than those uti- lizing variable speed drives. During the last three years AVEC had endured 20 radiator fan motor failures involving two speed motors originally installed by the APA. During this same time period AVEC has replaced 6 radiator motors involving two speed motors that were installed on vertical core radiators on AVEC installations. Finally, over the same time period, AVEC has replaced 4 radiator fan motors that were driven by variable speed drives. Additional Comments on Component Selection A. In letter there was mention of a MWC-D3Q radiator. In the Specification Sheet was listed MWC86E3Q Radiator On the Piping Schematic was listed a MWC 863D3Q Radiator Which is the correct Young Model number? B. Our standard antifreeze mix is 60/40, not 50/50. 60/40 is more viscous than 50/50. Higher viscosities cause greater pressure drops. Ethylene Glycol/Water mixtures have significantly different viscosities than pure water. Comments on "Piping Schematic Alternate I": 1) The B & C Ports on the AMOT seem to be mislabeled. 2) It is not clear how the new AMOT is individually removed (valved off) for repair. Perhaps it is expected that the big heat exchanger will be removed when the AMOT is out of service. 3) If the new AMOT is removed for repair (valved off), then the engines in Position #1 and Position #2 cannot use Position #4 radiator and vice versa. Perhaps it is expected that both the new radiator and AMOT will never be down at the same time. 4) If the new heat exchanger is removed for repair then the engine in Position #4 cannot use the new radiator. Perhaps it is expected that both Position #4 radiator and the new heat exchanger will never both be down at the same time. 5) Would it be a good idea to install flanged tees for future connection to an additional radiator on the butler building? Mr. Peter N. Hansen, P... February 16, 1989 Page 5 6) Would it be a good ideal to install flanged tees for future connection of a future engine in Position #1? 7) We would prefer to have a separate engine coolant circulating pump for each engine in the Butler building. Sincerely, Mark ¢ Sod Mark E. Teitzel Manager, Engineering APPENDIX Horizontal Remote Radiator Core Failures with Two Speed Fan Motors 2 @ Elim (APA) 2 @ Grayling (APA) 2 @ Kiana (APA) 2 @ Kaltag (APA) 3 @ Goodnews Bay (APA) 2 @ Savoonga (APA) i @ Shungnak (APA) 4 2 @ Mt. Village (AVEC) Vertical Remote Radiator Core Failures with Two Speed Fan Motors 1 @ Hooper Bay (AVEC) 1 @ Chevak (AVEC) 1 @ Noorvik (AVEC) 3 Horizontal Remote Radiator Core Failures with Variable Speed Fan Motors 2 @ Noatak (AVEC) i @ New Stuyahok (AVEC) Two Speed Fan Motor Failures on Horizontal Core Radiators 4 @ Grayling (APA) 2 @ Kiana (APA) 3 @ Elim (APA) 4 @ Savoonga (APA) 1 @ Ambler (APA) 1 @ Kaltag (APA) 1 @ Shungnak (APA) ;, @ Goodnews Bay (APA) 0 To Speed Fan Motor Failures on vertical Core Radiators 2 @ Holy Cross (AVEC) 1 @ Noorvik (AVEC) 2 @ St. Michael (AVEC) 1 @ Chevak (AVEC) 6 Fan Motor Failures on Variable Speed Driven Horizontal Core Radiators 1 @ Kiana (AVEC) 1 @ Shaktoolik (AVEC) 1 @ Scammon Bay (AVEC) 1 @ Gambell (AVEC) ri Horizontal Core Remote Radiators with Two Speed Fan Motors that are Installed Completely Outside 2 @ Ambler (APA) 2 @ Kiana (APA) 2 @ Shungnak (APA) 2 @ Savoonga (APA) 2 @ Elim (APA) 2 @ Kaltag (APA) 2 @ Grayling (APA) 2 @ Goodnews Bay (APA) 16 Horizontal Core Remote Radiators with Two Speed Motors that are Installed Inside Ambient Air Module Enclosures 2 @ Mt. Village Horizontal Core Remote Radiators with Variable Speed Driven Fan Motors that are Installed Completely Outside 1 @ New Stuyahok (AVEC) 1 @ Togiak (AVEC) 2 @ Shaktoolik (AVEC) 2 @ Nulato (AVEC) 1 @ Nunapitchuk (AVEC) 2 @ Mt. Village (AVEC) 1 @ Marshall (AVEC) 1 @ Huslia (AVEC) 1 @ Quinhagak (AVEC) 1 @ Holy Cross (AVEC) 1 @ Pilot Station (AVEC) 2 @ Emmonak (AVEC) 2 @ Scammon Bay (AVEC) 1 @ Tununak (AVEC) 1 @ Wales (AVEC) 1 @ Eek (AVEC) 1 @ Mekoryuk (AVEC) 2 @ Shishmaref (AVEC) (Under Construction) 10 @ Old Harbor (AVEC) (Under Construction) 25 Horizontal Core Remote Radiators with Variable Speed Driven Fan Motors that are Installed Inside Ambient Air Module Enclosures 2 @ Kiana (AVEC) 4 @ Noatak (AVEC) 4 @ Shungnak (AVEC) 2 @ Kivalina (AVEC) 4 @ Gambell (AVEC) 2 @ Nunapitchuk (AVEC) 2 @ Togiak (AVEC) 2 @ Savoonga (AVEC) 2 @ Shishmaref (AVEC) Vertical Core Remote Radiators with Two Speed Fan Motors that are Installed Inside Modules or Buildings 3 @ Noorvik 2 @ St. Michael 1 @ Hooper Bay 1 @ Chevak 2 @ Holy Cross 2 @ St. Marys Vertical Core Remote Radiators with Variable Speed Driven Fan Motors that are Installed Inside Modules 1 @ St. Michael Vertical Core Remote Radiators with Single Speed Fan Motors that are Installed Inside Modules 2 @ Old Harbor February 7, 1989 Mr. Mark E. Teitzel, Assistant General Manager Alaska Village Electric Cooperative 4831 Eagle Street Anchorage, Alaska 99503-7497 Subject: Chevak Waste Heat Design Dear Mr. Teitzel: Please find attached a set of revised draft blueprints for the above mentioned project. I have concentrated on Alternate 1 as requested in your letter of November 1, 1989, In reference to your numbered comments, please find below my answers to your comments, i. 2. We will continue the development of Alternate I as you have requested. The radiator will be elevated on a welded steel frame in order to raise the expansion tank above the engine coolant outlet. I agree that this should reduce snow drifting problems. I agree; we will place an 8-gallon Young tank with sight glass above the existing radiator and install a high pressure cap on the radiator and a low pressure cap on the tank. I will make it a point to adhere to this numbering system. I agree; we will use stainless steel flexes from Alde Industries, Inc. I will adhere to your request; please provide specifications for AVEC's standard fans. As we have previously discussed, I do not believe that the cold shocking theory is applicable to this situation; the radiator problems previously experienced with the Power Authority's waste heat systems appear to have been solved through a re-connection of the radiators in a single pass, parallel connection. I am very hesitant to specify the use of a variable speed drive due to the track record of these drives in the field. However, if AVEC will provide and maintain the variable speed drive, I will be happy to install it in Chevak. 4824/0D46/1 rage « 10. 11. 12. 13. 14, T agree that the proposed radiator is most likely too small. I was not aware of the peak loads described in your letter and it would not be prudent to install a marginal radiator under these circum- stances. I! would like to propose the installation of a Young MWC-D30 with a two speed, arctic duty motor. This radiator will have plenty of capacity and will also be quiet as you have requested. I agree, see item #8, Flow schematics and valve settinas will be provided as requested, I intend to provide you with pressure drop calculations which, in my opinion, will substantiate that we are within the manufacturer's limits. However, as I am sure that you are aware, pressure drop calculations are very rarely accurate; especially when we are dealing with very small total pressure drops. I intend to make a number of measurements in order to establish actual flow restric- tions as functions of valve settings and flow rates; knowing actual values will make me feel much more comfortable than simply having performed a number of calculations. I agree, we will relocate the existing low level switch gauges. I agree, such values will be calculated and supplied to you. Please find enclosed a revised list of components. Of special interest to you may be the selection of a vertical core radiator as discussed under Item #8. As T have previously mentioned, the Power Authority has been involved in a great many waste heat recapture projects throughout the state on AVEC as well as non-AVEC facil- ities. From our experience with horizontal as well as vertical core radiators and with Young AV and CI type coolers it appears that the horizontal core radiator is by far the most trouble prone in reference to core leakage as well as motor burn out. In refer- ence to your expressed concerns regarding snow drifting in Chevak, I certainly share your concerns; however, I am more concerned about snow drifting in conjunction with the use of a horizontal core radiator. I had an opportunity to spend a few days in Savoonaga during a snow storm and the horizontal core radiators used here were packed solidly with snow between the fan and the core. As you can imagine, it is quite difficult to clean this out while laying under the radiator. An even greater problem arose when the radiator was put into service. At this time the snow packed into the core melted and water dripped down on the fan shroud, where it froze and developed an impressive glacier, which locked the fan in place. I believe that this scenario would be very unlikely on a vertical core radiator. The drifting problem in Chevak will be somewhat reduced by the fact that the radiator will have to be elevated on a welded frame in order to get the radiator expansion tank above an engine coolant outlet. 4824/0046/2 If you have any further questions or comments, please do not hesitate to contact me, Sincerely, Me Peter N. Hansen, P.E. Project Manager Attachments as stated. PNH: aa 4824/DD46/3 MEMORANDUM Date: 1/12/89. To: Dominic Costanzo Contracts Officer From: Peter N. Hansen Wr Rural Systems Engineer Subject: Your questions pertaining to my memorandum to Marlys Hagen dated 1/10/89. Questions: "Why did we not issue an ITB"? Answer: At this time Power Authority management was pursuing immediate construction in Chevak; experience has shown that it takes 9-10 weeks from the date a request is submitted to the Power Authority's contracts staff until a contract is signed with a vendor. Question: "Why should APA be or accept any blame"? Answer: APA should not share the blame. Question: "Do we need this"? Answer: Yes. Question: “What was our original intention when all quotes exceeded 5K"? Answer: We had three options: a. Issue an ITB and delay construction. b. Modify specification to reduce price of unit. c. Pursue waiver for alternate procurement method. Question: "Is this total price including freight - original quote is FOB Tonawanda"? Answer: Price is F.o.B. Tonawanda, N.Y. cc: Don Shira Jerry Larson Marlys Hagen MEMORANDUM Date: 1/10/89. To: Marlys Hagen AKSAS/Contracts Assistant From: Peter N. Hansen Uf Rural Systems Engineer Quotations were solicited from 3 vendors for a heat exchanger for the Chevak project. The quotations covered a wide range of performances, however, even at the lowest acceptable performance JA ww level, no heat exchanger was available below $5,000 which is the upper limit for procurement without formal written solicitation. In order to quote a firm price, Normark Industries is forced to actually order a heat exchanger from the Manufacturer, APV Crepaco. It is then normal practice to cancel the order, if the potential customer does not order the heat exchanger from Normark Industries. Unfortunately, after quoting the Power Authority $6,400 for a particular heat exchanger, Normark Industries failed to cancel the order with APV Crepaco. Consequently, the heat exchanger was manufactured and shipped to the Power Authority in Anchorage. I explained to Mr. Hilkman from Normark Industries, that the Power Authority would be unable to purchase this heat exchanger, as the price exceeded the aforementioned $5,000 level. In a subsequent telefax, Mr. Hilkman offered the heat exchanger at $4,980, which is below any other offer received. Additionally, the capacity of this heat exchanger is 35% higher than the capacity of the units listed on the "Small Procurement Work Sheet". we Consequently, I believe that the Power Authority should purchase 5 ot this unit rather than notify the freight company, that the unit Z must be returned. It should be noted that Mr. Hilkman from Normark Industries has accepted complete responsibility for the i xe error and that nobody has attempted to place any blame on _ the xt j Z Power Authority. Quesnows 7 J- Do we need DHS our One bInAac T WwAS 2- wir wHrev ALL QAvores [rrew ow . excepe SKE yal 1 perce ! soe ) : pT 2- 15 THIS VP re . vo pein - OF'® 7 <A = nl December 7, 1988 88-M-363 TO: Loyd M. Hodson, General Manager FROM: Mark E, Teitzel, Manager, Engineering SUBJECT: New Diesel Electric Sets/Diesel Engines Only/Generators Only Proposed for Purchase Under the 1989-1990 Two Year Construction Work Plan The following units are proposed for purchase under the new Two Year Construction Work Plan: Ambler W.O0. 60614 Install Cummins KTA 1150 Generator Set $ 85,000 Anvik W.0. 51G19 Install Cummins LTA10 1200 RPM 1 Generator Set $ 65,000 Chevak W.0. 14625 Install Caterpillar 3412 1200 RPM Engine 2 Only or Equivalent $100,000 Eek W.O. 18G11 Install Larger Generator on AC 3500 #2 $ 15,0002 Hooper W.0. 8632 Install 400 KW (Cummins KTA 38) Generator Bay Set $125,000 Koyuk W.0. 40G22 Install Larger Generator on LTA 10 #1 $ 15,0004 Noatak W.0. 42626 Install] Cummins KTA 1150 Generator Set $ 85,000 Savoonga W.0. 29G11 Install Larger Generator on AC 6851 #3 $ 15,0004 Toksook W.0. 71626 Install Cummins KTA 1150 Generator Set $ 85,000 Bay Wales W.0. 62620 Install Cummins LTA 10 1200 RPM Generator 1 Set $ 65,000 Summar. One Cummins KTA 38 1200 RPM Generator Set (850 H.P.) One Caterpillar 3412 1200 RPM Engine Only (530 H.P.)? Three Cummins KTA 1150 1200 RPM Generator Sets (410 H.P.) 5 Cecem 88-M- Page Two C Two 2 One 1 Notes 1. Origi Wales New S New S Kalta Kalta Shung Scamm ber 7, 1988 363 2 ummins LTA 10 1200 RPM Generator Sets (184 H.P. Approx. )+ 68 KW Three Phase Rated 1800 RPM Generators’ 35 KW Three Phase Rated 1800 RPM Generator? ¢ ' 1200 RPM generators only may be available from retired 1200 RPM 8V-71 generator sets and may not have to be purchased as part of the set. nal 1200 RPM KATO Generators: KATO 105SU9D S$.N. 67931-3 (Used for Old Harbor) tuyahok KATO 105SU9D S.N. 67931-2 (Used at Wales) tuyahok KATO 105SU9D S.N. 67931-1 (In Yard, Proposed for Shageluk) g KATO 105SU9D S.N. 67931-4 (Still in Service) g KATO 105SU9D S.N. 69563-1 (Retired in Village) nak KATO 105SU9D S.N. 69563-3 (Still in Service) ion Bay KATO 105SU9D S.N. 67931-5 (Still in Service) The retired unit at Kaltag should be brought back to Anchorage, tested and put into stock as a backup unit. Currently there is one Caterpillar 3412 1200 RPM Engine Only in stock. It is the unit that was removed from Hooper Bay and repaired following discovery of the block corrosion problem. If this unit is used at Chevak, a spare unit is still needed to back up the existing 3412 at Emmonak, Hooper Bay, Mt. Village, Noorvik, Nunapitchuk, Selawik, and Togiak. This generator may not have to be purchased. An acceptable unit will become available when a larger generator is installed at Koyuk. One 268 KW 1800 RPM Generator may not be needed as it has been recommended that the AC 685I engine at Savoonga be relocated to a village where an existing AC 685I is due for an overhaul. One 268 KW 1800 RPM Generator became available following the decision to convert the Old Harbor module unit to 1200 RPM. It is still recommended that a spare 268 KW three phase 1800 RPM generator be kept in stock as a backup unit for Ambler, Elim, Goodnews Bay, Grayling, Holy Cross, Huslia, Kaltag, Kivalina, Koyuk, Marshall, Mekoryuk, Minto, New Stuyahok, Noatak, Old Harbor, Pilot Station, Quinhagak, Russian Mission, Scammon Bay, Shaktoolik, Shungnak, St. Michael, Stebbins, Toksook Bay, and Tununak. We currently do not have a spare KTA 1150 engine in stock to back up the existing KTA 1150s at Alakanuk, Gambell, Nulato, Pilot Station, Quinhagak, Savoonga, Shishmaref, and the future units at Ambler, Noatak, and Toksook Bay. Necember 7, 1988 88-M-363 Page 3 Final Summary Recommended for Purchase One Cummins KTA 38 1200 RPM Generator Set (850 H.P.) One Caterpillar 3412 1200 RPM Engine Only (530 H.P.) Three Cummins KTA 1150 1200 RPM Generator Sets (410 H.P.) One Cummins KTA 11501200 RPM Engine Only (410 H.P.) for a Spare Two Cummins LTA 10 1200 RPM Generator Sets (184 H.P. Approx.) One Cummins LTA 10 1800 RPM Engine Only (276 H.P.) for a spare with separate turbocharger for 1200 RPM use and with separate fuel pump calibrated for 1200 RPM use. , AL Lek ¢ AG ark E. Teitze Manager, Engineering x October 24, 1988 Mr. Mark E. Teitze} Assistant General Manager Alaska Village Electric Cooperative 4831 Eagle Street Anchorage, Ak. 99503-7497 Subject: Chevak Waste Heat Design Dear Mr. Teitzel: Please find attached a set of preliminary blueprints for the above mentioned project. I have developed 3 different scenarios; this letter discusses the advantages and disadvantages associated with the various concepts. As you will see, Alternate I rather closely resembles the concept, which you have approved for Togiak and New Stuyahok. Two generators are manifolded together and connected to one loop in a flat plate heat exchanger. Additional cooling is provided by a vertical core radiator equipped with a two speed motor. Flow patterns are controlled by an AMOT valve. The new radiator and heat exchanger will be placed on a platform, which will be similar to the platforms installed in New Stuyahok and Togiak. In Chevak I propose to use long sections of "C" channel, extending under the center of the Butler building and bolted to the foundation. The platform will be designed for 80 Ibs/ft2 load and will be an all welded design. The heat exchanger will be enclosed in a metal frame box, which will be covered with fire treated plywood. The generator set in the module will be connected to a separate loop in the same heat exchanger frame, and thus the new flat plate heat ex- changer will be of the 6-nozzle type, similar to the heat exchangers installed in Togiak and New Stuyahok. The internal Alaska Village eo Cooperative (AVEC) heating system is left in place with no changes. While this alternate probably will be the easiest to install, the shell and tube heat exchangers would probably necessitate the installation of a primary loop booster pump in case an engine with limited coolant pump capacity was installed at a later date. Additionally, the shell and tube heat exchanger in the Butler building certainly adds to congestion and makes maintenance on the engines somewhat more difficult. Alternate II is identical with the only difference being the removal of the existing shell and tube type heat exchangers for the internal AVEC heating system. This system will be connected to the new heat 4126/884/1 Page z exchangers secondary loop and will be equipped with its own circulating pump, operating in parallel with the pump, which is to be installed in the school's mechanical room. (Please refer to the piping schematic for Alternate III for details on the interconnection of AVEC's heating system with the school's heating system.) Alternate II would make the internal AVEC heating system dependent on the school's heating system as they would be using the same fluid. To enable the AVEC system to operate independently in case of a line break, I propose to maintain the existing expansion tank and to install isolat- ing valves, thereby allowing for continued operation of the AVEC heating system in case of a failure in the remaining secondary loop. It should be noted, that in an emergency situation the pump in the school's mechanical room could provide circulation through the AVEC heating system thereby providing the AVEC plant with heat from the school in case of a longer lasting outage. Alternate III is identical to Alternate II with the difference being the installation of the heat exchanger in the radiator section of the module. If the existing shel] and tube heat exchanger is removed, there will be sufficient room in which to instal] the heat exchanger and yet allow access to the radiator for service or replacement. A smaller radiator platform of a design similar to the above described will be constructed for the vertical core radiator. As you can see from the piping schematics, I have shown a number of by-pass valves in order to allow continued operation of any generator regardless of a failure of any heat exchanger, radiator, or AMOT valve. Due to the short length of some of these by-pass lines, I would propose to install them in a smaller diameter pipe, depending on the component being by-passed. (Example: a 2" by-pass around a radiator may still give less restriction to flow than the radiator at the same flow rate; naturally each case would be calculated separately.) In accordance with our previous discussions, the system will be designed around a 3412 or a 353, whichever gives the more restrictive design. (The radiator heat load is greater for a 353). Flow restrictions will be limited to approximately 5 psi. Ventilation fans in the Butler building will be thermostatically controlled and will be installed above the door. The two fans will have separate thermostats and will be connected to separate circuit breakers. While I would certainly recom- mend the use of exhaust fans, I am aware or your preference for air intake fans, and I will leave the choice up to you. Also attached, you will find a list of components initially selected for this project. Of special interest to you may be the selection of a vertical core radiator in lieu of the horizontal core radiator typically used. As you may be aware, the Power Authority has been involved in a great many waste heat recapture projects throughout the state. From our experiences with horizontal as well as vertical core radiators and with 4126/884/2 rage o Young AV and CI type coolers it appears that the horizontal core radiat- or is by far the most trouble prone in reference to core leakage as well as motor burn out. The horizontal core radiator's potential benefits from reduced cooling power consumption appear somewhat marginal, especi- ally when it is installed in a location, where the waste heat recapture system will be capable of utilizing all available waste heat during 8-9 months out of the year. It is my impression from working on the waste heat recapture systems previously installed on AVEC power plants, that we have been installing vastly oversized radiators. I realize that the radiator selection has probably been based on the largest unit operating at max. continuous load on a 80 degree day. Even though this situation in theory could take place, it is in reality very unlikely. As an example I can men- tion, that the average load in July in Chevak is only 97.3 kw. I have initially selected a Young MWC66D3 radiator with a 2 speed, 3 phase arctic type motor. To illustrate the suitability of this radiator, I have printed out a smal] LOTUS spreadsheet showing the cooling capac- ities of this radiator at low and high speeds as functions of ambient temperature. Accordingly, the spreadsheet shows the corresponding generator loads that the radiator could cool with a 353 or 3412 (or any other engines with similar specific heat rejection) on line. Please note that this spreadsheet does not take into account piping losses, AVEC heating system losses/consumption, or any heat removed by the waste heat recapture system. As can be seen, even with the waste heat recapture system off line, the radiator will basically never need to operate at high speed, even if the 353 was used. It should be noted that even at high speed, the noise ag = this radiator is only 83 db(A) while it is only 70 db(A) at ow speed, As we are still contemplating construction this year, an expedient design review by your staff would be greatly appreciated. If you have any questions, please do not hesitate to contact me. Sincerely, by Bit Gg Ss Peter N. Hansen, P.E. Project Manager. — PHimt Attachments as stated. 4126/884/3 “ly, Le (end to QOGs creo +t - ott ° | OD-C a /1 7/€& Alaska Village Electric.Coépérative, Inc. g 4831 Eagle Street : 1 5 Anchorage, Alaska 99503-7497 6 NOV 17 P8 03 (907) 561-1848 ore? November 16, 1988 Mr. David Denig-Chakroff Manager of Project Evaluation Alaska Power Authority P.0. Box 190869 Anchorage, Alaska 99519-0869 RE: Chevak Waste Heat Agreement Dear Mr. Denig-Chakroff: The above-referenced agreement has been reviewed for conformance with the recommendations of our legal council which were presented in letter form dated September 25, 1987, following review of the Togiak Waste Heat Agreement. Those recommendations appear to have been incorporated into the Togiak and New Stuyahok agreements which were approved by AVEC. However, one of the requested changes appears to have been deleted from the Chevak agreement. The following additions and modifications are requested: 1. The following covenant should be added to Article A and Article C: Immediately notify the Cooperative of any situation which may affect the safe and efficient operation of the Cooperative facilities. 2. The first sentence of Article D Paragraph 3 should be modified by the addition of the following statement "subject to the Cooperative's right of design approval in Article A, Paragraph 2 of this Agreement". 3. New to this agreement is Article B Paragraph 10 which requires the cooperative to provide information which is already being submitted as part of the PCE Program and therefore should be deleted from this agreement. Not critical to the acceptability of the agreement are the following items that should be corrected if the entire agreement is redrafted. 1. Article D Paragraph 4a: Delete “ensure the recommissioning" and add "secure the commissioning". 2. Article D Paragraph 4B: Delete “recommission the system in the third quarter of 1989" and add "commission the system in the quarter of " Se Mr. David-Denig-Chakro. November 16, 1988 Page 2 Although not specifically stated, AVEC assumes that if funding is withdrawn, reduced or limited in any way after the effective date of this agreement and before the completion of performance, the APA will restore to proper working order any portion of the AVEC system that may be dismantled, partly modified or only partially completed. Sincerely yours, MHak € SAGA Mark E. Teitzel Assistant General Manager Alaska Village Electric Cooperative, Inc. 4831 Eagle Street Anchorage, Alaska 99503-7497 , (907) 561-1818 RECEIVED BY. SLASKA Pal November 1, 1988 BB NOV -2 P7+13 Mr. Peter N. Hansen, P.E. Project Manager Alaska Power Authority P.0. Box 190869 Anchorage, Alaska 99519-0869 RE: Chevak Waste Heat Design Dear Peter: We have reviewed your letter and set of preliminary blueprints, received October 26, 1988, on the above mentioned project and have the following comments. 1s We prefer alternative I with the request that the existing shell and tube heat exchanger be relocated to the wall of the power plant structure in order to reduce congestion and the difficulty of performing maintenance on the D353. We request that the base of the proposed new radiator be installed no lower than the existing floor level of the Butler building due to the substantial snow drifting problems often encountered at Chevak. A separate expansion tank will likely be required above the existing radiator to provide for proper operation in the event the Butler building units are operated with the Hussman module radiator. AVEC's standard engine numbering convention establishes Position #1 in the Butler building on the switchgear end of the building, Position #2 in the middle, Position #3 nearest the daytank and Position #4 and #5 assigned to modules that are installed in addition to the Butler building. Both the Butler building and the Hussman module continue to settle and must be leveled from time to time. Therefore any piping that is suspended from or between these two structures must have suitable means of allowing for differential movement. Stainless steel flex hoses are recommended (not rubber hose). It is requested that two ventilation systems identical to AVEC's standard be installed on the front of the Butler building as high as possible and Mr. Peter N. Hansen, P November 1, 1988 Page 2 10. each side of the door in order to force outside air into the interior of the building. The door and louver alongside the door are occasionally removed in order to move major equipment items into and out of the building and therefore the ventilation system should not be installed in this specific section of the building. One theory relating to radiator core failure is that anytime a radiator core circulating 185°F coolant is suddenly subjected to forced ventilation capable of lowering the coolant temperature to O0°F in less than one minute, a core failure will occur. Methods of preventing core failure include installation of radiators inside a heated area (not very efficient), running the radiator fan all of the time (again not very efficient), reducing the size of the radiator core and/or fan motor size in order to reduce the maximum cooling rate, installing restrictive louvers to reduce either intake or exhaust air flow through the radiator (also not every’ efficient), installing thermostatically controlled, motor operated shutters on the radiator core (another potential maintenance problem) or installing a variable speed drive to slowly increase fan speed. AVEC's preference is the use of variable speed drives. While the average loads are relatively low, it is not the average loads that we are concerned with when it comes to meeting the peak energy re- quirements of the villages. The peak 15 minute loads for Chevak have been: June 1988 180 KW July 1988 169 KW August 1988 252 KW September 1988 242 KW We feel that greater cooling capacity is necessary to meet future load growth based upon a projected fifteen year life of this project. Our preference is a 33 series horizontal core with an elevated cover to prevent snow or rain from falling directly on the core. If a vertical core is desired, then it should be an 86 series in order to standardize with the existing unit and to provide for future load growth. We are quite con- cerned with the problem related to snow drifting around the vertical core unit and therefore recommend the 33 series horizontal core. WIth the recent build-up of structures adjacent to and around the AVEC power plants, noise has become of increasing concern by people living in the village. Where noise levels can be reduced with minimal cost, steps should be taken. A 33D3Q has a maximum sound level of only 73 db(A) at 25 feet compared to 83 db(A) for the 66D3 which is nearly four times as loud. Therefore, a quiet rated radiator should be specified. We would very much appreciate seeing the flow schematic with proper valve settings for each operating alternative, i.e., engine #1 in the Butler building operating with radiator #2 in the Hussman module, engine #4 in the Hussman module operating with radiator #1 on the Butler building, etc., with conditions of plate heat exchanger removing adequate heat to bypass the radiator and plate exchanger not removing adequate heat to bypass the Mr. Peter N. Hansen, P._- November 1, 1988 Page 3 ll. 12s 13. 14, radiator. Separate flow schematics would show valve settings when each item is bypassed for repair. We would very much appreciate seeing a pressure drop chart with individual pressure drops for rated flows through the existing shell and tube heat exchanger, new plate heat exchanger, and the new and existing radiator and piping compared against the engine manufacturers maximum recommended restrictions. Low coolant level switchgauges should be incorporated in the expansion tanks of each radiator. We would very much appreciate seeing estimates on coolant capacity and expected expansion volume and comparison with installed expansion tank volume. I was unable to locate the list of components initially selected for this project that was referenced in your letter. Sincerely yours, Mek SRN Mark E. Teitzel Manager, Engineering February 23, 19789. Mr. Mark E. Teitzel, Assistant General Manager Alaska Village Electric Cooperative 4831 Eagle Street Anchorage, Ak. 99503-7497 Subject: Chevak waste heat design. Dear Mr. Teitze!l: l have received your letter of 2/16/89 concerning Chevak, and | am at this time somewhat discouraged by what appears ta be history repeating itself. Every time we get into the mode of design review, a retatively simple design is madified with additiana! layers of complexity» until the original design philosophy has been last. The unfortunate AVEC specified, AFA installed series/2-pass configuration of two horizontal core radiators with a step controller is a clear example of this. bie is my firm beliet that in order to get these systems to work reliably with [ittle maintenance needed aver an extended periad, they must be kept very simple and basic. Operator involvement must be avoided or kept tao an absolut minimum, and if such involvement becomes necessary> the complexity must match the capability af the ever-changing local operations personne!. Once installed oan an existing facility» the big picture must still appear simple and straight forward ta the operator and ta the maintenance personne!, and in this area I teel that previous installations have tailed miserably. Atter reading your letter and after reviewing recent operational problems in Savaonga and Chevak with Mr. John Lyons, I hereby Propose that we start al! over in Chevak and develop a ~reliable and yet very simple design. It appears obvious that the snow problems encountered in Savoonga warrant a complete reevaluation of the way we design cocling systems for intermittent service in areas with blowing snow. Evidently, the radiators have to be mounted as high as passible, and it would alsa be helpfuls if the radiator design was well suited for operation in snow. As iftfustrated in Chevak, we cannot rely on the operator to clear Snow away trom the radiator. What I wil! be proposing to you will be a design> which may seem unusual to yous yet it is a design which, due to its simplicity» has proven itself in some of ‘the feast maintenance capab!e communities in Alaska. My proposal! is as follows: ‘ All radiators in Chevak be located on a stee! framework on top of ray the module. as 3 “ea. circular core radiators in up-blast configuration be used tor engines #1,2 and the existing MWC-84 or 3 ea. additiana! circular core radiators be used for engine #4. The circular core radiators will be 1-1/2 hp» single speed; 3-phase motors with completely independent controls on three different elregl* breakers. These radiators will be sized tao pravide adequate cooling for a Cat 353 at ful! !oad on a 40 degree day with only two radiators in service. The radiators will have a “hat” toa reduce the amount of snow, which accumulates on the radiator. 2 The heat exchanger be located in the radiator plenum in the module,» thereby camp!etely eliminating the need for a platform on the Butler building. 4. The two systems be kept completely independent» thereby eliminating the need for several by-pass valves and additiana! expansion tank components» which the local operator wil! be unable ta utililze anyway. 2 The existing shel! and tube heat exchangers be removed and the existing AVEC heating system be connected to the new flat plate heat exchanger with appropriate provisions to allow tor stand- alone operation at AVEC’s heating system in case at a line break on the line to the high school. Iocan mention to you that very similar systems are working with fittle or no maintenance in Atka, Diomede, White Mountain> Golovin» Koyukuk» Birch Creeks and Nikolai. I am attaching a spec. sheet on the radiators,» which in reality are down blast unit heaters. Please note that these unit heaters are sold as radiators by Young; a phone cal! to Young contirmed my Bpicion that they are identical to Younsg’s unit heaters. I have used other manutacturers such as Dunham~Busch and Coi! Company, and my preference is for Coil Company because of the !ower pressure drap in their design. Wwe have to date not experienced a single motor failure, and due to the circular, brazed tube design af the core, I certainly do nat expect +6 see any core failures. Another obvious advantage is that these radiators weigh approximately 200 Ibs. including the motor and will fit nicely in a Cessna 207. With the motor, fan and other components removeds they can be hand!ied by ane man (1 have tried its and even though it would be a chore; it certainly is no comparison to handiing a core tram a horizontal or vertica! core radiator!). The motor is a standard (quiet) 1140 rpm 3-phase mator costing about $200 and weighing in at tess than 50 Ibs. Please discuss this proposal with your Operations Department and tee! tree to contact me-at 261 7221 if you have any questions or comments. Sincerely, Peter N. Hansen» P.E. Project Manaser. Attachments? As stated. 4/12/87. Loren Rasmussen» Chiet Design & Construction Standards Department of Transportation and Public Facilities PO. Bax Z Juneau» Alaska 97811-2500 Reterence: Your letter of 1/20/89 regarding Chevak Waste Heat recovery Project. Dear Mr. Rasmussen: In response to your request of 1/20/89, please be informed that the project was postponed ta the 1989 caonstructian season due toa delays in the final engineering review process involving the local utid Lty. Accordingly» Bid Waiver #88280301028 was not used and can be cancelled. We expect tO commence conStruction as 500n as weather permits and expect to construct the project on a force-account basis using focally available labor under Power Authority statf supervision. In you have any further questions, please da nat hesitate ta contact me. Sincerely» Peter N. Hansen Praject Manager. he Cs iP November 39, 1989 RECEIVED nen 2 1989 ALASKA ENERGY AUTHORITY Alaska Energy Authority 701 East Tudor Road Anchorage, Alaska 99519-0869 Attention: Mr. Gary Smith Reference: Chefornak Fuel System Study FPE #AEA-89035 Gentlemen: This letter transmits four copies of the study regarding the investigation of the Chefornak bulk fuel storage system. This study was authorized in your notice to proceed issued under Contract AEA 2800097, Work Order #4, dated October 16, 1989. The study addresses the conditions and problems associated with the existing bulk fuel storage system at Chefornak. The study makes recommendations for improve- ments to the tank farm, improvements to the transfer pipeline and pumping system, and other upgrades and improvements to be considered. After you have had the oportunity to review the information, we will be happy to discuss any aspect of the data with you or your appointed representative. Thank you for the opportunity to assist you in this important project. Please contact us if we may be of further service. Sincerely, FRYER/PRESSLEY ENGINEERING, INC. Thomas Redmond Project Manager FRYER/PRESSLEY ENGINEERING, INC. 560 E. 34th Ave., Suite 300 e Anchorage, AK 99503 e Ph: 907/561-1666 e FAX: 907/561-7028