Here’s an informative guide to help you understand how to choose not only the correct size of gas booster, but an insight to the overall package type.

Determine the Flow Rate Requirements for your Gas Booster 

The first step in choosing a gas booster is to determine the maximum gas flow rate required for the application, typically measured in cubic metres per hour (m³/hr). This can be achieved by calculating the total installed flow rate of all gas products after the gas booter when operating at full capacity.

Total Gas Consumption = ∑ Individual Gas Consumptions

For example, if you have:

• Two gas burners, each consuming 100 m³/hr
• One CHP consuming 250 m³/hr

The total gas consumption = (100×2) +250=200+250=450 m³/hr

If the rated consumption is not known, you can use the rated power in KW and do a conversion:

1 m³/hr ≈ 10.5 kW

For example, for an 800 kW boiler:

It is essential to ensure that the gas booster you select can handle your required flow rate without any risk of overloading or underperformance. Secomak offers models that accommodate a wide range of flow rates, from as low as 300 m³/hr to as high as 2000 m³/hr. Choose a model that matches or slightly exceeds your required flow rate to ensure efficiency.

Current gas pressure prior to boosting.

You need to know the working gas pressure to the inlet of the gas booster; this will be in mbar. In the UK the pressure is typically regulated to 19-21mbar.  For natural gas booster installations that are covered by the IGEM UP/2 regulations, it is requirement to have a minimum of 10mbar.

Consider the Required working pressure.

What pressure do you require after boosting? This is vital to determine the size of the gas booster. Different applications require different levels of gas pressure, you will need to check the specifications of all the gas appliances to understand their minimum required gas pressure.

Calculate the pressure lift

Typically measured in millibars (mbar), and it refers to the amount by which the booster will increase the incoming gas pressure to meet operational demands. You simply must subtract the required working pressure from your current pressure, the difference is your required pressure lift.

Pressure Lift = Required Working Pressure − Incoming Pressure

For example, if the Incoming Pressure is 20 mbar and the Required Working Pressure is 60 mbar:

Pressure Lift = 60 mbar−20 mbar = 40 mbar

Secomak’s standard gas boosters are available with pressure boosts from 30 mbar to 112 mbar with special solutions capable of up to 500mbar.  It’s essential to understand the pressure requirements of your specific application. Selecting a booster that can easily meet the required pressure boost ensures smooth operation and avoids potential safety risks.

Gas Booster Model Selection

Once you understand the required flow rates and the boosted pressure lift requirements, with these two bits of key information, you can select the Secomak gas booster model that matches the requirements. Simply enter your flow rate and pressure lift requirements into the gas booster product selector, and you’ll be provided with the ideal gas booster that meets your needs.

But that is not where the journey ends, there are other considerations to make when selecting the best overall package. Do you need a Duty & Standby configuration, or is a single gas booster sufficient? What type of controls are right, variable speed driven or run 100% all the time? Are there other consideration to make such as power requirements or noise level?0 Let’s explore them further:

Duty & Standby by?

Gas boosters’ packages mainly come in two types, either a single unit or a duty & standby, but what is a duty & standby?

Essentially, they both do the same thing, with only one gas booster running at a time but with a duty & standby configuration you have the added comfort that if the running gas booster has a fault, there is another booster waiting in standby. With Secomak’s Duty & Standby configuration you get a single control panel to operate both boosters, so in the unlikely event the running booster did fail, the standby booster would automatically kick in providing uninterrupted boosted pressure supply. There are other benefits to the Secomak duty & standby too, every 7 days the system will automatically switch which is the running gas booster, providing equal wear and ensuring the backup booster is always available. It also allows routine maintenance to take place without interrupting gas supply, whereas on a single package you would have to isolate the appliances requiring booster pressure.

So why would you choose the duty & standby over the single unit when it is likely to cost more? That’s simple, if the requirement for boosted pressure is process critical and you cannot afford interrupted gas pressure, the duty & standby is the right option.

Variable speed drive

With all Secomak’s gas booster’s packages, you have the option to have the booster variable speed driven or to run at 100% all the time. Secomak’s variable speed package is known as an APS booster, standing for Automatic Pressure Stabilisation. This gives the added benefit of adjusting the speed of the gas booster via the use of an Inverter (VFD) to match a desired target pressure. During a commissioning process, the engineer will set the target booster pressure requirement via a potentiometer located on the control panel. There is a pressure transducer included in the package that is required to be installed in the pipework after the gas booster, to measure the current pressure. As the flow changes and demand for the booster pressure changes, the gas booster will automatically adjust to match it.

So, what is the benefit of the APS system? If the demand on gas is variable of the requirement for boosted pressure is low, regulating the speed of the gas booster will reduce, power consumption, wear and tear & operating noise levels.  Is the perfect package for variable demand applications.

Noise Considerations

Operational noise is an important consideration, especially for facilities where noise sensitivity is a concern. All Secomak’s gas boosters operate at noise levels below 85 dBA, which is within the industry standard for acceptable noise output. If your facility has strict noise requirements, consider adding additional noise-reducing features such as the Secomak acoustic enclosure, which can be supplied with all types of our gas  boosters.

Please be aware that if a booster is installed in an acoustic enclosure or an area lower than 10m³, a DSEAR risk assessment will be required and may be required. We offer an upgraded safety package for these types of applications referred to as our gas sensor system. We add additional safety measures an incorporate Duomo gas detectors on our gas boosters that in the event of a small gas leak will isolate the electrical supply to the booster to stop it running.

Safety Requirements

Installations of natural gas boosters are regulated by the IGEM UP/2 standards and for installations operating below 150mbar are covered by the British Standard BS 8487:2007 & 2013. All Secomak’s gas booster packages comply with these regulations. There are additional ancillary products required on gas booster installation to meet the regulatory standards. These include:

• Anti Vibration feet, to reduce gas booster vibration and stress on pipework connections.
• Flexible connectors on the inlet & outlet of the gas booster, again to reduce vibration and stress on pipework connections.
• Non-Return Valves (NRVs) to ensure that boosted pressure does not return through the booster and to other lower pressure gas pipework.

Secomak package boosters are usually supplied with the above installation accessories but it’s imperative that installer check that they are sized appropriately to the application.

Power supply

Not all gas boosters are alike, with the large variety of models and packages, the electrical requirements can be different. Therefore, it’s crucial to ensure that the gas booster is compatible with your facility’s power supply. Secomak gas boosters come in both 230V single-phase and 400V three-phase options. Make sure that the selected booster matches the power specifications of your facility.

Check for Space Availability

The physical size of the gas booster is another key factor in your selection. Secomak’s centrifugal gas boosters are designed to be compact and efficient, but you’ll still need to ensure that the chosen model fits within your installation space. Take the time to measure the available space, allowing for proper airflow, ventilation, and easy access for maintenance.

Consider Maintenance and Serviceability

Gas boosters are long-term investments, so it’s essential to select one that is easy to maintain. Secomak gas boosters are known for their durability, but regular maintenance is still necessary. Secomak offers ongoing technical support and spare parts, which helps keep your equipment in top shape.

Review Flexibility for Future Adjustments

Depending on your application, you may need to adjust the gas booster’s performance over time. Whether it’s a change in operational needs, shifts in pressure requirements, or alterations in flow rates, Secomak offers models with flexible configurations that allow for future adjustments. This flexibility can be crucial for businesses that may expand or change their operational setup over time.

Consult with Secomak Experts

Choosing the right gas booster doesn’t have to be complicated. Secomak’s team of experts is always available to help you select the most suitable model for your specific requirements. Whether you need assistance with technical specifications or just need guidance on installation, Secomak provides comprehensive support to ensure that your gas boosting system is a perfect match for your needs. CONTACT 

 Secomak Gas Booster Models Overview

Below is an overview of some of Secomak’s gas booster models. This table highlights key specifications such as flow rate, pressure boost, and power requirements, which can help guide your decision.

Conclusion

Selecting the correct Secomak gas booster ensures not only the efficiency and safety of your operation but also long-term reliability. By considering the flow rate, pressure boost, power supply, space constraints, and safety features, you can make a more informed decision. With Secomak’s range of high-quality gas boosters and expert support, you’ll be able to meet your gas boosting needs.

If you’re unsure which Secomak gas booster is the best fit for your application, don’t hesitate to reach out to our team for personalised assistance. CONTACT

The post How to Choose the Right Secomak Gas Booster for Your Needs first appeared on Gas Boosters by Secomak.

As a company, we have nearly a century of history, we understand the importance of honouring our past while embracing the future. At Secomak, we are excited to announce a significant milestone in our journey: the introduction of our new logo.

Rebranding a company with nearly 100 years of tradition & innovation was always going to be challenging. We believe our new logo strikes a careful balance between modernism and a homage to the legacy we’ve built over decades.

This refreshed branding is being rolled out across our entire range of gas boosters. While the logo may be new, the quality, reliability, and engineering excellence that you’ve come to expect from us remain unchanged.

The decision to rebrand wasn’t taken lightly. We wanted to ensure that our new look not only represents who we are today but also where we’re headed. This fresh identity symbolises our commitment to innovation and delivering high quality products for years to come.

We’d like to extend our thanks to our team, partners, and loyal customers for your continued support as we embrace this new chapter. We’re confident that this rebrand will help us better serve you and strengthen our position as a leader in the industry.

Stay tuned for more updates as we continue to roll out our new branding. We look forward to your feedback and continuing this journey with you, now with a fresh new look.

The post New Gas Booster Logo 2024 first appeared on Gas Boosters by Secomak.

A good gas booster installation means it is installed on a flat indoor surface but not in a meter room. There should be adequate waterproofing, and only flexible connections should be used before and after the booster. Non-return valves and the positioning of pressure switches are also crucial.

There’s a bit more to it than that, though. If you want to ensure optimal efficiency, reduced maintenance costs, and an extended lifespan on your equipment, it’s important to cover all bases of a good gas booster installation. To learn more about common issues faced by gas booster systems, read our detailed guide. Let’s go into more detail so you can know what to look out for.

Key Indicators of Proper Gas Booster Installation

There are several basic points to look out for, including the following:

•       The gas booster should be installed on a flat and stable surface. This ensures that the booster remains steady during operation, reducing vibration and noise, while also preventing potential damage to the booster and connected systems.
•       Ideally, gas boosters should be installed indoors. This protects the equipment from weather elements and temperature fluctuations, which can affect its performance and lifespan.
•       Gas boosters should not be installed in a meter room. This is due to safety considerations, as meter rooms often house other utilities and equipment. A separate, dedicated space for the gas booster reduces the risk of gas leaks or pressure issues affecting other systems.
•       The installation site should have good ventilation. This helps to dissipate heat generated by the booster during operation, preventing overheating and ensuring efficient performance.
•       The gas booster should be installed in a location that allows easy access for maintenance and servicing. This ensures that any potential issues can be detected and addressed promptly, reducing downtime and maintenance costs.
•       The orientation of the gas booster and its components is crucial. For instance, non-return valves should be positioned horizontally with the arrow facing the right way. This ensures the correct flow of gas and prevents backflow.

Importance of Weatherproofing and Indoor Installation

It’s best to install a gas booster indoors. If that isn’t possible, a weatherproof enclosure is absolutely essential.

Like any other mechanical equipment, gas boosters are susceptible to damage from weather elements such as rain, snow, extreme heat, and cold. Weatherproofing, which involves using protective enclosures or shields, helps protect the gas booster from these elements, ensuring its longevity and consistent performance.

Weather elements, particularly moisture, can lead to corrosion of the gas booster and its components. Indoor installation or the use of weatherproof enclosures can significantly reduce exposure to moisture, thereby reducing the risk of corrosion.

Gas boosters also operate best within certain temperature ranges. Extreme cold can cause parts to contract, while extreme heat can lead to overheating. Indoor installation helps maintain a stable temperature, thereby ensuring optimal operation.

Furthermore, indoor installation can enhance safety by reducing the risk of accidental damage to the gas booster. It also provides a controlled environment that can be equipped with additional safety measures such as ventilation systems, fire suppression systems, and gas leak detectors.

It could also be a matter of compliance. In many regions, regulations may require gas boosters to be installed indoors or within weatherproof enclosures to ensure safety and environmental protection.

The Role of Flexible Connections

Gas boosters can vibrate during their operation. It’s normal, but it could cause strain and stress on various components, primarily connections. That’s why it’s important to use flexible connections before and after your booster.

Flexible connections help absorb vibrations, preventing them from being transmitted to the rest of the system. This reduces wear and tear on other components and contributes to the overall longevity of the system.

In some cases, there could also be slight movement in the system due to changes in temperature, pressure, or other factors. Flexible connections can accommodate this movement without causing damage or leaks.

By allowing for some movement and flexibility, these connections can reduce the stress on the gas booster and other components. This is particularly important in systems that often operate at high pressures or where there are rapid changes in pressure, such as gas boosters.

It’s important to note that, while flexible connections offer these advantages, they must be installed correctly to function effectively. They should be straight and not bent, as bends can cause stress and potential failure. Also, over time, flexible connections can wear out and may need to be replaced to maintain the efficiency and safety of the system. To see options for flexible connectors that can enhance your installation, check out our accessories page.

Correct Installation of Non-Return Valves

The next parts to inspect to ensure your gas booster has been installed properly are the non-return valves.

Non-return valves are designed to allow gas to flow in one direction only. They play a crucial role in preventing backflow, which could potentially damage the gas booster or other components of the system. Incorrect installation of these can be detrimental to the performance and overall health of your system.

They should be installed after the outlet flexible connection to ensure that the valve operates effectively to prevent backflow. The valve should be positioned horizontally, with the arrow on the valve body pointing in the direction of the gas flow. This orientation is critical for the proper functioning of the valve.

By preventing backflow, non-return valves protect downstream equipment from potential damage caused by reverse gas flow. This is particularly important in systems where there are rapid changes in pressure. The correct installation of non-return valves is often a requirement under safety standards and regulations, so the importance of proper installation cannot be overstated.

Like other components of a gas booster system, non-return valves require regular inspection and maintenance to ensure they continue to function correctly. Any signs of wear or damage should be addressed promptly to prevent potential issues. Learn more about our non-return valves and their installation to ensure proper flow direction and prevention of backflow.

Installation and Positioning of Pressure Transducers and Switches

Pressure transducers and switches play a pivotal role in monitoring the gas pressure within the system. They provide real-time data on the pressure levels and enable the system to respond appropriately to any changes.

The pressure transducers should be installed after the non-return valve. This placement ensures that they can accurately measure the pressure of the gas after it has passed through the booster and the non-return valve. Pressure switches are typically installed at strategic points in the system where pressure monitoring is most critical. Correct positioning is vital for safety and efficiency.

By providing accurate and timely pressure data, pressure transducers and switches help detect potential issues such as overpressure or underpressure conditions, allowing for prompt corrective action, ensuring that the system operates within its optimal pressure range for safety and efficiency.

Accurately installed pressure transducers and switches not only ensure operational efficiency but also significantly aid in preventative maintenance by providing early warnings of potential issues.

While pressure transducers and switches may seem like small components, their role in a gas booster system is significant. Incorrect installation or failure of these devices can lead to operational issues and potential safety risks.

Ensuring Effective Control and Maintenance Access

The gas booster should be installed in a location that allows easy access for maintenance and servicing to ensure that any potential issues can be detected and addressed promptly. Adequate space should be provided around the gas booster to allow engineers to perform maintenance checks and servicing easily. This space should be kept clear of any obstructions.

It’s important to note that the control bypass is distinct from general maintenance considerations. It’s a control feature that allows the system to bypass certain operations under specific conditions, enhancing the system’s adaptability.

Essentially, control bypass contributes to the system’s operational performance, while general maintenance practices ensure the system’s health and longevity. Both are important, but they serve different purposes. The control bypass is about managing the system’s operation, while maintenance is about taking care of its physical condition.

Regular maintenance, enabled by easy access, can help keep the gas booster system running at its most efficient. It can prevent minor issues from escalating into major problems that could impact the system’s performance. Ensuring effective control and maintenance access also contributes to the overall safety of the system by allowing inspection and prompt resolution of safety issues.

Structural and Operational Considerations

Checking on the structural soundness of the gas booster, as well as all the associated operational considerations, is just as important. There are several things to look out for, including:

•       The pipework leading into the gas booster should be as straight as possible. This helps to ensure a smooth and unrestricted flow of gas into the booster, which is crucial for its efficient operation. Bends or kinks in the pipework can cause turbulence, which can reduce the efficiency of the booster and potentially cause wear and tear on the system.
•       Gas boosters can generate vibrations during operation. Installing the booster on anti-vibration mounts can help absorb these vibrations, reduce noise, and prevent the vibrations from being transmitted to the rest of the system. This can extend the lifespan of the booster and other connected components.
•       The environment in which the gas booster is installed should be quiet and free of debris. Noise can make it difficult to detect any unusual sounds that might indicate a problem. Debris can clog the system and cause damage. Regular cleaning and maintenance are important to keep the environment suitable for the booster’s operation.
•       System Design: The design of the system in which the gas booster is installed can also impact its operation. Factors such as the size of the pipework, the number of bends in the system, and the distance the gas needs to travel can all affect the pressure and flow rate of the gas. The system should minimise pressure losses and ensure an efficient flow of gas.

These structural and operational considerations are general guidelines and may vary depending on the specific model of the gas booster and the requirements of the installation site. Learn more about boosting gas pressure effectively with our detailed guide.

Support Systems and Environmental Controls

It makes sense that the size and design of the supporting pipework will play a crucial role in the operation of a gas booster. The pipework should be correctly sized to ensure minimal restrictions and optimal gas flow, since any restrictions in the pipework can cause pressure drops and reduce the efficiency of the gas booster.

But proper ventilation is also essential for the safe and efficient operation of a gas booster. A well-ventilated room helps to dissipate heat generated by the booster during operation, preventing overheating and ensuring efficient performance. It also helps to ensure a safe operating environment by allowing any leaked gas to disperse quickly.

The operating environment of the gas booster should be kept within the temperature range recommended by the manufacturer. Extreme temperatures can affect the performance of the booster and may lead to premature wear and tear.

These factors have become even more crucial for regulatory compliance. The design and installation of the gas booster system should comply with industry standards such as IGEM UP/2, which provides guidelines on various aspects, including ventilation, installation, maintenance, and safety procedures. For detailed information on compliance with British standards in gas booster installations, visit our guide.

Leveraging APS Systems

Incorporating Advanced Pressure Systems (APS) into a gas booster installation should really be common practice when we consider the benefits they offer.

APS systems are designed to enhance the responsiveness of gas booster systems. They do this by adjusting the motor speeds to match the operational demands of the system, meaning that the gas booster can respond more quickly and accurately to changes in demand. This improves the overall efficiency of the system.

By adjusting motor speeds to match operational demands, APS systems can optimise energy usage. In other words, the gas booster only uses as much energy as is necessary for the current demand, reducing waste and saving on energy costs.

Operating a motor at high speeds constantly can lead to wear and tear over time. APS systems help to mitigate this by adjusting the motor speed based on demand, resulting in less wear and tear on the motor and prolonging its life.

APS systems contribute to the operational stability of the gas booster system. By ensuring that the motor speed matches the operational demand, APS systems help to prevent issues such as pressure fluctuations that can impact the stability of the system.

It’s important to note that, while APS systems play a crucial role in managing gas pressure, they are not regulators. They do not control the pressure in the system, but rather adjust the motor speed to meet the demand. This distinction is important for understanding how APS systems function and their role in a gas booster system.

While APS systems optimise motor speed and reduce wear, they complement but do not replace the need for accurate gas pressure regulation and system design considerations. For an in-depth look at how APS can stabilise your gas pressures, see our article on APS systems.

Overall, an APS can improve your gas booster’s performance, reduce wear, and make the system more energy efficient. These factors make APS systems a crucial part of any gas booster installation.

Conclusion

Proper installation is a critical step towards maximising the benefits of your gas booster system. Adhering to these installation guidelines not only extends the life of gas boosters, but also ensures safety and efficiency, leading to reduced downtime and lower maintenance costs. Regularly check your gas booster’s performance and maintenance needs. Here’s how.

To ensure your gas booster is installed for optimal performance, it’s always wise to contact the experts. With over 90 years of experience in the industry, why not give Secomak a call? To learn more about our expertise and services, visit our about page.

The post The Signs of a Good Gas Booster Installation first appeared on Gas Boosters by Secomak.

Most common gas booster pump issues are related to unstable or incorrect inlet or output pressures. It’s often caused by low pressure from the supplier, but internal issues like motor overload or incorrect belt alignment also cause output pressure problems. Regular maintenance can avoid most issues.

Gas boosters are powerful and complex, but they aren’t the most difficult devices to troubleshoot. They have a few essential components that make them work, and a good understanding of those components can help us solve the most common issues. Let’s explore the inner workings of a gas booster and discuss what could go wrong (and how to fix it).

Introduction to Gas Booster Challenges

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Gas boosters are valuable in various industries and fields—pretty much any industry that requires a stable gas supply. These include industrial uses like air knives, surface cleaning, electronics manufacturing, HVAC systems, etc. Even aviation ground support teams use gas pressure boosters.

Some of the most common problems these users experience with their gas boosters include:

• Loss of input pressure, which is usually caused by poor gas input from the supplier, clogged filters, or leaks, often shows itself by tripping pressure switches.
• Loss of output pressure, which is often caused by factors such as belt misalignment.
• Noisy operation because of poor belt alignment, worn bearings.

Understanding Gas Booster Mechanics

A gas booster takes low-pressure gas (or air) and increases its pressure to a higher level. It achieves this by using a piston or diaphragm mechanism driven by compressed air or centrifugal fans.

There are various types of gas boosters that suit different use cases. Secomak’s gas boosters consist of the following essential components:

• Booster impeller chamber
• Drive motor
• Drive belt and belt guard
• Outlet pressure switch (OP)
• Inlet pressure switch (IP)
• Booster bearing assembly

When all of these components are correctly set up, the gas booster will work as it should. However, many of the components require regular maintenance. The likelihood of problems increases if maintenance isn’t done on time or when components are incorrectly replaced during maintenance.

Troubleshooting Low Inlet Pressure

When you have low inlet pressure, the first step should be to check if you are receiving adequate pressure from the supplier. If not, it’s worth checking with the supplier to find out if there’s a supply problem. You can also use gas reservoirs to overcome inlet issues and ensure stable inlet pressure.

It’s also worth checking inlet filters, connections, and the inlet flange for any leaks, clogs, or faulty components.

The Role of Inlet Pressure Switches

Secomak gas boosters come with inlet pressure (IP) switches to protect the mechanisms. Whenever the inlet pressure drops too much or exceeds the limitations of the device, the inlet pressure switch will turn off the gas booster for safety purposes.

If the IP switch trips, the button on the switch must be manually pressed to reset the system. However, it’s essential to first check if your inlet pressure is within the safe operating range. If not, perform all the checks mentioned above or use gas reservoirs to stabilise the inlet pressure.

Enhancing Safety with Fire Alarms and Pressure Switches

Integrating a fire alarm system with your gas booster is a vital safety measure designed to automatically shut off the gas supply in the event of a fire. This precaution ensures that, during a fire, the risk of gas fueling the flames is minimised, enhancing the safety of the facility. Unlike pressure fluctuations, which are managed through other means, the direct link between fire alarms and gas boosters specifically addresses fire safety concerns.

Upon activation of the fire alarm, the gas booster’s connection to the fire safety system triggers an immediate response, shutting off the gas at the inlet to help prevent the escalation of the fire. Following such an incident, it’s essential to conduct a thorough safety inspection of all gas booster components and verify that the input pressure is stable. This ensures the system is safe and operational before manually resetting the inlet switch to resume normal operations.

This integrated safety feature underscores the importance of a proactive approach to fire safety, offering peace of mind and protecting against potential hazards associated with gas supply systems.

Utilising Gas Reservoirs for Inlet Stability

We aren’t always in control of the inlet pressure since it depends on our gas supplier. When the IP drops and the problem isn’t on our side, there’s only so much we can do to rectify the matter.

Maintaining consistent inlet pressure is crucial for the smooth operation of gas boosters. Still, this pressure can be subject to fluctuations beyond our control, primarily due to variances from the gas supply side. When sudden drops in inlet pressure (IP) occur, preventing the gas booster from tripping is paramount.

A strategic approach to mitigate these fluctuations involves integrating a gas reservoir into the booster system. This reservoir isn’t a standalone supply source but rather a temporary buffer. It connects directly to the pipework, offering a few crucial seconds of stability when the main supply momentarily dips. By smoothing out these initial pressure losses, the reservoir ensures the gas booster continues operating without interruption, effectively preventing unwanted trips of the inlet pressure switch.

Rather than replacing the main supply, the reservoir works in tandem with it, acting as an immediate response mechanism to preserve operational continuity. This setup allows the gas booster to maintain optimal functionality, drawing primarily from the main gas supply while relying on the reservoir’s support during transient pressure drops.

Managing Pressure During Duty and Standby Switchovers

Gas boosters are designed to operate efficiently under two distinct modes to ensure a reliable and consistent gas pressure supply. The system employs a structured cycle that alternates between these modes over a seven-day period, optimising performance and equipment longevity.

• Duty Mode: This is the primary operation mode, where the gas booster actively works at full capacity to boost the gas pressure as per the system’s requirements. It’s during this phase that the booster provides the necessary pressure to meet operational demands, ensuring optimal functionality of the connected systems.
• Standby Mode: In this secondary mode, the booster remains inactive but ready to engage instantly should the duty booster encounter any faults. This setup guarantees that there is no interruption in service, as the standby booster can immediately take over, maintaining an uninterrupted gas supply.

The transition from duty to standby booster is not triggered by fluctuating demand but is instead based on a predetermined seven-day schedule. This ensures that wear and tear are evenly distributed between the two boosters, enhancing their durability and service life. Only one booster operates at any given time, with the standby unit stepping in solely in case of a malfunction in the duty unit.

An integral component of this system is the inverter-driven technology, which plays a crucial role in maintaining the required outlet pressure. This technology allows for fine adjustments to the booster’s operation, ensuring that the gas pressure remains stable and consistent, regardless of the switch between duty and standby modes. The inverter-driven system significantly contributes to the efficiency and reliability of the gas supply, ensuring that pressure needs are met without overburdening the equipment.

Addressing Low Outlet Pressure and Belt Issues

Secomak pumps have a convenient Low Output Pressure light to indicate when the outlet pressure is too low. Several factors can cause pressure to drop at the outlet valve.

The belt might have come off. Since the booster pump is driven by a belt system, the gas pressure will drop when the belt is dislodged from its pulleys.

The belt might be misaligned. This often happens immediately after maintenance if the belt isn’t replaced correctly or when the belt is worn because it’s time for a service. You will probably hear some noise from the gas booster, and the outlet pressure might drop.

If some parts of the outlet valve or pipes are clogged, this will also adversely affect the outlet gas pressure.

The belt is usually the first component to check since it’s the most likely culprit. You can open the belt housing and ensure that the belt is firmly in place. If it is, you can check for leaks in the pipes or clogs in the filters or valves.

Regulating Pressure with APS and Governors

Sometimes, the gas booster pump will be functioning optimally, but the pressure delivered to the appliance will be too high. There are two solutions to this.

1. Install a gas pressure governor at the appliance’s input. Governors or regulators are designed to reduce the inlet pressure at the appliance to safe levels. The ideal level will depend on the appliance, and there are different types of governors to cater for different pressure requirements.
2. Use Secomak’s APS system. An Automatic Pressure Setpoint system, also known as an APS inverter, is a device that can be installed between the gas booster and the appliance to regulate the pressure and ensure that it remains stable. It uses a pressure transducer to constantly monitor the pressure and a controller to adjust the gas output to the perfect level.

Governors are helpful, but it’s an excellent idea to install an APS inverter to help ensure a consistent, stable gas supply to your appliances.

Optimising Performance with Inverter Adjustments

It’s possible that you already have an APS inverter installed since it can be easily integrated with a gas booster pump. If you do and the gas pressure is still too low when it arrives at the appliance’s input valve, the problem could be something as simple as a setting.

The APS inverter has a built-in controller in the form of a pot switch that you can use to adjust the output pressure. Making fine adjustments using the pot will usually help you find the perfect pressure for your appliance.

Solving the Mystery of a “Hunting” Gas Booster

A “hunting” gas booster refers to a situation where the booster cycles back and forth around the set point (SP) without stabilising. It oscillates excessively, causing pressure fluctuations.

The most common way to troubleshoot this is through PID tuning. The booster’s control loop uses a proportional-integral-derivative (PID) controller to regulate the output and maintain the desired pressure. Incorrect PID tuning parameters can lead to hunting.

Adjusting the proportional gain (P), integral time (I), and derivative time (D) to the correct settings will probably help.

Ensuring Proper Pressure with NRV and Flexibles

Non-return valves (NRVs) and flexible connections are essential components of a gas supply system designed for safety and operational flexibility. While integral to the system’s integrity, they can contribute to pressure loss, a characteristic not indicative of a fault but rather a consequence of their function in regulating gas flow.

Understanding this, it’s crucial to proactively manage and minimise such losses to ensure an efficient and reliable gas supply. Initial system design considerations should include a thorough evaluation of potential pressure drops associated with NRVs and flexible connections. This foresight allows for selecting components best suited to your system’s specific needs.

In response to this challenge, Secomak offers strategic solutions aimed at optimising your gas supply system’s performance. One effective method is the installation of larger non-return valves and flexible connections. These upsized components are designed to facilitate a smoother flow of gas, effectively reducing the resistance that contributes to pressure loss. By allowing a more free-flowing gas supply, these larger ancillaries significantly mitigate the impact of pressure drops, ensuring your system operates within its optimal pressure range.

To assist in this optimisation, Secomak provides valuable resources for accurately calculating the expected pressure loss through your system’s NRVs and flexibles. Armed with this knowledge, you can make informed decisions on the appropriate sizes and specifications for these components. This proactive approach not only enhances the efficiency of your gas booster system but also ensures it is equipped to deliver the necessary gas pressure consistently and reliably.

The Criticality of Belt Alignment

We’ve seen how critical belt alignment can be to the smooth operation of your gas booster. Apart from coming loose, a belt can also be misaligned, which often happens if it is improperly fitted during maintenance.

A misaligned belt could cause your gas booster to perform below its optimal capabilities and deliver low gas pressure. Still, it can also lead to several other problems that aren’t necessarily immediately noticeable.

For example, it will cause the belt to wear out more quickly, requiring more frequent maintenance, thereby incurring unnecessary costs. It will also adversely affect the lifespan of the bearing assembly since a belt that doesn’t run true will cause unstable operation and some rattling in the bearings.

Thankfully, Secomak pumps make it easy to fix this issue. It’s pretty easy to open and remove the outer belt guard, which will give you access to the belt itself. With the device powered off, run the belt with your hand to see if it is appropriately aligned. Since this step is so simple, it’s worth repeating it from time to time.

Preventive Maintenance: A Key to Longevity

When our machines and equipment are running as they should, it’s easy to forget about them. In fact, that’s kind of ideal—a good machine is one that runs so well that we don’t even have to think about it again. Unfortunately, even the best quality equipment needs maintenance from time to time.

Many of the faults and issues we’ve seen can be easily avoided when we perform regular maintenance. These maintenance times should be used to check all the parts of your gas supply system, including gas boosters, APS inverters, pipes, and valves. Look for leaks, clean out clogs, clean and replace filters, and check the gas booster’s belt and bearing assembly.

The challenge is to do this regularly. If we leave it too long, problems will sneak in. So, ideally, we should create a fixed maintenance schedule that accommodates downtime for the equipment so that everything can be inspected, cleaned, fixed, and replaced.

The specifics of your schedule should obviously depend on your use case, but it’s also a good idea to consider the running time of your equipment when calculating it. Ensure that you do maintenance before you reach the estimated time when parts like the belt should be replaced to avoid unplanned downtime.

Conclusion: Ensuring Reliability in Gas Boosters

A gas booster can revolutionise the way you operate your gas machinery and appliances. It is an affordable and energy-efficient device that will save you time and money in the long run. Unfortunately, problems will slip in from time to time that require proper troubleshooting and repair.

The tips we’ve been looking at come from Secomak’s many years of experience in the field of gas boosters and APS inverters. This means you can rely on this information to help you make the right choices and take the best steps, not only to fix any current issues you might have but also to help you avoid more severe problems in the future.

The post The Common Issues for Gas Boosters and their Solutions first appeared on Gas Boosters by Secomak.

I’ve always found the service provided by the team at Secomak to be first class, their product knowledge is excellent and are always willing to assist with any query be it product or delivery related. I would have no problem in recommending them as a supplier for Gas Boosters, they are our first-choice supplier in this field.

– Richard Parkes, Purchasing Manager, Enertech Limited.

Visit website

The post Testimonial: Enertech Limited first appeared on Gas Boosters by Secomak.

Regular maintenance protects your investment, ensures the equipment lasts longer and minimises downtime.

Please see below the minimum recommendations for predictive maintenance intervals that follows British Standards BS8487:2007.

Once a Year

Drive Belts should be replaced annually with our approved flat belt. This flat design allows the belt to slip off harmlessly should there be any rotation issues.

Every Five Years

Replace Gas Bearing Assemblies with the approved Secomak design every five years. Our Bearing Assemblies are made from sealed for life cartridges complete with a high precision impellor machined from a single piece of aluminium. They have been designed to minimise dust and dirt ingress, reduce heat & friction and simplify installation.

Replace Flexible Connectors every five years irrespective of how they appear, ensuring a tight seal whilst minimising vibration and metal fatigue.

If in doubt give us a call and our friendly sales team will be more than happy to help you out.

Gas boosters need to be maintained every 1-5 years according to British Standards BS8487:2007.

The post Winter Is Coming, Have You Checked Your Gas Booster? first appeared on Gas Boosters by Secomak.

Secomak is proud to announce that our preparations are in full swing for this highly anticipated event. In the lead-up to the show, we are thrilled to present a spotlight on one of our most fantastic products, the groundbreaking Gas Boosters!

Our journey with Gas Boosters dates back to 1966 when we first developed these exceptional devices. Fast forward to today, and we manufacture a diverse range of centrifugal gas boosters catering to residential, commercial, and manufacturing applications.

This year at the PPMA Show, we are unveiling our latest innovation, the cutting-edge HMI based control system, an upgrade on our immensely popular “Duty & Standby APS” control package.

What makes the Duty & Standby configuration so vital is its ability to ensure an uninterrupted supply of booster gas when it is critically needed. The controls are designed to automatically switch over the running booster every 7 days, guaranteeing equal wear and enabling preventive maintenance at a user-convenient time. In case of an unexpected stoppage, the backup gas booster swiftly takes over, ensuring continuous operation without any interruptions.

Introducing APS, which stands for Automatic Pressure Setpoint – this feature empowers users to enter their desired boosted pressure. In conjunction with the included inverters, the system automatically regulates the gas booster’s speed to maintain the desired outlet pressure. The primary purpose of APS controls is to ensure the gas pressure remains stable, even amidst fluctuating demand. This unparalleled precision makes our Gas Boosters ideal for industries such as food processing, medical equipment, and manufacturing processes.

One of the most significant advantages of APS controls is the reduction in wear and tear. Unlike traditional systems that run at 100% capacity all the time, our Gas Boosters only run at the required speed to achieve the desired pressure. This results in reduced energy consumption, lower noise levels, and significantly extends the overall lifespan of the gas booster.

In a nutshell, the Duty & Standby package, combined with APS controls, makes our Gas Boosters the most reliable option for applications where raised gas pressure is essential.

Make sure to visit our booth at the PPMA Show 2023 and witness the future of gas boosting technology firsthand. Our team will be thrilled to demonstrate the power and efficiency of these extraordinary gas boosters. Don’t miss out on this opportunity to elevate your gas pressure requirements to new heights!

The post Secomak exhibiting at PPMA 2023 first appeared on Gas Boosters by Secomak.

Gas supply is regulated for various safety reasons. However, gas pressure requirements also escalate as the population (and its needs) increase. Getting gas providers to increase capacity is tedious and often futile, so gas boosters are often the best way to increase gas pressure locally.

Having a gas supply as part of your infrastructure is essential for some people, and it’s the standard in some regions, like London. But having fixed infrastructure also means there are limitations in the gas pressure available to you. Let’s look at gas boosters and the problems that make them a necessity rather than a luxury.

Why Are Gas Pressures So Strictly Regulated?

Gas providers are responsible for setting and regulating gas pressure to ensure the safe and efficient distribution of gas to consumers. They carefully determine the appropriate pressure levels to maintain the integrity of the gas infrastructure and prevent safety hazards.

By restricting gas pressure, providers can control gas flow, avoid excessive strain on pipelines, and minimise the risk of leaks or accidents.

They do this for several reasons:

1. Safety Considerations. Safety is the first priority when it comes to gas distribution. Restricting gas pressure helps prevent accidents, leaks, and potential hazards. By maintaining a controlled and moderate pressure level, gas providers can minimise the risk of pipeline ruptures, explosions, and other incidents that could harm people and property.

High-pressure gas systems require more stringent safety measures, and restricting pressure ensures the infrastructure can operate safely.

1. Pipeline Integrity. Gas pipelines are designed to withstand specific pressure levels, and excessive pressure can strain the pipeline’s integrity, leading to leaks or structural failures. By restricting gas pressure within the recommended limits, gas providers can extend the lifespan of the pipeline infrastructure and reduce the likelihood of costly repairs or replacements.
2. System Efficiency. Gas providers aim to optimise the efficiency of the gas distribution system. By carefully controlling pressure levels, providers can maintain a balance between supply and demand. Excessive pressure can lead to inefficiencies, such as excessive gas usage or waste, while low pressure may result in inadequate heating or appliance performance.
3. Resource Conservation. Gas is a valuable and finite resource. Restricting gas pressure helps conserve this resource by minimising wasteful consumption. By regulating the pressure, gas providers can ensure that consumers receive the necessary amount of gas for their needs without excessive waste.
4. Infrastructure Compatibility. Gas distribution systems comprise an intricate network of pipelines, valves, and other components. Different parts of the system may have varying pressure tolerance levels. By restricting gas pressure, providers can ensure compatibility with the existing infrastructure.

The Challenging Process Of Increasing Gas Pressure

According to the United Kingdom’s Department for Business, Energy, and Industrial Strategy, domestic gas consumption increased by 7.4% in 2021 over 2020, while the industrial sector saw an increase of 7.2%. There is a general upward trend in gas demand due to the rising population and the increasing number of appliances and systems that use gas.

This could lead to gas pressures being inadequate in many cases.

For consumers who require higher gas pressure at their location, obtaining an increase in pressure from the gas provider is not a simple task. It involves a complex process, often requiring applications, studies, and assessments. Consumers must communicate their specific needs to the gas provider and provide justifications for the desired pressure increase.

The gas provider then evaluates the feasibility of the request, considering factors such as the existing infrastructure and the potential costs associated with upgrading pipework to accommodate higher pressure. If the infrastructure costs are deemed excessive, the gas provider may reject the application, leaving the consumer with limited options to address their gas pressure requirements.

Throughout this process, the above safety concerns must also be considered. Higher gas pressure requires significant infrastructure changes to ensure it is done safely and without waste or injury.

London’s Costly And Time-Consuming Application Process

One notable example of the challenging process of increasing gas pressure can be found in the city of London. Due to the capital’s extensive and complex gas network, applications for increased gas pressure can be both costly and time-consuming.

The high-density urban environment of London presents unique challenges for gas providers in terms of infrastructure upgrades and ensuring the safety and reliability of the gas supply, mainly for the following reasons:

• London has an extensive gas network serving many residential, industrial, and commercial properties. The network consists of numerous interconnected pipelines, valves, and distribution points spread across the city. Managing such a large and intricate system poses significant logistical and operational challenges for gas providers.
• London is a densely populated city with a high concentration of buildings and infrastructure, which presents additional complexities. The proximity of buildings, underground utilities, and transportation infrastructure makes it challenging to upgrade or modify the gas infrastructure without disrupting other essential services.
• London’s gas network has evolved over many decades, incorporating infrastructure from different eras. Some parts of the network may be pretty old and may not be compatible with higher gas pressure requirements. Upgrading or retrofitting these older sections of the infrastructure to accommodate increased pressure can be costly and technically challenging.
• As a highly regulated industry, the gas sector in London operates under strict safety standards and regulatory frameworks. Any modifications to the gas infrastructure, including pressure increases, must adhere to these regulations and undergo rigorous safety assessments. These processes ensure that any changes to the system do not compromise safety or pose risks.
• Increasing gas pressure in a complex urban environment like London often involves substantial infrastructure costs. Upgrading pipelines, valves, and other components to handle higher pressure levels can require significant investments.

The costs associated with conducting feasibility studies, engineering assessments, and implementing the necessary upgrades can be considerable, making the application process expensive for consumers.

• Coordinating with multiple stakeholders is crucial in the process of increasing gas pressure in London. Gas providers must collaborate with local authorities, planning departments, engineering consultants, and other parties to ensure compliance with applicable regulations and mitigate any potential impacts on the surrounding infrastructure or environment.

In many cases, applications for increased gas pressure in London involve comprehensive studies and assessments, often necessitating the involvement of specialised engineers and consultants. These studies aim to determine the feasibility and potential impact of the pressure increase on the existing gas infrastructure.

The costs associated with these studies, combined with any necessary infrastructure upgrades, can be substantial, making the application process burdensome for consumers, and that’s a real-life example of how difficult it could be to get government approval for improved gas supply infrastructure.

Possible Solutions To The Gas Pressure Problem

Apart from applying to the gas providers to improve infrastructure, there are a few ways in which people and corporations are trying to address these issues, but not all solutions are equally viable. These are large-scale attempts to resolve low gas pressure problems, but they still have individual shortcomings and limitations.

District Heating

In recent years, district heating technology has gained momentum as a sustainable and efficient solution for heating multiple buildings or an entire neighbourhood. District heating systems involve centralised heat generation, which is then distributed to individual buildings through a network of insulated pipes.

These systems can utilise various energy sources, including gas, biomass, or waste heat from industrial processes.

With the increasing adoption of district heating technology, consumers may find their gas pressure requirements addressed at a broader level. District heating schemes often involve careful planning and consideration of the gas pressure needs of the entire network, ensuring that sufficient pressure is available to meet the demand of all connected buildings.

This approach reduces the need for individual consumers to seek pressure increases, streamlining the process and minimising the associated costs and complexities.

However, these systems could take many years to implement because developers tend to prioritise certain “high need” areas, which is understandable. Companies also have to go through feasibility studies and tests before implementing district heating to ensure that it is viable for the region.

In most cases, district heating is also implemented by the people living in the region, not by the government, increasing costs and making it more of a niche solution.

Improved Gas Pressure In New Build Projects

When undertaking a new build project, developers and architects typically conduct thorough analyses of gas pressure availability before construction begins. This step is crucial to ensure that the gas supply meets the requirements of the building’s heating and appliance systems.

By considering gas pressure availability early in the planning stages, developers can make informed decisions and avoid potential issues or delays associated with insufficient pressure. Unfortunately, this still poses two problems:

1. What about users in older buildings that don’t have access to these improved systems? This does not solve their problem.
2. For how long will these improved implementations be sufficient? After all, when the current buildings were planned and built, the gas infrastructure was adequate for the needs and requirements of the time.

So, even though proper gas infrastructure planning is a good step forward, it’s not a perfect (or necessarily long-term) solution.

Why A Gas Booster Is A Perfect Solution

The alternative option for consumers needing increased gas pressure is to utilise a gas booster system, such as Secomak’s. A gas booster is a device specifically designed to raise the existing gas pressure at a particular location, providing an effective solution without the need for extensive infrastructure upgrades. These devices offer the following advantages:

Pressure Increase

Gas boosters work by taking the existing gas pressure and increasing it to the desired level. They are designed to deliver a precise and controlled pressure boost, allowing consumers to achieve the specific pressure required for their heating systems or appliances. By boosting the pressure locally, consumers can overcome the limitations imposed by the gas provider’s restricted pressure levels.

Compact And Easy To Install

Gas boosters are typically compact and easy to install, making them suitable for various applications. They can be installed directly at the point of use, such as residential properties, commercial buildings, or industrial facilities. The compact nature of gas boosters enables them to be integrated into existing gas systems without requiring significant modifications or disruptions.

Cost-Effective Solution

Gas boosters offer a cost-effective alternative to infrastructure upgrades for consumers in need of increased gas pressure. As mentioned earlier, the process of increasing gas pressure through the gas provider can be time-consuming and expensive. In contrast, gas boosters provide a more economical solution, as they eliminate the need for extensive modifications to the gas distribution system.

Flexibility And Customisation

Gas boosters can be customised to meet specific pressure requirements. Different models and configurations are available to accommodate varying gas flow rates and pressure levels. This flexibility allows consumers to tailor the gas booster system to their unique needs, ensuring optimal performance and efficiency.

Enhanced Reliability

By locally boosting the gas pressure, consumers can enhance the reliability of their gas supply. Gas boosters ensure a consistent and adequate pressure level, reducing the likelihood of performance issues, such as inadequate heating or appliance malfunctions.

This reliability is particularly crucial for commercial and industrial operations that depend on a reliable gas supply for their processes and equipment.

Complementary To Existing Infrastructure

Gas boosters work in conjunction with the existing gas infrastructure. They do not replace or interfere with the gas provider’s network but rather increase the pressure at the specific location where they are installed with no detrimental effects on the rest of the gas supply.

This compatibility allows consumers to overcome the limitations imposed by the gas provider’s pressure restrictions while maintaining the integrity and functionality of the overall gas distribution system.

Conclusion

Gas boosters provide consumers with a practical, compact, and cost-efficient solution for increasing gas pressure at specific locations. They offer pressure boosting, easy installation, customisation options, enhanced reliability, and compatibility with the existing infrastructure, solving most of the problems commonly faced by people who need higher gas pressures.

By utilising Secomak’s gas boosters, consumers can meet their increased gas pressure requirements without the need for extensive infrastructure upgrades or reliance on the gas provider’s approval process. There are no regulatory processes or bureaucratic red tape to navigate. All it takes is one quick installation, and a simple but effective gas booster will meet all your gas pressure needs.

The post Why Buy A Gas Booster In The First Place? first appeared on Gas Boosters by Secomak.

Secomak’s Duty Standby Packages comprise two gas boosters that automatically alternate every seven days. Since the gas boosters alternate on a fixed schedule, it allows for preventive maintenance to avoid breakdowns. As a result, it manages wear and tear better and eliminates costly downtime.

Other backup systems are less efficient than having a duty standby in place. For example, manually reconnecting a backup gas booster means there will likely be an interruption in supply. Additionally, if the backup has yet to be checked and doesn’t perform as necessary, the increased downtime can result in devastating losses and unforeseen expenses.

What Are Duty Standby Packages?

A Duty Standby Package is a configuration used for critical applications where a dip in gas supply or electricity could be detrimental. For example, hospitals require an uninterrupted gas supply for their patients and other operations. Additionally, many manufacturers employ Duty Standby configurations to ensure production can continue unabated.

Secomak’s Duty Standby package consists of the following components:

• Two Secomak Gas Boosters (Duplex boosters),
• One wall-mounted control panel which monitors the status of both boosters,
• Flexible connectors,
• Anti-vibration mounts,
• Flanges,
• Non-return valves, and
• Connection leads.

There are two pumps or boosters in Duty Standby packages: one on duty and one on standby. There are a few ways to implement Duty Standby configurations. One way is to use the standby (backup) booster only in case of duty booster maintenance or failure. However, this risks the pump standing idle, creating new problems.

Secomak’s Duty Standby Package is implemented in a way that engineers prefer:

The wall-mounted control panel that controls the two boosters has a timer that automatically alternates the gas boosters’ operation on a weekly cycle. This means each booster is on duty for a week, then on standby for a week. This way, the boosters work in parallel to create an active redundant or hot standby configuration.

Advantages Of Duty Standby Packages

Having a Duty Standby Package for your gas booster has numerous advantages. Apart from offering a reliable system for uninterrupted gas supply, it is proven to prolong the lifespan of gas boosters. Let’s look at the benefits of Secomak’s Duty Standby packages next.

1. Enhanced Reliability

   Secomak’s Duty Standby packages offer peace of mind through enhanced reliability. The automatic switching between the two gas boosters requires minimal or no human intervention for each changeover. Additionally, should the control panel detect a fault in the gas booster on duty, it will immediately activate the standby booster.

   Having an uninterrupted gas supply even during maintenance or faults will boost the reliability of your system and, therefore, your business. This means operations can run as usual, protecting your business from unnecessary losses.

   Additionally, routine maintenance can be planned without needing an emergency backup, meaning you can employ preventive maintenance measures.

   Secomak Gas Boosters are designed and made to surpass British Standard BS 8487:2007. This standard recommends drive belts be changed annually and bearing assemblies every five years.

2. Prolonged Equipment Lifespan

   When using a duty standby package that runs in parallel, it prolongs the lifespan of the equipment. The regular alternation of gas boosters prevents either one from being overused and results in the equalised wear of the boosters’ bearings and drives.

   For example, a standby pump that has been standing idle is unlikely to work optimally for the following reasons:

   The system fluid left in the pump might settle and leave silt or sludge in the pump or pipework, and the build-up can cause blockages if it becomes too hard, and the bearings can wear faster due to being flattened when the pump is not turning.

   Another practical reason to have a set alternation schedule for gas boosters is that you can plan routine maintenance well in advance. That way, you can order parts before the time and book the service technicians in advance, eliminating unnecessary downtime.

3. Minimal Downtime

   As mentioned, performing routine and preventive maintenance without interrupting the gas supply helps minimise downtime. In addition, regular maintenance ensures the availability of at least one operational booster at any given time, ensuring a business can go on as usual.

   Many businesses –especially those performing critical operations – invest in a duty standby configuration as it minimises unnecessary losses.

4. Flexibility And Customisation

Secomak is a well-established company that has supplied industry-leading products for over 90 years. Apart from developing solutions for complex industrial blowing, heating, and dry beverage packaging applications, we also have flexible and customisable solutions for gas boosters.

Gas booster configurations will differ according to the company’s specialised requirements. Secomak offers flexible customisations to suit each gas booster configuration. For example, we can recommend the perfect gas booster solution based on your required volume (up to 2,000 cu.m/h) and pressure (up to 113 mbar).

Additionally, the duty and standby alternation intervals are also customisable based on the preferences or needs of the application. For instance, instead of a 7-day alternation cycle, a customer could choose shorter or longer intervals based on the configuration’s number, type, and age of the gas boosters.

Applications Benefiting From Duty Standby Packages

Duty Standby packages can benefit any business wishing to have an uninterrupted and reliable gas supply. But where are duty standby configurations used most, and what type of gas and boosters do they commonly use?

Hospitals And Healthcare Facilities

A reliable and continuous supply of high-pressure gas is essential for the smooth functioning of many critical hospital systems. From supplying medical gas for patient care to heating, ventilation, and air conditioning (HVAC) systems, the importance of uninterrupted gas flow cannot be underestimated.

Hospitals need a robust backup system to ensure that these vital services are not disrupted. Secomak’s Duty Standby Packages for gas boosters provide the ideal solution, offering unparalleled reliability and efficiency.

The Importance of Uninterrupted Gas Supply in Hospitals

Gas supply plays a crucial role in various hospital operations. Medical gases such as oxygen, nitrous oxide, and medical air are indispensable in life support, pain relief, and anaesthesia applications. Gas-powered heating and cooling systems also maintain a comfortable environment for patients and staff, while ensuring proper temperature control in crucial areas like operating rooms and intensive care units.

Any interruption in the supply of medical gas could jeopardise patient care, compromise safety, and result in significant financial losses. As such, hospitals must prioritise the implementation of an efficient and reliable backup system for their gas boosters.

Secomak’s Duty Standby Package: The Optimal Solution

Secomak’s Duty Standby Package is specifically designed to ensure a consistent, high-pressure supply by incorporating two gas boosters that automatically alternate every seven days. This scheduled rotation not only guarantees uninterrupted service but also allows for preventive maintenance and efficient management of wear and tear, thereby reducing the risk of system breakdowns.

By using a Duty Standby Package, hospitals can avoid costly downtime that may result from other backup electrical systems. For instance, manually reconnecting a backup gas booster could lead to an interruption in supply, which may have severe consequences in a healthcare setting. Furthermore, if the backup booster is not adequately maintained and fails to perform as required, the resulting downtime could lead to devastating losses and unforeseen expenses.

Benefits of Secomak’s Duty Standby Package for Hospitals

1. Uninterrupted Gas Supply: The automatic rotation of the gas boosters ensures a continuous supply of high-pressure gas, which is crucial for maintaining critical hospital operations.
2. Preventive Maintenance: The scheduled alternation of boosters allows for timely maintenance and prevents unexpected system failures, thereby avoiding the risks of relying on a single booster.
3. Reduced Downtime: With two boosters in place, the risk of downtime due to system failures is significantly minimised, ensuring that hospital operations remain unaffected.
4. Cost Efficiency: Secomak’s Duty Standby Package helps hospitals avoid financial losses associated with the interrupted gas supply by preventing downtime and allowing for proactive maintenance.
5. Enhanced Safety: The consistent and reliable gas supply provided by the Duty Standby Package ensures that critical medical gas systems and HVAC systems function as intended, protecting patients and staff from potential hazards.

In a hospital setting, a dependable and uninterrupted gas supply is paramount. A Duty Standby Package offers a reliable backup solution for gas boosters, ensuring that hospitals can maintain critical operations without downtime. By investing in a Duty Standby Package, healthcare facilities can ensure the safety and well-being of their patients and staff while minimising the financial impact of unexpected system failures.

Residential Homes And Hotels

Duty standby configurations for gas boosters are commonly used in hotels and residences for uninterrupted gas supply. Hotels and homes use natural gas supplies because they are economical, reliable, and powerful. Hotels can ensure their guests remain happy and warm by employing a duty standby configuration for gas supply needs.

Hotels and private residences use natural gas for:

• Cooking,
• Space heating, and
• Water heating.

Schools And Educational Institutions

Schools and other educational institutions use natural gas supplies for similar reasons to hotels and residences. That is, they may need it for cooking and heating water and space. Additionally, schools with science laboratories and kitchens for the students (e.g., catering schools and food tech labs) will benefit from having an uninterrupted gas supply.

Offices And Commercial Buildings

Commercial buildings and large offices can also use duty standby packages for their gas boosters to keep the spaces warm. Additionally, should there be a need for cooking or heating water (e.g., gym bathrooms and washing), an uninterrupted gas supply would also be beneficial.

Factories And Process Applications

About 12% of the natural gas consumption in the United Kingdom is used in the industrial sector. As such, gas boosters and duty standby packages benefit multiple industries by ensuring around-the-clock production. Some of the industries that use gas and would benefit from employing a duty standby package include the following:

• Chemical,
• Energy,
• Food Processing,
• Glass,
• Metal,
• Mining,
• Petroleum,
• Plastic, and
• Refining industries.

In the manufacturing industry and for process applications, natural gas is used for the following (and so much more):

• As a raw input material for medical products such as bags, catheters, gloves, masks, and intravenous lines.
• As a raw input material to produce substances, including hydrogen, for clean energy.
• As an essential building block for fertiliser and petrochemical products, including medicine, synthetic fibres, plastics, acrylic lenses, and cosmetics.
• As fuel to manufacture products such as glass, bricks, paper, steel, and iron.
• For leak detection, pressure testing, increased force, and pressure systems.
• In Combined Heat and Power (CHP) processes, excess heat and steam are captured for lowered emissions and costs.
• To heat water and space and to dehumidify.

Integrating Duty Standby Packages With Other Gas Booster Features

Secomak added centrifugal gas boosters to our repertoire of air-moving solutions in 1966. Apart from offering a duty standby package for uninterrupted gas supply, we also provide additional gas booster features which can be integrated into their systems. These include APS inverter systems, gas sensor systems, and other features mentioned next.

APS Inverter Systems For Energy Efficiency And Consistent Pressure

Secomak’s Automatic Pressure Setpoint (APS) Inverter System is designed to raise and keep constant gas pressure levels reliably and cost-effectively. Their APS inverter system is compatible with any of Secomak’s Gas Boosters and can be integrated into Secomak’s Duty Standby control box.

Secomak’s APS Inverter system offers the following features:

• Maintaining consistent outlet pressure, even if the inlet pressure dips.
• Reduces shock and load with Soft-Start Technology, which extends the lifetime of components (e.g., motor and bearings).
• Reduced electrical consumption.
• It can be specialised to incorporate an optional auto-changeover system.
• Suitable for use with duty standby, single stream, and parallel systems. Also suitable for use with any building management system.

Gas Sensor Systems For Enhanced Safety And Leak Detection

Secomak’s Gas Sensor System offers a unique “Sniffer” sensor that detects potential gas leaks and eliminates risk. This system is suitable for acoustic enclosures and can be combined with Secomak’s Duty Standby packages for their gas boosters. But how does it work?

• If the “Sniffer” sensor detects potential gas leaks, it sets off Two Stage Pre-Alarm warnings before employing the Automatic Safety Cut Off.
• The one alarm is an audible siren, while the second is a visual warning light.
• Depending on the gas volume measured in the immediate atmosphere, the Automatic Safety Cut-Off is activated.
• The Automatic Safety Cut-Off breaks the electrical supply linked to the gas safety shut-off valve, eliminating any danger.

Combining Duty Standby With Other Features For Maximum Reliability, Efficiency, And Safety

As is evident, Secomak strives to provide gas booster systems that are reliable, energy-efficient, and safe. Furthermore, our gas booster configurations can complement our Duty Standby Packages, APS Inverter Systems, and Gas Sensor systems to improve energy efficiency and safety further.

Secomak also offers accessories to enhance our services further and maintain our excellent product range. These accessories include the following:

• Acoustic Enclosures,
• Bearing Assemblies,
• Connection Kits,
• Drive Belts,
• Flexible Connectors,
• Gas Reservoirs, and
• Non-Return Valves.

Secomak’s Duty Standby packages help to provide an uninterrupted gas supply while eliminating downtime and reducing motor and bearing wear. Our Duty Standby packages are the perfect solution for applications requiring a reliable, continuous gas supply. Therefore, a company wishing to enhance the reliability of its business should consider investing in a Secomak Duty Standby package.

The post Why Duty Standby Packages Are the Best Choice first appeared on Gas Boosters by Secomak.

Unfortunately, fluctuations in gas pressure can lead to inefficiencies in gas delivery, causing increased operational costs and even damage to equipment. That’s where Automatic Pressure Setpoint (APS) controls come in. APS controls regulate your gas pressure to keep it stable despite those inevitable fluctuations.

Let’s explore APS controls for gas booster systems, their key components, and how they work to maintain stable gas pressures.

What Are APS Controls?

APS controls are automated pressure regulating systems that maintain a consistent gas outlet pressure.

Definition And Purpose

The primary purpose of APS controls is to ensure that the gas pressure remains stable, even when the demand for gas fluctuates. This makes them ideal for systems that require precise gas pressures, such as food processing, medical equipment, and manufacturing processes.

Key Components Of An APS Control System

The critical components of an APS control system include a pressure transducer and a wall-mounted control panel.

• Pressure Transducer

  The pressure transducer is responsible for consistently monitoring the outlet gas pressure. It is typically located downstream of the gas booster, where the gas pressure is at its highest. The sensor sends a constant signal to the controller indicating the current gas pressure level.

• Controller

  Within the control panel, the controller is the central processing component of the APS control system. It receives the pressure transducer’s feedback, processes it, and sends a signal to the included Inverter Drive (also commonly referred to as a variable speed drive or frequency converter) to adjust the speed of the gas booster as needed.

  Acting as a mini-computer, the controller employs a proportional-integral-derivative (PID) algorithm to deftly adjust the speed of the gas booster, considering the difference between the desired setpoint pressure and the actual output pressure. It can also be programmed with various settings, such as acceleration and deceleration times, as well as settings to ensure compliance with specific gas supplier requirements.

How APS Controls Work To Maintain Stable Gas Pressures

APS controls work by automatically adjusting the speed of the gas booster to match and maintain the pressure set point. As the demand for gas fluctuates, either increasing or decreasing, without the APS controls, the gas outlet pressure after the gas booster would also increase or decrease, potentially detrimentally affecting the process or application.

The pressure transducer continuously and automatically monitors the outlet pressure. If the pressure deviates from the pressure set point, the controller sends a signal to the Inverter Drive to adjust the speed of the gas booster accordingly.

One of the critical benefits of APS controls is their ability to respond quickly to changes in gas demand. This is due to the pressure transducer and controller’s fast response time. When the pressure transducer detects a deviation from the pressure setpoint input by the user, the controller sends a signal to the VSD to adjust the speed.

This ensures that the outlet pressure remains constant, even if there are sudden changes in gas demand.

Advantages Of Using APS Controls

There are several advantages to using APS controls in gas booster systems. These include maintaining consistent outlet pressure, better energy efficiency, reduced noise levels and wear, and enhanced control functionality.

1. Consistent Outlet Pressure

   The primary advantage of APS controls is that they ensure a consistent outlet pressure. This is essential for applications requiring precise gas pressures, such as medical equipment, food processing, and various manufacturing machinery. APS controls automatically adjust the gas booster based on demand, ensuring the setpoint pressure is always maintained.

2. Energy Efficiency

   APS controls can also lead to significant energy savings because they can reduce energy consumption (and, in the process, operational costs) by reducing the gas booster speed when the equipment does not require maximum performance.

   This benefits the environment, of course, since your organisation’s electrical consumption will be lower than it would be without APS controls. But it also helps the organisation’s bottom line since lower energy expenses in manufacturing or other use scenarios mean greater profits.

3. Reduced Noise Levels And Wear

   Using APS controls can also reduce noise levels and lower wear on booster components. These aspects are entirely separate but closely related.

   Because the APS controls maintain a stable pressure setpoint, they lower the strain on the gas booster’s components, prolonging the equipment’s lifespan and reducing maintenance. Lower stress also means the machine will generate less noise, creating a slightly more pleasant working environment.

4. Enhanced Control Functionality

   APS controls offer enhanced control functionality compared to traditional gas booster systems. They allow for improved booster acceleration (ramp-up) and deceleration times, enabling more precise control over gas pressure fluctuations.

   This is important, as many gas suppliers require it to help prevent low-pressure warnings when you install the boosters on shared main gas supplies. This way, APS controls can help you comply with gas supplier requirements by ensuring that gas pressures remain within the specified range.

Applications Benefiting From APS Controls

APS controls can benefit a wide range of applications that require stable and consistent gas pressures. These include industrial processes, heating and ventilation systems, commercial and residential buildings, and the food and beverage industry.

Industrial Processes Requiring Stable Gas Pressures

Many industrial and manufacturing processes require stable gas pressures to ensure precision and efficiency. Examples include welding and cutting systems. Welding with insufficient gas pressure can cause porosity and brittle welds, which results in lower-quality manufacturing.

Industries that rely heavily on welding, like the automotive and aeronautics industries, need their welding to be on a high standard because failing to do so could cause loss of life.

APS controls can provide stability in gas pressure that leads to increased productivity, better manufacturing quality, and reduced costs.

Heating And Ventilation Systems

Heating and ventilation systems rely on consistent gas pressures to operate effectively. APS controls can ensure these pressures remain stable with more efficient operation and lower energy consumption.

For example, let’s consider a large commercial building with a heating and ventilation system that uses a gas booster to ensure a reliable gas supply for heating and hot water.

Since most tenants will be at home, cooking and showering at more or less the same time, there is high demand during peak hours, but the demand usually drops significantly during off-peak hours. Without an APS control system, the gas booster would operate at maximum speed and pressure throughout the day, wasting energy and increasing operational costs.

By integrating an APS control system into this heating and ventilation system, the gas booster can adjust its speed and pressure based on the current demand for gas.

During peak hours, the gas booster operates at maximum speed and pressure to meet the high demand for gas. However, during off-peak hours, the gas booster slows down and reduces the gas pressure to match the lower demand. This leads to significant savings in energy and operational costs.

In addition to these energy savings, APS controls can also help improve the comfort of building occupants. By ensuring that gas pressures remain stable, APS controls can help prevent fluctuations in temperature and hot water supply, leading to a more comfortable and consistent indoor environment and, consequently, happier occupants.

Commercial And Residential Buildings

APS controls can benefit commercial and residential buildings. The four primary benefits are:

1. Improved Comfort and Safety: Gas booster systems are often used in commercial and residential buildings to ensure reliable gas supply for heating, hot water, and cooking. Using APS controls in these systems can help ensure that gas pressures remain stable, improving the comfort and safety of building occupants.Stable gas pressures lead to fewer fluctuations in temperature and hot water supply, resulting in a more comfortable (and safer) indoor environment.
2. Energy Efficiency: APS controls can help improve the energy efficiency of gas booster systems in commercial and residential buildings. By adjusting the speed based on the current demand for gas, APS controls can reduce energy consumption during off-peak hours, leading to significant energy savings and reduced operational costs.
3. Reduced Noise Levels and Wear: Using APS controls can reduce noise levels and wear on booster components in gas booster systems. By maintaining a stable pressure setpoint, APS controls lessen the strain on booster components, prolonging equipment lifespan and reducing the need for maintenance.This leads to a quieter and more reliable operation of the gas booster system, lowering your maintenance costs and improving the environment for the occupants of the building.
4. Compliance with Gas Supplier Requirements: APS controls can help commercial and residential buildings to comply with gas supplier requirements, ensuring that gas pressures remain within the specified range. This helps ensure the safety and reliability of the gas supply for commercial and residential buildings.

Food And Beverage Industry

The food and beverage industry leans heavily on gas booster systems for various applications, from bottling to packaging and beyond. These applications require precise gas pressure levels to ensure product quality and safety.

Of course, the food and beverage industry will also benefit from improved energy efficiency, lower noise levels, reduced wear, and industry-standard compliance, from which the other sectors also benefit. However, it also gains improved product quality and safety.

The food and beverage industry requires precise gas pressure levels for several applications, including bottling and packaging. Any deviation from these exact pressure levels can lead to inconsistencies in product quality and safety. APS controls help ensure that these pressures remain stable and consistent, which improves their quality and safety levels.

Integrating APS Controls With Other Gas Booster Features

APS controls can be integrated with other gas booster features to enhance performance, efficiency, and safety even more. These features include duty standby packages, gas sensor systems, and combining APS controls with other components.

• Duty Standby Packages For Increased Reliability

  Duty standby packages can provide increased reliability in gas booster systems by helping to prevent downtime. It involves having a backup booster ready to take over in the event of a failure, ensuring that gas pressures remain stable and consistent even during an equipment failure.

  A duty standby package generally has two gas boosters that alternate automatically every seven days. Even if you must shut down a gas booster for maintenance, the other one will still function at optimal power with its integrated APS controls.

• Gas Sensor Systems For Enhanced Safety And Leak Detection

  Gas sensor systems can enhance safety and leak detection in gas booster systems. They continuously monitor gas levels to detect leaks and other safety hazards, usually with alarm systems and automatic emergency shut-down functions to stop leaks before they become a significant problem.

Conclusion

APS controls can ensure that gas pressures remain stable and consistent even as gas demand fluctuates. They offer several advantages, including constant outlet pressure, energy efficiency, reduced noise levels, lower wear on equipment, and enhanced control functionality.

APS controls can benefit a wide range of applications, including (but not limited to) any industrial processes, heating and ventilation systems, commercial and residential buildings, and the food and beverage industry. If you require stable and consistent gas pressures in your business’ gas boosters, APS controls will offer that while saving you some operational costs.

The post Ensuring Stable Gas Pressures With APS Controls first appeared on Gas Boosters by Secomak.