One of the problems the plant was having was getting enough hot water to fill kettles of 300 to 1000 gallons of water at temperatures as high as 160 F degrees .While Joe is a very skilled residential and Commercial electrician he was not as familiar with motor controls and transformers as I am so I agreed to help him and Joe has picked up some pointers along the way as we have worked on several major projects ,including installing a Rotary Phase converter to make 3 phase 230 volts out of 230 single phase at the plant auxiliary building .
|Converter in process of being wired|
|Capacitors used to balance load|
After getting together with the Professional Engineer the plant hired he wanted to be able to run an instantaneous pulsed water heater that needed 480 volts 3 phase at 200 amps the problem the 480 volt 3 phase delta available was being provided by a step up transformer from a 1200 amp 230 volt 3 phase delta service and was already at its maximum use So we would have to come up with a way to determine if we either had to install a new service or copy what was already in place. After a complete examination of the power system and its use we determined we could put in another step up transformer as well.
|Transformer in process of being wired|
Joe had his relatives who work with him do the heavy work and I made all the connections etc. to make sure they where done properly one wrong connection could result in serious damage to equipment and any one near by it could be injured when we tested it .
We got the Transformer and heater in place in preparation for adding on the pump and Variable Speed Drive and control panel I would have to build to control the pump.
|Control ready for labeling|
|cabinet allows drive LED output to be viewed|
We set the unit up and I ran the initial programming and then tweaked it as engineer stood by and observed the settings to see how much water at what temperature was coming out .
The engineer also designed in an auxiliary water flow monitor which will allow employees to set how many gallons they need I wired in to automatically shut off pump to prevent over filling. We had to do this work over a series of Saturdays so as to not disrupt normal production in the plant and we had to observe
GMP practices for sanitation purposes to insure no products would get contaminated by what we did '