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60 HP Blower Field Balance, Repair and Motor Upgrade

Commissioned: Partnered with an HVAC Manufacturer/Contractor

Date: 3/23/2011 - 3/25/2011

Location: Office Building, Hauppauge, New York

Services Provided: Dynamic Balancing, Laser Alignment, Pillow Block Bearing Replacement, Motor Upgrade, Motor Base Retrofit, and Sheave and Belt Replacement. 

Background: KG Power Systems was contacted by an HVAC Manufacturer/Contractor on February 22, 2010 to help them repair and upgrade two existing 60 HP HVAC Blowers in Hauppauge, New York. The HVAC Manufacturer felt that it was in their best interest to Sub-Contract the repair work as their comparative advantage lies in complete sales and not in repair work. 

The following day KG Power Systems began servicing the two units. 

On the Blower End: After years of operation the blowers were not balanced causing excess vibration and excessive wear on the unit. The pillow block bearings had uneven wear and needed to be changed, KG Power Systems changed the pillow block bearings on site and used its Portable Dynamic Balancer to balance the two blowers. 

Blower Balancing and Repair

On the Motor End: The units had soft foot problems (motor bases were broken, rotting or chipped causing the motor to become misaligned and/or vibrate). This also caused the belts and pulleys to have excess and uneven wear. To repair the soft foot problem, K&G retrofitted two new motor bases, allowing for a suitable area to mount the new premium efficient motors. The techs also installed new pulleys and belts. To ensure the motor end sheave and the blower end sheave were aligned properly, KG Power Systems used a Laser Aligner to ensure a perfectly straight and aligned connection. This is very important, especially on a 60 HP blower, because if two sheaves are tilted the sheaves and belt will wear quickly, the connection will vibrate excessively causing increased wear on the bearings within the motor. 

Upgrade:  The two existing standard efficient motors were replaced by two Premium Efficient Motors. This upgraded the motor efficiency from 91.8% to 95%. (Inputs: 18 cents a kilowatt, 60 HP, and running 24 hours per day)

The yearly estimated energy savings per blower = $1,706.19

Pay Back Cycle for the Motor Cost = 16 Months

Please Contact KG Power Systems for more information about this job:

Phone: 631-342-1171

Email: Sales@kgpowersystems.com

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