Pipe Coating Firm for Oil & Gas Industry uses Vortex A/C(TM) Electrical Enclosure Coolers to Solve Space, Heat, Airborne Contaminant Issues
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Vortex Tube technology reduces cost vs. conventional air conditioners while delivering superior protection in harsh environments
Panama City, FL, February 2010: Large diameter steel pipe powder coating firm EB Pipe Coating, Inc. solved persistent maintenance, cost and protection performance issues it experienced with conventional air conditioners by replacing them with the new Vortex A/C(TM) from ITW Vortec.
According to EB Pipe Coating Electrical Design & Maintenance Supervisor Ray Hickman, refrigerant-based air conditioners not only were substantially more expensive than comparable Vortex A/C(TM) units, they required high maintenance to withstand the heat and airborne contaminants present in the Florida-based powder coating facility. He says that not only did the six Vortex A/C(TM) units he recently installed eliminate the maintenance issues, they also delivered much better protection of sensitive electrical components while offering a more compact and aesthetically pleasing product.
"The conventional air conditioners we used previously cost a lot more (than the Vortex A/C(TM) models) and they also had maintenance issues," says Hickman. "Even some distance away from the powder coating booth we still have powder in the air, and frequently cleaning the air conditioner filters became a nuisance. With the Vortex A/C(TM) there really is no maintenance involved."
Continual Positive Pressure Protects Against Harsh Environment
EB Pipe Coating protects large diameter steel pipes from corrosion by applying a fusion bond epoxy (FBE) coating to the exterior of the pipes that are used primarily for natural gas pipelines. The process involves blasting, washing, heating, and then powder coating the pipes. The control systems require PLCs (programmable logic controllers), variable frequency drives, and other electronic devices used in various operational stages as well as the pipe transport system used to convey the large pipes through the plant. Hickman explains that not only do the electronic devices create heat inside their enclosure, hot and humid ambient temperatures (especially during Florida summers) and airborne contaminants from blasting and powder coating create a harsh and potentially damaging environment for the sensitive electrical equipment.
"The big thing we like about the Vortex A/C(TM) is its mechanical thermostat that doesn't require any electrical wiring," says Hickman. "The mechanical thermostat maintains a positive pressure inside the enclosure even when it's not hot which keeps all that dust and powder that's in the ambient air from entering the panel, and that was a big selling point."
The compressed-air based Vortex A/C(TM) solves heat and environmental issues by consistently delivering below-ambient cooling in environments up to 175° F (as opposed to a maximum ambient of 131° F for refrigerant-based air conditioners), as well as by creating a positive pressure of 1-2 psi inside the enclosure that keeps it free of any airborne contaminants and humidity. The Vortex A/C's 5-micron, auto-drain compressed air filter provides additional protection by ensuring only clean, dry, refrigerated air enters the cabinet.
Compact Size Key to EB Pipe Coating's New Powder Coating System
When installing a new FBE powder coating system recently, Hickman explains that the Vortex A/C's compact size-less than one-tenth the mounting footprint of a comparable air conditioner-proved to be critically important to the new system's design and function. "We found the compact size (of the Vortex A/C) to be an important advantage when we purchased a new system that required three control panels to get 48 powder coating guns," says Hickman.
"The panels needed to be pushed up next to each other but that couldn't be done with conventional air conditioners mounted on the side of each panel, which was what the manufacturer was offering. So, we told them we didn't want the air conditioners and we purchased the Vortex A/Cs and mounted them on top of the panels ourselves. That enabled us to butt those three enclosures right up against each other which was the way we wanted it. It worked out beautifully and it looks really nice, too." Hickman adds that the manufacturer was so impressed with the Vortex A/C(TM) cooling system EB Pipe Coating created for its powder coating operation, they are considering offering it as an option to other customers.
"The Vortex A/Cs also were very easy to install," says Hickman. "We knocked out an inch and a half hole in the enclosure and just mounted them right in. They also have a good strong mounting system. And, our operators really like them because they are quiet."
How the Vortex A/C Works
The Vortex A/C utilizes vortex tube technology to create refrigerated air. With no moving parts, a vortex tube spins compressed air into a vortex where hot and cold airstreams are separated at rotational speeds of up to 1 million rpm. The hot air is muffled and exhausted out the back of the unit, while the cold air reaches as low as 50° F below the compressed air inlet temperature. The cold air stream passes through an external muffler before being released into the electrical enclosure where it creates a positive pressure (1-2 psi) to keep external contaminants from entering the cabinet. As cold air loses its refrigeration to cool the electronics, it forces rising hot air out of vent openings. A highly reliable, built-in mechanical thermostat operates a valve to control airflow and cooling to maintain the cabinet within a temperature range of 80-90° F.
Best in Class Warranty Offered on All Four Models
Four models of the Vortex A/C are available-900, 1,500, 2,500 and 5,000 BTUH of refrigeration capacity-and every model is backed by an unparalleled 10-year warranty as compared to a typical one-year air conditioner warranty.
The 5,000 BTUH model features a two-stage vortex cooler design that conserves energy while providing increased flexibility in directing refrigerated air in a cabinet.
All models are UL Listed for NEMA Type 12, 4 and 4X rated electrical cabinets, and they require no electrical connections. They also offer quiet operating noise levels equal to a comparable air conditioner (62-64 dBA).
With models priced at approximately $800, the Vortex A/C is about one-third the cost of a comparable refrigerant-based air conditioner.
For more information on the Vortex A/C, visit www.vortec.com. For more digital images of the Vortex A/C, contact Steve Broerman at 513-891-7474
(x 230) or sbroerman@itw-air.com.
