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Resurrection of a CFEI 100 KVA Induction Furnace

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awemawson:
Following Phil's regulator comment I've been doing a bit of 'internet research' this afternoon.

Firstly, the forge is rated at 22 kW which is equivalent to 1.6 kg/H of propane - many regulators are marginal being rated for 1.5 kg/H and some only 1.0 kg/H.

Secondly most propane appliances expect 37 mBar input pressure so it's reasonable that this the forge when converted would be the same.

I have no idea of the rating of my regulator, but if it and it's pipework (8 mm) are not capable  of maintaining 37 mBar at the forge input I'll replace it.

If the regulator isn't 'up to snuff' to supply enough throughput the output pressure will fall with demand, and owing to the way the forge works drawing gas by an air operated venturi the gas / air mix will be too weak, so combustion should be complete anyway.

Internally the propane is further regulated down, and while this second regulator is on the bench I'll see if I can measure its output pressure.

 . . .now to seek out a drop of dye or proper ink to colour the water in my Monument water gauge so I can see the level!

hermetic:
Re the yellow flame Andrew, yes, that is what I would expect, but my hearth has a 4psi air blast and although it produced a blue flame, it seems there is a cold centre to the flame, as if the gas is fed to the nozzle round the outside, and the air in the centre. If you look at the nozzle, this seems to be the case.. It was fairly belching out CO, and only took a few minutes to set the detector off, whereas now, with a 37mbar regulator the flame is much hotter, and no CO is detected! It had me scratching my head because as you say, it doesnt make a lot of sense, but it seems to work very well now.
Phil.

awemawson:
Phil can you confirm that your new regulator is definitely a 37mBar one? Have you any idea of it’s rated through put in kg/H and what does the rating plate of the hearth say about heat output in kW ?

You’ll be pleased to hear that I’ve ordered a couple of CO monitor / alarms !

hermetic:
Its this one Andrew
https://www.ebay.co.uk/itm/IGT-37mbar-PROPANE-GAS-REGULATOR-WITH-PRESSURE-GAUGE-2-M-HOSE-KIT-WITH-2-CLIPS/163753022109?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649. All the other information is at the workshop and we are having a snow day today, so I will get it as soon as I am back there. The torch on my hearth is a flamefast T4.
Phil

awemawson:
Well, developments of sorts. I spoke to Flamefast in Warrington, and it turns out that the 'regulator' that all the input gass passes through is not a regulator but a non return valve. This would explain why when I tried to measure it's output pressure having made a 'mock nozzle' of the same 4.1 mm diameter as is currently fitted I got the same pressure in input and output! Apparently all the internals when on propane are supposed to run at 37 mBar.

In the absence of ink I used some red food colouring dye in my water manometer to make the level easier to see, but being intended for natural gas it only goes up to 30 mBar !

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