Monitoring Equipment - Energy Efficiency Guide for Industry In Asia
Contents
1. Check the operating manual of the monitoring equipment for more detailed instructions on safety and precautions before using the equipment Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 6 Monitoring Equipment 2 COMBUSTION ANALYZERS 2 1 What a combustion analyzer does A combustion analyzer is used to measure the composition of the flue gases after combustion has taken place Different combustion analyzers can be ordered to match the requirements at a plant Basically all combustion analyzers measure the percentage oxygen O2 or carbon dioxide CO2 in the exit flue gases and then use an inbuilt programme to calculate the combustion efficiency if required The various types of combustion analyzers are given below Fuel Efficiency Monitor This measures oxygen and temperature of the flue gas Calorific values of common fuels are fed into the microprocessor which calculates the combustion efficiency Fyrite A hand bellow pump draws the flue gas sample into a solution inside the fyrite A chemical reaction changes the liquid volume revealing the amount of gas The percentage oxygen or CO can be read from the scale Gas Analyzer This instrument has in built chemical cells which measure various gases such as CO CO NOx SOx etc Monitoring Equipment 2 2 Where a combustion analyzer is used Combustion analyzers are used to determine the composition of the flue gases in the duct The duct is2. form for educational or non profit purposes without special permission from the copyright holder provided acknowledgement of the source is made UNEP would appreciate receiving a copy of any publication that uses this publication as a source No use of this publication may be made for resale or any other commercial purpose whatsoever without prior permission from the United Nations Environment Programme Disclaimer This energy equipment module was prepared as part of the project Greenhouse Gas Emission Reduction from Industry in Asia and the Pacific GERIAP by the National Productivity Council India While reasonable efforts have been made to ensure that the contents of this publication are factually correct and properly referenced UNEP does not accept responsibility for the accuracy or completeness of the contents and shall not be liable for any loss or damage that may be occasioned directly or indirectly through the use of or reliance on the contents of this publication Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 26
3. high accuracy It consists of two dissimilar metals joined together at one end The thermocouple metal alloys are commonly available as wire A thermocouple is available in different combinations of metals or calibrations The four most common calibrations are J K T and E There are high temperature calibrations R S C and GB Each calibration has a different temperature range and environment although the maximum temperature varies with the diameter of the wire used in the thermocouple Although the thermocouple calibration dictates the temperature range the maximum range is also limited by the diameter of the thermocouple wire Figure 11 Thermocouple Thermometer Reliability Direct Inc Non contact or infrared thermometer A norcontact or infrared thermometer allows the measurement of temperatures without physical contact between the thermometer and the object of which the temperature is determined The thermometer is directed at the surface and immediately gives a temperature reading This instrument is useful for measuring hot spots in furnaces surface temperatures etc Infrared thermometer allows users to measure temperature in applications where conventional sensors cannot be used or cannot produce accurate temperature readings such as Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 12 Monitoring Equipment When a fast response or measurement is required such as moving objects i e roll
4. speeded up by further increases or decreases in the strobe flash rate When the image is stopped the flash rate of the strobe equals the speed of the moving object And since the flash rate is known the speed of the object is also known Thus the stroboscope has a dual purpose of measuring speed and of apparently slowing down or stopping rapid motion for observation The practical significance of the slow motion effect is that since it is the true copy of the high speed motion all irregularities vibration torsion chattering whip present in the high speed motion can be studied Figure 18 Principle of the Working of a Stroboscope NPC 2006 For audit studies we generally use contact type of tachometers since they are readily available 6 2 Where tachometers and stroboscopes are used Tachometers and stroboscopes are used measure the speed of rotation of motors fans pulleys etc 6 3 How to operate a tachometer and stroboscope In a contact type tachometer the wheel of the tachometer is brought in contact with the rotating body Due to friction between the two after few seconds the speed of the wheel of the tachometer is the same as the speed of the rotating body This speed is displayed on the panel as rpm The digital stroboscope is a versatile flashing light source that is used to measure the speed of fast moving objects or to produce the optical effect of stopping or slowing down high speed motion for purposes of observatio
5. Monitoring Equipment MONITORING EQUIPMENT 1 ELECTRICAL MEASURING INSTRUMENTS eere eene 2 2 COMBUSTION ANALYZER S susc oat ensi o P tpm ke Yu ee UU sae F la go so se si aes or ado 7 6 TACHOMETERS STROBOSCOPES eere eere eren nnne enne sees 1 Monitoring equipment can be useful to measure the actual operating parameters of various energy equipment and compare them with the design parameters to determine if energy efficiency can be improved Or monitoring equipment can be used to identify measure steam or compressed air leaks Parameters that are often monitored during an energy assessment are Basic electrical parameters in AC amp DC systems voltage V current I power factor active power kW maximum demand kVA reactive power KVAr energy consumption kWh frequency Hz harmonics etc Other non electrical parameters temperature and heat flow radiation air and gas flow liquid flow revolutions per minute RPM air velocity noise and vibration dust concentration total dissolved solids TDS pH moisture content relative humidity flue gas analysis CO O2 CO SOx NOx combustion efficiency etc This module provides information for various monitoring equipment that are often used during energy assessments in industry Electrical measuring instruments Combustion analyzer Thermometers Manometers Water flow meters Tachometers Stroboscopes Leak detector
6. What lux meters do Lux meters are used to measure illumination light levels Most lux meters consist of a body a sensor with a photo cell and a display panel The sensor is placed under the light source The light that falls on the photo cell has energy which is transferred by the photo ell into electric current The more light is absorbed by the cell the higher the generated current The meter reads the electrical current and calculates the appropriate value of either Lux or Foot candles This value is shown on the display panel A key thing to remember about light is that it is usually made up of many different types colors of light at different wavelengths The reading therefore is a result of the combined effects of all the wavelengths A standard color can be referred to as color temperature and is expressed in degrees Kelvin The standard color temperature for calibration of most light meters is 2856 degrees Kelvin which is more yellow than pure white Different types of light bulbs burn at different color temperatures Lux meter readings will therefore vary with different light sources of the same intensity This is why some lights seem harsher or softer than others 9 Cc LtGuT METER Figure 20 Lux Meters Reliability Direct Inc 8 2 Where lux meters are used Lux meters are used to measure illumination levels in offices factories etc 8 3 How to operate a lux meters This instrument is very simple to operat
7. anometer The differerce in level of the manometer gives the total velocity pressure For example in case of a digital manometer the readings are displayed as mm of the water column Manometer Pitot tube Pitot Tube Section cg to show detail Figure 10 Measurement using Pitot Tube and Manometer Dwyer Instruments Inc Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 10 Monitoring Equipment 3 4 Precautions and safety measures Manometers should not be exposed to very high pressures In case of high pressures inclined tune manometers should be used Check the operating manual of the monitoring equipment for more detailed instructions on safety and precautions before using the equipment Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 11 Monitoring Equipment 4 THERMOMETERS 4 1 What a thermometer does Thermometers are instruments used to measure the temperature of fluids surfaces or gases for example of the flue gases after combustion has taken place Thermometers are classified as contact thermometers or non contact or infrared thermometers and are described below Contact thermometer There are many types of contact thermometers A simple clinical thermometer is the best known example of a contact thermometer However for the purpose of energy audits in an industrial plant we generally use thermocouples for measuring temperatures with a
8. bout half filled with liquid With both ends of the tube open the liquid is at the same height in each leg Figure Ob When positive pressure is applied to one leg the liquid is forced down in that leg and up in the other The difference in height h which is the sum of the readings above and below zero indicates the pressure Figure 9c When a vacuum is applied to one leg the liquid rises in that leg and falls in the other The difference in height h which is the sum of the readings above and below zero indicates the amount of vacuum There are three main types of manometers Single limb liquid column manometer has a larger reservoir instead of one side of the U tube and has a scale beside the narrower column This column can further amplify the liquid movement Liquid column manometers can be used to measure small differences between high pressures Flexible Membrane Type This type uses the deflection of a flexible membrane that seals off a volume with a fixed reference pressure The degree of deflection of the membrane corresponds with a specific pressure Reference tables exist to determine the pressure for different deflections Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 9 Monitoring Equipment Coiled Tube Type A third variant uses a coiled tube which will expand with increasing pressure This causes a rotation of an arm connected to the tube 3 2 Where the manometer is us
9. distance from one sensor to the other 5 4 Precautions and safety measures The following precautions should be taken when using water flow meters The probes sensors should be placed on the surface of the pipes after thorough cleaning of the spot Care should be taken that there is no speck of paint etc Ideally the spot where the sensors are placed should be filed by a emery paper The meter would not give the measurements if the internal condition of the pipe is corroded or has any alga growth The measurement should be taken where the pipe flow is expected to be laminar and the pipe must be flowing full Check the operating manual of the monitoring equipment for more detailed instructions on safety and precautions before using the equipment Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 18 Monitoring Equipment 6 TACHOMETERS STROBOSCOPES 6 1 What tachometers and stroboscopes do In any audit exercise speed measurements of for example motors are critical as they may change with frequency belt slip and loading There are two main types of speed measurement instruments the tachometer and the stroboscope Figure 17 A tachometer left and a stroboscope right Reliability Direct Inc Tachometer A simple tachometer is a contact type instrument which can be used to measure speeds where direct access is possible Stroboscope More sophisticated and safer instruments to measur
10. e The sensor is to be placed at the work station or at the place where intensity of the light is to be measured and the instrument will directly give the reading on the display panel Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 24 Monitoring Equipment 8 4 Precautions and safety measures The following measures should be taken when working with lux meters The sensor is to be properly placed on the work station to obtain an accurate reading Due to the high sensitivity of sensor it should be stored safely Check the operating manual of the monitoring equipment for more detailed instructions on safety and precautions before using the equipment Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 25 Monitoring Equipment 9 REFERENCES The text for this chapter is based on the section with information on energy equipment from the Energy Manager Training website with kind permission from India s Bureau of Energy Efficiency supplemented with field experience from the National Productivity Council of India www energymanagertraining com energy_audit_instrume nts new_energy_audit_equipment htm The references for the figures in this chapter are as follows Figure 1 Hioki Ltd www hioki co jp eng product power 328620 html Figure 2 8 Hioki Ltd Users Manual Hioki Hi Tester 32860 Figure 9 Dwyer Instruments Inc USA Measurement of Pressure with
11. e the temperature range for which the thermocouple is designed for should be checked The probe of the thermocouple should never touch the bare flame Before using a non contact thermometer the emissivity should be set in accordance with the surface where the temperature is to be measured Check the operating manual of the monitoring equipment for more detailed instructions on safety and precautions before using the equipment Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 14 Monitoring Equipment 5 WATER FLOW METERS 5 1 What a water flow meter does A flow meter is an instrument used to measure the linear nonlinear mass or volumetric flow rate of a liquid or a gas This section deals specifically with water flow meters The choice of method or type of water flow meter depends on the site conditions and the required measurement accuracy Apart from water flow meters there are several methods available to measure water flow during an audit Two common methods to obtain reasonably accurate estimates of the water flow are Time of fill method Water is allowed to fill a known volume of a vessel or tank m The time taken to fill up this volume is recorded using a stop watch seconds The volume divided by the time gives the average flow in m sec Float method This method is generally used to measure the flow in an open channel A specific distance for example 25 meters or 50 meters is mark
12. e speed are non contact instruments such as stroboscopes A stroboscope is a source of flashing light that can be synchronized with any fast repetitive motion so that a rapidly moving device seems to stand still or to move slowly To illustrate this principle consider the following example Assume a white disk with a single black dot mounted on the shaft of an 1800 rpm motor When the disk is rotating at 1800 rpm it is impossible for the human eye to distinguish a single image and the dot will appear to be a blurred continuous circle When illuminated by the flashing stroboscope light synchronized to flash once every revolution of the disk when the dot is at 3 o clock for example the dot will be seen at this position and only at this position at a rate of 1800 times each minute Thus the dot will appear to freeze or stand still If the flash rate of the stroboscope is slowed to 1799 flashes per minute the dot will be illuminated at a slightly different position each time the disc revolves and the dot will appear to Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 19 Monitoring Equipment move slowly in the direction of rotation through 360 and arrive at its original position 1 minute later A similar movement but in a direction opposite the rotation of the dot will be observed if the flash rate of the stroboscope is increased to 1801 fpm If desired the rate of apparent movement can be
13. ed During conducting of energy audit studies manometers are used to determine the differential pressure between two points in a duct carrying exhaust gases or air The pressure differential is then used to calculate the velocity of flow in the duct using the Bernoulli s equation Pressure Differential v 2g A more detailed account of use of manometer is given in section on hoe to operate a manometer However the same can be used for measuring the differential pressure across two points in a pipe carrying any fluid In this case the precaution to be taken is that the manometer should be compatible to be used for fluid flows The velocity of flow of fluid is given by Differential pressure f LV 2gD where f is the friction factor of the pipe material L is distance between two points across which pressure differential is taken D is the diameter of the pipe and g is the gravitational constant 3 3 How to operate a manometer It is not easy to explain one way of operating manometers The reason is that there are many different kinds of manometers that require different ways of handling However some operating steps are the same During energy audits air velocity in ducts can be measured using a pitot tube and flows are calculated using a manometer A sampling hole is made in the duct pipe carrying exhaust gases and the pitot tube is inserted into the duct The two openings at the end of the pitot tube are connected to the two openings of the m
14. ed on the side of the channel A ping pong ball is placed on the water and the time it takes for the ball to float to the marked distance is recorded Multiple readings are taken to get a more accurate timing The velocity of the water is calculated by Distance traveled by the ball Average time taken Depending on the flow conditions and the site characteristics the calculated velocity is further divided by a factor 0 8 to 0 9 to obtain the peak velocity in an open channel since the velocity at the surface is reduced due to drag forces of the wind etc Some of the most common types of flow meters are given below Rotameter or variable area flow meter for gases and liquids The rotameter consists of a tapered tube and a float It is the most widely used variable area flow meter because of its low cost simplicity low pressure drop relatively wide range ability and linear output Figure 13 Rotameter Omega Engineering Ltd Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 15 Monitoring Equipment Variable flow meters spring and piston flow meters for gases and liquids Piston type flow meters use an annular orifice formed by a piston and a tapered cone The piston is held in place at the base of the cone in the no flow position by a calibrated spring Scales are based on specific gravities of 0 84 for oil meters and 1 0 for water meters Their simple design and the ease with which they can be equ
15. ers moving machinery or a conveyor belt Where noncontact measurements are required because of contamination or hazardous reasons such as high voltage Too large distances or heights Too high temperatures for thermocouples or other contact sensors The object is contained in a vacuum or other controlled atmosphere The object is surrounded by an electromagnetic field such as induction heating The basic principle of the infrared thermometer is that all objects emit infrared energy The hotter an object the more active its molecules are and the more infrared energy it emits An infrared thermometer contains a lens that focuses the collected infrared energy from the object onto a detector The detector converts the energy into an electrical signal which is amplified and displayed in units of temperature after corrections for ambient temperature variations Figure 12 Non contact or Infrared Thermometer Nitonuk Ltd 2003 4 2 Where the thermometer is used In energy audits the temperature is one of the most important parameters to be measured in order to determine the thermal energy loss or to make a thermal energy balance Temperature measurements are taken for the audit of air conditioning units boilers furnaces steam systems waste heat recovery systems heat exchangers etc During the audits the temperature can be measured of the Ambient air Chilled water in refrigeration plants Inlet air into the Air Hand
16. f the leak can be heard through a set of headphones and traced to its source Any turbulent gas will generate ultrasound when it leaks therefore it does not matter what refrigerant you are leak testing Ultrasonic detectors will even detect air as it rushes into a system under vacuum Background noises Because the ultrasonic detector is focused on a specific band frequency of sound it will not detect wind voices traffic and most normal operational sounds However larger systems with a multitude of pressure regulating valves and high velocity flow may produce hissing sounds at frequencies where ultrasonic detectors are most Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 22 Monitoring Equipment sensitive In this case it would be necessary to shut the system down or use another method of detecting leaks Choice of leak detector Always consider the capabilities and the limitations of the leak detection method used It is thereby important to consider more than just the sensitivity under laboratory testing conditions when choosing a leak detector For example a highly sensitive sniffer type was able to detect a leak of 0 250z of refrigerant per year in a controlled laboratory setting But the leak detector would give different results when used on the windy and dirty rooftop where you might be trying to find refrigerant leaks 7 2 Where leak detectors are used Ultrasonic leak detectors are
17. ia www energyefficiencyasia org UNEP 17 Monitoring Equipment is conductive Displays are integral or an analog output can be used for remote monitoring or data logging 5 2 Where the water flow meter is used During energy audits water flow measurements are of significant importance Generally the measurements are taken to quantify the amount of liquid water flowing in a pipe If there is no flow measurement device attached to the pipe line then the flow can be quantified using an ultrasonic flow meter Typical cases where the measurement of the water flow is absolutely essential are as part of determining the efficiency of pumps the efficiency of cooling towers chillers and air conditioning plants heat exchangers and condensers 5 3 How to operate water flow meters There are many varieties of the ultrasonic flow meters available on the market The functioning of each model differs from the other However the basic principle of all remains same The 2 probes sensors of the ultrasonic flow meters are placed on the surface of the pipe at some distance apart along a straight line The diameter of the pipe determines the distance between the probes When the meter is turned on it generates sonic waves which are transmitted via one of the probes sensors and are received by the other The meter is calibrated to display the velocity or volume of the flow of liquid inside the pipe based on the time required by the sonic waves to travel the
18. ipment 7 LEAK DETECTORS 7 1 What leak detectors do As the name implies ultrasonic leak detectors detect the ultrasonic sound of a leak You are probably familiar with the hissing sound a large leak makes Smaller leaks also emit a sound however the frequency is too high for our ears to detect it An ultrasonic leak detector transforms the ultrasonic hissing sound to a sound that humans can hear and thus leads to the source of the leak Figure 19 Leak Detectors Reliability Direct Inc Some other information about ultrasonic leak detectors includes Distance and access Some leaks can be heard from a several meters away therefore access to the leak is not always necessary As long as the leak is turbulent there will be enough sound that can be detected ultrasonically Pressure High pressure of leaks is not necessary Ultrasonic can detect pinhole kaks with a pressure as low as 1 psi However the more pressure behind the leak the easier it will be to locate Sensitivity to sound Ultrasonic leak detectors are very sensitive to sound A good ultrasonic leak detector can actually let you hear the blink of the human eye A leak test can be done in an enclosed area which is saturated with refrigerant and the only indication an ultrasonic will give you is the sound of the leak A good ultrasonic detector uses an electronic process called heterodyning to convert this high frequency leak sound to a lower range where the hissing o
19. ipped to transmit electrical signals has made them an economical alternative to rotameters for flow rate indication and control Figure 14 Spring and Piston Flow Meters Omega Engineering Ltd Ultrasonic flow meters Non Intrusive or Doppler for Liquids Ultrasonic doppler flow meters are commonly used in dirty applications such as wastewater and other dirty fluids and slurries which ordinarily cause damage to conventional sensors The basic principle of operation employs the frequency shift Doppler Effect of an ultrasonic signal when it is reflected by suspended particles or gas bubbles discontinuities in motion Figure 15 Ultrasonic Flow Meter Dynasonics Ltd Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org OUNEP 16 Monitoring Equipment Figure 16 How an Ultrasonic Flow Meter works Eesiflow International Pty Ltd Turbine flow meters The turbine meter is a very accurate meter 0 5 of the reading and can be used for clean liquids and viscous liquids up to 100 centistokes A minimum of 10 pipe diameters of straight pipe is required on the inlet The most common outputs are a sine wave or square wave frequencies but signal conditioners can be placed on the top of the meter for analog outputs and explosion proof classifications The meters consist of a multtbladed rotor mounted at right angles to the flow and suspended in the fluid stream on a free running bearing Paddlewheel sensors Padd
20. is j ddns 160g Figure 4 Power and Power Factor Measurement on Three phase Three wire Circuit Hioki Ltd U o t o c U 2 lt 2 Q D Figure 5 Alternative Method of Power and Power Factor Measurement on Three phase Three wire Circuit Hioki Ltd Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org OUNEP 4 Monitoring Equipment Yelldw Na y o 0360 epis Ajddns jeMod Figure 6 Power and Power Factor Measurement on Three phase Four wire Circuit Hioki Ltd Gente 5 Figure 7 Current Measurement Hioki Ltd J E epis Aiddns 4 epis Ajddns samog Yellow Black is Figure 8 Voltage Measurement Hioki Ltd Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org OUNEP 3 Monitoring Equipment 1 4 Precautions and safety measures Some precautions and safety measures to be taken while using clamp on and power analyzers are To avoid short circuits and potentially life threatening hazards never attach the clamp to a circuit that operates at more than the maximum rated voltage or over bare conductors The clamp on probe should be connected to the secondary side of a breaker so the breaker can prevent an accident if a short circuit occurs While using the instrument use rubber hand gloves boots and a safety helmet to avoid electrical shocks and do not use the instrument when hands are wet
21. lewheel sensors are one of the most popular cost effective flow meters for water or water like fluids Many are offered with flow fittings or insertions styles These meters like the turbine meter require a minimum of 10 pipe diameters of straight pipe on the inlet and 5 on the outlet Chemical compatibility should be verified when not using water Sine wave and square wave pulse outputs are typical but transmitters are available for integral or panel mounting The rotor of the paddlewheel sensor is perpendicular to the flow and is in contact with only a limited cross section of the flow Positive displacement flow meters These meters are used for water applications when no straight pipe is available and when turbine meters and paddlewheel sensor would cause too much turbulence The positive displacement flow meters are also used for measuring the flow of viscous liquids Vortex meters The main advantages of vortex meters are their low sensitivity to variations in process conditions and low wear relative to orifices or turbine meters Also initial and maintenance costs are low For these reasons they have are widely accepted by users Vortex meters do require sizing Magnetic flow meters for conductive liquids These flow meters are available in in line or insertion style The magnetic flow meters do not have any moving parts and are ideal for measuring the flow of wastewater or any dirty liquid that Energy Efficiency Guide for Industry in As
22. ling unit of AC plant Cooling water inlet and out let at the Cooling Tower Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 13 Monitoring Equipment Surfaces of steam pipelines boilers kilns Input water to the boiler Exhaust gases Condensate returned Pre heated air supply for combustion Temperature of the fuel oil 4 3 How to operate a thermometer The thermocouple contact thermometer consists of two dissimilar metals joined together at one end When the junction of the two metals is heated or cooled a voltage is produced that can be correlated back to the temperature A probe is inserted into a liquid or gaseous stream to measure the temperature of for example flue gas hot air or water A leaf type probe is used to measure surface temperatures In most of the cases the thermocouple directly gives the reading in the desired units Centigrade or Fahrenheit on a digital panel The operation of a nom contact or infrared thermometer is simple The infrared thermometer gun is pointed towards the surface where the temperature must be measured The measurement result is read directly from the panel 4 4 Precautions and safety measures The following precautions and safety measures apply when using a thermometer The probe must be immersed in the fluid and the measurement must be taken after 12 minutes i e after the stabilization of the readings Before using the thermocoupl
23. n analysis or high speed photography The stroboscope emits a high intensity short duration flash of light The instrument features an electronic pulse Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 20 Monitoring Equipment generator that controls the flash rate a line operated power supply and a light emitting diode LED readout in flashes per minute The light can be aimed at most moving objects including those in otherwise inaccessible areas When measuring the rotational speed of an object set the flash rate initially to a higher setting than the estimated speed of the object Then slowly reduce the flash rate until the first single image appears At this point the strobe flash rate is equal to the rotational speed of the object and the speed can be read directly from the digital display 6 4 Precautions and safety measures The following precautions should be taken when using a tachometer and stroboscopes Care should be taken while bringing the wheel of the tachometer in contact with the rotating body From a safety point of view never wear loose clothing when taking measurements with tachometers Avoid being alone when taking measurements Check the operating manual of the monitoring equipment for more detailed instructions on safety and precautions before using the equipment Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 21 Monitoring Equ
24. r Hioko Ltd 1 2 Where electrical measuring instruments are used These instruments are applied on line to measure various electrical parameters of motors transformers and electrical heaters There is no need to stop the equipment while taking the measurements 1 3 How to operate electrical measuring instruments The instrument has three leads wires which are connected to the crocodile clips at the end The three leads are yellow black and red Figures 2 to 8 give illustrate the measurement method for various conditions However operating procedures may vary for different types of clamp on or power analyzers For the correct operation procedure the operator should always check the instruction manual supplied with the instrument Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 2 Monitoring Equipment ae a Oooo 00000 1 U o D e o c U ES a o Figure 3 Power and Power Factor Measurement on Single phase Three wire Circuit Hioki Ltd The power and power factor of a single phase three wire circuit are measured similarly to a single phase two wire circuit Connect the black lad to the neutral wire as shown and then switch the red lead and clamp sensor to the respective wires Now the power and power factor between the wires can be measured Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 3 Monitoring Equipment ep
25. s Lux meters Qo Qv EA Pe UA pos For each type of monitoring equipment the following information is given What the monitoring equipment does Where the monitoring equipment is used How to operate the monitoring equipment Precautions and safety measures necessary for the monitoring equipment Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 1 Monitoring Equipment 1 ELECTRICAL MEASURING INSTRUMENTS 1 1 What electrical measuring instruments do Electrical measuring instruments include clamp on or power analyzers and are used to measure main electrical parameters such as KVA kW PF Hertz KVAr Amps and Volts Some of these instruments also measure harmonics Instant measurements can be taken with hand held meters while more advanced ones facilitates cumulative readings with print outs at specified intervals There are several models available in the market from different companies One such instrument is the HIOKI 3286 20 Clamp on Power Hitester Figure 1 It measures the following parameters Voltage 150 V to 600 V 3 ranges Current 200 A or 1000 A 2 ranges Voltage current peak Effective reactive apparent power single phase or 3 phase 30 kW to 1200 kW 14 combination patterns Power factor Reactivity Phase angle Frequency Phase detection 3 phase Voltage current harmonic levels up to 20th Figure 1 Hioki 3286 20 Clamp on Power Hiteste
26. the Manometer 2005 www dwyer inst com htdocs pressure ManometerIntroduction cfm Figure 10 Dwyer Instruments Inc USA Air Velocity Introduction www dwyer inst com htdocs airvelocity AirVelocityIntroduction cfm Figurel1 Reliability Direct Inc Extech Instruments User Guide Model EA15 2004 www extech com instrument products alpha EA10 15ThermoCouple html Figure 12 Nitonuk Ltd 2003 www nitonuk co uk infared infaredTI2 1 3EL shtml Figure 13 Omega Engineering Ltd USA 2003 www omega com pptst FL77 78 html Figure 14 Omega Engineering Ltd USA 2003 www omega com Figure 15 Dynasonics Ltd Flow Meter Data Sheets DXF Model 2003 www dynasonics com resources products pdfs DFX pdf Figure 16 Eesiflow International Pty Ltd www eesiflo com measuring html Figure 17 Reliability Direct Inc Extech 461840 Programmable Digital Stroboscope www reliabilitydirect com strobeproducts EXT 461840 htm Figure 18 National Productivity Council NPC India experience from various industrial studies 2006 Figure 19 Reliability Direct Inc Whisper Ultrasonic Leak Detector www reliability direct com ultrasoundproducts INF whisper htm Figure 20 Reliability Direct Inc Extech Instruments User Manual Model 401027 Pocket Foot Candle Light Meter www reliabilitydirect com lightmeters Copyright Copyright United Nations Environment Programme year 2006 This publication may be reproduced in whole or in part and in any
27. the large piping arrangement of rectangular configuration and is used to flush out the combusted gases to the chimney The values for the different components of the flue gases are volume based Mostly these instruments measure the percentage oxygen and carbon dioxide and the temperature of the flue gas During energy audits it is desirable to know the composition of the flue gases in order to assess the combustion conditions and efficiency and leakages of atmospheric air into the system 2 3 How to operate Different types of the combustion analyzers are operated differently For all types of combustion analyzers the probe is inserted into the duct through a small hole made in the duct for monitoring purposes In case of a fyrite combustion analyzer which is manually operated the flue gas from the duct is sucked out using a manual pumping device In most of the other analyzers the flue gases are pumped out of the ducts using a suction pump The collected gases react with the chemical cells and give readings of oxygen or carbon dioxide 2 4 Precautions and safety measures Some precautions and safety measures to be taken while using combustion analyzers are Always calibrate the instrument in open fresh air before taking a set of measurements Check for the clogging of the air filters of the instrument During measurements ensure that the rubber tubing carrying the gases from the duct to the instrument is not bent After insertion of
28. the probe into the duct care should be taken to wrap the left opening space with cotton rags to ensure that there is no filtration of air into the system or air escaping the system Thick cotton hand gloves goggles a safety helmet and other safety gear should be worn before taking the readings Remember that the gases you are handling are very hot Check the operating manual of the monitoring equipment for more detailed instructions on safety and precautions before using the equipment Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 8 Monitoring Equipment 3 MANOMETERS 3 1 What a manometer does Manometers are widely used instrument in energy audits for measuring the differential pressure across two points The oldest type is the liquid column manometer A very simple version of a liquid column manometer is a U shaped tube see Figure 9 that is half full of liquid usually oil water or mercury where the measured pressure is applied to one side of the tube whilst the reference pressure which might be that of the atmosphere is applied to the other The difference in liquid level represents the applied pressure PRESSURE VACUUM BUON Ss OR NW ES 4 3 2 1 0 1 2 3 4 Sewn OHNE Figure 9 Schematic illustration of a liquid column manometer Dwyer Instruments Inc The principles of how a manometer works are as follows Figure 9a In its simplest form the manometer is a U tube a
29. used to detect leaks of compressed air and other gases which are normally not possible to detect with the human ear No leak detector will find every leak every time It is often a combination of several available methods which will insure the highest rate of success 7 3 How to operate a leak detectors It is not easy to generalize the operating method of a leak detector The reason is that there are many different kinds of leak detectors that require different ways of handling However some steps are the same The probe of the ultrasonic leak detector instrument is placed near the gas steam pipe Ine where a leak is suspected The headphone attached to the instrument is placed on the ears The probe is moved slowly until the person can hear a hissing sound through headphone indicating a leak The position is marked to identify the location of the leakage 7 4 Precautions and safety measures The following measures should be taken when using ultrasonic leak detectors Dust or smoke should not be coming out of the pipe otherwise dust smoke will choke the probe and leads to the instrument failure Avoid measurement at the places where sound levels are high Check the operating manual of the monitoring equipment for more detailed instructions on safety and precautions before using the equipment Energy Efficiency Guide for Industry in Asia www energyefficiencyasia org UNEP 23 Monitoring Equipment 8 LUX METERS 8 1
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