EMISSION MONITORING IN BOILERS AND FURNACES

PROCESS:  In every combustion system, a fuel and air mixture is burned inside the combustion chamber. All liquid, solid, and gas fuels are basically hydrocarbons, and the process of burning results into production of various air pollutants. Especially uncontrolled combustion produces a high concentration of pollutants.  These pollutants damage the environment and are harmful to the population as well as the vegetation in the nearby areas where such plants are located.

It is very important that pollutants like CO, NO, NO2, SO2, HC, H2S, and to some extent, CO2, need to be monitored, so that they can be controlled later. Pollution Control Board has certain norms, and industries have to adhere to such norms and regulate the hazardous emissions, released from their exhausts.

MEASUREMENT:  In the combustion exhaust, gases like CO, NO, NO2, SO2, HC are to be measured in the stack, of all burning processes in boilers, furnaces, incinerators, and heaters.

SOLUTION: testo 340 and testo 350 with 4 and 6 sensors can be used in this application, depending on the no of gases to be measured by the client, and the other process conditions.

Into the digital age with analog measurement methods?

Digital technology is now found in all areas of life, often simplifying our daily routine. The refrigeration trade is no exception. And yet analog manifolds are still very widespread in refrigeration technology. This is a worrying development, because according to a number of studies, up to 74% of all refrigeration systems are incorrectly adjusted using the analog measurement method*. Not because of the qualification of the refrigeration technicians, but as a result of the insufficient accuracy and possibilities provided by analog manifolds.

The application

Measure more than just high and low pressure. The jobs involved in the construction of refrigeration systems are extremely diverse, reaching from project planning via installation and commissioning to maintenance and servicing of refrigeration and air conditioning systems or heat pumps. In order to ensure that a system is functional, the technician must always address the question of the respective pressures and temperatures of the refrigerant, and in particular the superheating and subcooling of the system. From these parameters, the operational status of the system can be determined, and information on its safety and efficiency obtained. The limits of what a technician can do are soon reached using an analog manifold for these wide-ranging activities, because these manifolds record only the high and low pressure of a refrigeration system. For every other measurement, for instance of temperature, an additional measuring instrument is needed. The complicated handling, the time needed for a measurement and the excessive room for interpretation in the recording of the measurement results do the rest. The consequences: inefficiently adjusted systems and additional costs for the customer.

The solution

The ideal multi-function instrument. Modern manifolds such as the testo 570 do justice to the daily requirements in the refrgieration trade. They record various operating parameters with only one instrument. This means that pressure as well as temperature values can be measured quickly and easily. Two temperature inputs as a rule also ensure the simultaneous calculation of the superheating and subcooling of the system. Many digital manifolds furthermore support the evacuation of the system with the help of an integrated vacuum measurement. It is also possible to conduct a temperature-compensated tightness test. In addition to this, almost all common refrigerants are stored in the instrument as standard. More modern instruments even allow data storage and analysis on a PC using special software, or the printout of the measurement protocol direct on site with the customer. The multi-functionality of digital manifolds thus creates considerable handling advantages, allowing fast and efficient work on site.

Benefits for the customer

In the age of energy efficiency. Against the background of the current discussion on the optimization of energy efficiency in technical systems, as well as the reduction of CO2 emissions, the accuracy of measurement results is of ever increasing significance. So it is time to replace the analog manifold with a digital one, because a manometer block can never provide a comprehensive picture of the status of a refrigeration system. However, the more precise the measurement results, the more reliably the working points, and thus the energy efficiency of a system can be determined. The possible potential for energy cost savings can be up to 12%*. The refrigeration technician saves time and costs not only for the customer, but also for himself. And as a bonus, he can be absolutely sure of the quality of his work.

Detect anomalies promptly, carry out inspections more efficiently, increase system availability. Use thermography

In the global competition for market shares, companies depend on efficient manufacturing processes and machines that run reliably. Service engineers play a key role in this: they bear the responsibility for ensuring the permanent availability of production facilities. To them, thermography is a valuable diagnostic tool.

Problems with electrical and mechanical installations usually become evident at an early stage due to thermal irregularities. Thermal imagers visualize status changes and weak spots – and they do this in a non-contact, non-destructive manner. The next few pages outline how thermal imagers from Testo can help you to perform typical preventive maintenance tasks more reliably, easily and safely.

The challenge

Maintenance was previously considered to be purely a tool for rectifying faults. These days, it is seen as a preventive maintenance service which ensures the permanent availability of production facilities and plays a vital role in the competitiveness of industrial companies. Every day, specialist personnel are at the forefront of the struggle to minimize down times, prevent damage to mechanical and electrical components, fully exploit the level of equipment utilization, and as a result also reduce maintenance costs. Since production usually focuses on a small number of machines or automated systems, when these are shut down this often has far-reaching consequences: one leaky valve can spoil the entire batch, a machine fire could end up jeopardising your company's million euro contract, or your company's fire insurance may threaten higher premiums as an additional penalty. Large-scale damage may result in the plant shutting down. One out of three fires in industrial companies can be attributed to electrical components overheating, with minor defects such as loose terminals or damaged cables often the cause.

Fault-free plant status also guarantees safety in the workplace. There is additional pressure from national and international legislation, as well as the standards of employers' liability insurance associations or trade associations. These are all in place for your own safety, since work-related accidents are more likely to occur in maintenance than in production, despite the lower number of employees. Lastly, all inspections need to be documented, and your supervisor expects a complete, technically accurate report. Thermography is a safe, efficient and simple measuring technique for these typical industrial tasks.

The solution

Thermal imagers convert thermal radiation in the infrared range into electrical signals and make them visible. This extension of the range and function of human vision by means of the thermal image is akin to a sixth sense, which service engineers can use to detect concealed defects and anomalies before they turn into proper malfunctions and endanger system availability.

Versatile and flexible

 In electrical installations, thermographic measurement methods are possible at all voltage levels. This means that entire switch cabinets, not to mention medium, high and ultra-high voltage installations, can be inspected efficiently and in compliance with the necessary safety clearance. Carrying out thermographic inspection for just a second time reduces a system's rate of failure by 80 % and provides an added safeguard against fire. Even before damage occurs, the thermal image provides information about the operating status of mechanical assemblies. Motors, gears, couplings or bearings can be examined individually or as a functional unit. Thermal imagers can be used for precise temperature measurements even on complex aggregates, containers for liquids and gases, turbines or filters. You can use thermography to inspect insulation, and also to detect internal deposits in pipelines and containers.

Safe and non-contact

A thermal imager can be used to examine live components or moving parts from a safe distance. This means that thermography can be used to monitor even difficult­ to ­access areas safely and accurately. This increases occupational safety and allows inspections which were previously only possible through investing considerable effort – by shutting down machines or disconnecting electrical installations. The examination also reveals the thermal behavior under full load. Problematic areas are clearly indicated on a display. This allows the on-site service engineer to detect and eliminate sources of error at the very moment that these crop up. Using a pyrometer could cause the service engineer to miss these crucial details. In addition, thermograms facilitate clear error documentation and long-term time series comparison of system status. The software can be used to analyze the images quickly and easily, and summaries all work in a report. This reduces tedious paperwork.

Place your trust in the global market leader

Testo AG is one of the world's leading manufacturers of portable, innovative measuring instruments and thermal imagers. With an infrared resolution of 320 × 240 pixels, thetesto 885 professional thermal imager is the flagship instrument for universal applications. The testo 890 high­ end system's 640 × 480 pixel detector will satisfy even the most demanding of requirements.

Most associations recommend detector sizes of at least 320 × 240 pixels for applications in industrial thermography. Testo Super Resolution improves the quality of each recorded infrared image, making it a cut above the rest: the patent-pending technology produces four times as many readings and a usable geometric resolution that is 1.6 times higher. testo Site Recognition facilitates repeated thermal imaging of similar measurement objects: The function's immediate measuring location detection and automatic thermal image assignment enable efficient inspection route management. The ergonomic camcorder design and extra features such as the lens protection glass ensure safe handling in tough industrial environments.

Key advantages of thermography

•        Safety during measurement, precision and reliability of measurement results

•        Visualise load changes over the course of time, preventing system breakdowns

•        Cost and time efficiency