COMPRESSED AIR CONSUMPTION MONITORING

Make your Compressor save your money

Why compressed air?

Virtually in every manufacturing facility in the world, for hundreds of industrial control applications, compressed air systems are used as power sources for tools and equipment. Most industrial facilities need some form of compressed air - from running a simple air tool to operating pneumatic controls.

Leaks waste energy and money

Compressed air is an advantageous but also rather costly energy source. An undetected hole or a leak in compressed air lines can cost a plant several thousand rupees per year. Predictive leak detection and repair will result in substantial cost savings and system efficiency. However, if these costs are not measured and accounted for separately then there is no motivation for the person responsible for the equipment to work towards cutting the costs of compressed air consumption. If the system's compressed air consumption is recorded, however, there is greater motivation to detect leaks and reduce consumption.

How are the leaks detected?
Dividing a plant into zones is key to leak detection

In order to provide predictive maintenance information, a plant should be first divided into zones based on the number of fittings and potential leakage points. After sectioning a plant into smaller, more manageable zones, the meter is mounted in the supply line to the zone. The sensor will detect leakage areas based on the zone's increase in air consumption over time or monitor air consumption when machines in the zone are shut down.

After a leakage area is detected, leak repair can occur quickly.  A compressed air flow meter will target a leakage area by zone so that plant personnel can focus on a specific, smaller area, rather than search an entire plant for air leaks. With the zone identified, maintenance can quickly pinpoint the exact leak location and repair the leak. 

Thus, a compressed air flow meter can monitor:

·         Leakage per individual machine

·         Leakage per zones in a plant

·         Consumption per machine cycle

·         Consumption per shift

·         Consumption per zones in a plant

It can also verify leak repair and help in system improvements.

How can Testo help?
∙ We discuss with you the details and condition of your compressed air network.
∙ We offer a suitable instrument for demo of your requirements (if you want to start on a small scale)
∙ We offer complete systems that can include monitoring of consumption - Dew point Transmitter for air quality and Compressed air flow meter for quantity, with or without PC communication for data analysis.

In other words, we cater to your compressed air system needs with simple or complex smart solutions and make the burden of looking after your compressed air, easy to handle.

Benefits:

Not only the energy costs could be reduced by monitoring the compressed air, but the purchase of another compressor is no longer necessary and an existing compressor could be switched to standby. Installation and purchase of the compressed air meter is paid off in no time.

While Testo Compressed Air Flow Meter 6440 monitors consumption of compressed air, Testo Dew Point Transmitter 6740 monitors quality of compressed air.

Compressed air is used in all areas of industry. Humidity is normally undesirable because it can cause damage or impair the quality of the end product. Testo trace humidity sensors enable you to keep an eye on these processes.

Courtesy: Testo India Pvt. Ltd.
For more info: Write to info@testoindia.com or visit www.testo.com/en-IN.

Use of Testo Thermography in Electrical Industry

What is Thermography?

Thermography is technology by which you can see the thermal patterns of your equipments, material, buildings and trace the thermal abnormality of the object. With this you can save your expensive equipments from premature wear out or damage and reduce maintenance cost by taking timely actions. It works on infrared radiation detection from your objects.Lately it has become very important to monitor your electrical and electronic equipments so as to reduce its down time and increase the quality and productivity of the same.

All objects which are warmer than minus 273 degrees centigrade (absolute zero), emit infrared heat radiation. Infrared radiation cannot be seen by the human eye. Thermal imagers, however, can convert this infrared radiation into electrical signals, and present them as a thermal image. The heat radiation is thus made visible for the human eye.

Salient features of Testo Thermal Imagers

·         Best in class thermal sensitivity

·         Ease of operation

·         Wide temperature range

·         High image quality

·         Fast and comprehensive analysis

·         Upgradation to higher resolution possible with SuperResolution technology

Most common applications for Thermal Imagers in Electrical field

1.    Regular checks in electrical maintenance

Testo thermal imagers allow an evaluation of the heat status of low, medium and high voltage systems. Thermal images lead to early recognition of defective components, so that the required preventive steps can be taken. This minimizes the risk of fire that avoids costly production downtimes.

2.    Thermography in the inspection of switch cabinets

In electrical installations or cables, increased temperatures are always an indication of an overload, an imminent malfunction or an existing defect. The technology of thermography is particularly useful in the maintenance of switch cabinets, as the measurements can be carried out non-contact and at a safe distance. Anomalies can therefore be detected and counter measures can be implemented.

3.    Detection and storage of measuring site – automatically

The SiteRecognition technology also supports efficient and reliable inspection routing for lots of similar switch cabinets. The thermal imager automatically detects the measuring location and stores the measured thermal images in defined folders. Therefore the thermal images of the switch cabinets can be analysed conveniently and safely on the PC.

4.    Maintenance of electrical installations: conductors and connections

Different temperatures in conductors and connections in electrical installations may be a sign of loose or corroded connections. As shown in the image, heat propagation is also monitored in the cable duct and bundled cables.

5.    Maintenance of electrical installations: electrical components

In case of electrical components, heat distribution within the individual components is also significant, as well as the connections and access lines. Different temperatures within maintenance indicate the operating status, but can also be indicative of a malfunction.

The image shows an overloaded electrical fuse. It may be that this fuse is too small, or the electrical components are producing excessive current.

6.    Maintenance of electrical installations: transformers

Depending on the type of insulation, the connections, cores or insulation in components of medium-voltage installations such as transformers can be inspected for thermal irregularities.

7.    Maintenance of electrical installations: overhead power lines

The electrical connection points and insulators for overhead power lines in substations or the overhead power lines of high-voltage systems can be checked for maintenance purposes. Typically, these locations are difficult to access. Lots of locations can be inspected thermographically using a telephoto lens with correspondingly high resolution, conveniently from the ground.

8.    Maintenance of electrical installations: control and regulation systems

Electrical distribution systems are operated at low voltage and can be inspected quickly and easily using thermography. These systems are normally maintained using thermal imagers with a high detector resolution. The higher detector resolution makes smaller details visible. Thus, even the smallest electrical components can be analysed thermographically. Many more applications are possible in design and development and so on.

Seeing it is believing it so see the problem before the problem sees you. Call us for a demonstration and finfd more applications for your self.

To know more and have a demonstration write to us at info@testoindia.com or visit www.testo.com/en-IN.

TECHNICAL ARTICLE - COMPRESSED AIR CONSUMPTION MONITORING

Make your Compressor save your money

Why compressed air?

Virtually in every manufacturing facility in the world, for hundreds of industrial control applications, compressed air systems are used as power sources for tools and equipment. Most industrial facilities need some form of compressed air - from running a simple air tool to operating pneumatic controls.

Leaks waste energy and money

Compressed air is an advantageous but also rather costly energy source. An undetected hole or a leak in compressed air lines can cost a plant several thousand rupees per year. Predictive leak detection and repair will result in substantial cost savings and system efficiency. However, if these costs are not measured and accounted for separately then there is no motivation for the person responsible for the equipment to work towards cutting the costs of compressed air consumption. If the system's compressed air consumption is recorded, however, there is greater motivation to detect leaks and reduce consumption.

How are the leaks detected?
Dividing a plant into zones is key to leak detection

In order to provide predictive maintenance information, a plant should be first divided into zones based on the number of fittings and potential leakage points. After sectioning a plant into smaller, more manageable zones, the meter is mounted in the supply line to the zone. The sensor will detect leakage areas based on the zone's increase in air consumption over time or monitor air consumption when machines in the zone are shut down.

After a leakage area is detected, leak repair can occur quickly.  A compressed air flow meter will target a leakage area by zone so that plant personnel can focus on a specific, smaller area, rather than search an entire plant for air leaks. With the zone identified, maintenance can quickly pinpoint the exact leak location and repair the leak.

Thus, a compressed air flow meter can monitor:

·         Leakage per individual machine

·         Leakage per zones in a plant

·         Consumption per machine cycle

·         Consumption per shift

·         Consumption per zones in a plant

It can also verify leak repair and help in system improvements.

How can Testo help?

∙ We discuss with you the details and condition of your compressed air network.
∙ We offer a suitable instrument for demo of your requirements (if you want to start on a small scale)
∙ We offer complete systems that can include monitoring of consumption - Dewpoint Transmitter for air quality and Compressed air flow meter for quantity, with or without PC communication for data analysis.

In other words, we cater to  your compressed air system needs with simple or complex smart solutions and make the burden of looking after your compressed air, easy to handle.

Benefits:

Not only the energy costs could be reduced by monitoring the compressed air, but the purchase of another compressor is no longer necessary and an existing compressor could be switched to standby. Installation and purchase of the compressed air meter is paid off in no time.

While Testo Compressed Air Flow Meter 6440 monitors consumption of compressed air, TestoDew Point Transmitter 6740 monitors quality of compressed air.

Compressed air is used in all areas of industry. Humidity is normally undesirable because it can cause damage or impair the quality of the end product. Testo trace humidity sensors enable you to keep an eye on these processes.

Courtesy: Testo India Pvt. Ltd.
For more info: Write to info@testoindia.com or visit www.testo.com/en-IN.

Fast, non- contact measurement of surface temperature with Infrared Technology

Testo 830: The series of universally applicable infraredthermometers from testo for non- contact temperature measurement in trade and industry.

Equipped with new processor, testo 830 IR thermometers provide better resolution for even more precise measurements with accuracy of 0.1 °C. The limit values of the last measurement can be displayed and even better monitored, all thanks to the min./max. function.

The testo 830-T1 with 1-point laser measurement spot marking and 10:1 optics.

With an impressive speed, testo 830-T1 can take two measurements per second that helps you undertake bigger measuring tasks quickly and efficiently.

The testo 830-T2 with 2-point laser sighting and connection for external probes.

It is designed to perform fast and accurate surface temperature measurements in the HVAC area and industry with a new high resolution processor that enables measurement results of unbelievable accuracy. Thanks to the min./max. function which allows defining of temperature limit values according to user needs. To control the limits with the help of an audible and visual alarm has never been easier.

The testo 830-T4 with 30:1 optics for exact measurement at a distance

This universal infrared thermometer is ideal for applications, where, from a secure distance even smaller, difficult to access or dangerous targets can be measured without any problems. The new high resolution processor enables measurement results of unbelievable accuracy. In addition, the min./max. function facilitates defining of temperature limit values according to individual needs. The limits can be easily controlled by an audible and visual alarm.

For infraredtemperature gun, the emission level can be individually set which allows you to adjust it precisely to the surface of the material being measured, to achieve the best possible measurement results.