Tuesday, 28 April 2015

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

Tuesday, 24 March 2015

Testo 870: The New Thermal Imager from Testo! We Bet You Can't Get Better than This

See thermally without compromise.                 

testo 870. The new basic thermal imager that can take care of your basic predictive maintenance without compromise!

Keeping up to its legacy of giving the best technology to the customer, without them compromising on the technical aspects. Testo takes another big leap in bringing the economic range of thermal imagers for its customers.

With the launch of the new testo 870 we bring in the same faith with 2 years’ warrantee and the best of after sales service, and loads of features in its class; to name a few, High Resolution digital camera, Focus Free thermal image, same resolution even in the entry level model, and many more so that your thermography is not downgraded. In this we bring in two variants: testo 870 – 1 & testo 870 – 2 variants.

We understand the importance of a good thermal image and the implications on prediction because of a poor thermal image hence we have given a lot of functions in the new imager that makes thermography an easy tool to predict problems before they catch you.

Some of the important features that a good thermal imager should have are:

  • Image Resolution: a good thermal imager should have a good thermal image and this can be achieved only by using a good resolution sensor (detector); hence we bring in the same resolution detector with 160 x 120 resolution.
  • Focus: Sharper the image, easier is the analysis. Focusing is one of the keys to get a sharp image. Hence, we bring in the focus free imager which is as simple as an IR thermometer. Just beam at the object and Shoot.
  • Super Resolution: An innovative technology by testo that gives you 4 times higher data points (resolution) of your detector size, so that you can do more data analysis. Additionally, increasing the IFOV of your imager allows you to see the smallest of a problem.
  • Larger Display size: testo 870 has the horizontal large screen of 3.5” making it very easy for the user to see and analyze the image.
  • Digital camera: With the 870 – 2 we offer you a high resolution digital image of 3.1 MP to help you detect your actual point of problem and eliminate it.
  • Wider angle lens: With a wider angle lens you can cover larger area / objects from a shorter distance. The lens selected is so apt that it gives you the required information without losing the smallest data.


Write back to us to know more about testo 870: info@testoindia.com 
Log on to our site www.testo.in/870  and book your free demo now!
Understand the importance of using a good thermal imager and the benefits that you get.
With our complete backup support, state of art calibration lab and a well trained service team, we assure you maximum support for all testo products at all times.

Testo India Pvt. Ltd., a 100% subsidiary of Testo AG, Germany was founded in 2006 in Pune. The company has established thirteen home offices in major metros and a dealers’ network covering this enormous country.

Testo AG is a world leader in the design, development and manufacturing of portable test and measuring instruments. Testo has also become a major supplier for HVAC industries, refrigeration, airflow and environmental monitoring instruments for markets as diverse as chemical, steel, power, cement, food and beverages, pharmaceuticals, biotech etc.

Today, Testo consists of 2450 employees, 30 subsidiaries and 80 sales & service partners in other 43 countries.

TECHNICAL ARTICLE - COMPRESSED AIR CONSUMPTION MONITORING

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, 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.
Refrigerant Leak Detector
Refrigeration And Heat Pumps Leak Detection System
Gas And Water Pipes Leak Detection System
Refrigeration And Heat Pumps Optical Inspection Instruments

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

Testo 816-1 -Sound level measurement with integrated data storage

The testo 816-1 sound level meter is ideal for measuring sound level  at workplaces, industrial and production halls, and public places.  The measuring instrument can be switched from Slow (1 sec.) to Fast (125 ms) with the touch of a button. Additionally, it is also facilitated to switch between the frequency weighting characteristic curves A (corresponds to the sound pressure sensitivity of the human ear )and curve C (for evaluating low-frequency components of a noise) and vice versa. ation of testo 816-1. The integrated data store allows the storage of over 30000 measurement values in the instrument, these can be administered using the software included in delivery. In addition to this, the software allows online measurements over a longerperiod to be carried out. With the optional sound calibrator and the adjustment accessory included with it, the testo 816-1 can be re-calibrated on site.
Features-
•          Backlit display
•          Bar graph display
•          Frequency weighting A and C
•          Sound level measurement acc. to IEC 61672-1 class 2 and ANSI S1.4 Type 2
•          Integrated data storage for up to 31000 measurement values
•          can be switched from Slow (1 sec.) to Fast (125 ms)
•          Software for data management and long term measurement
•          AC and DC output for the connection of other instruments
•          On site calibration with the optional sound calibrator

Thursday, 26 February 2015

Identifying damp walls and avoiding mould

When old buildings are restored, this is done with the best intentions. The restoration is carried out in order to correct defective heat insulation and to avoid the increased energy costs caused by this. This usually involves installing new windows. While this solves the problem of the heat insulation, modern windows seal so well that the necessary air exchange is hindered. The consequence: The air humidity increases, forming the basis for the feared mould growth on walls and ceilings.   How does mould develop?   Mould spores, the seeds of the mould fungus, are everywhere. In order to grow, they need – in addition to nutrients such as dust, plaster, wallpaper or wood – above all water. If, for instance, water has penetrated into the living quarters due to a burst pipe, or if the indoor air has been too damp over several days, mould spores find ideal living conditions. The more humid the air, the better the mould can grow. The causes can be constructional defects, incorrectly implemented restoration or insufficient heating and ventilation, for example. In addition to the damage to health caused by mould, the building substance is also permanently damaged. Because of this, mould needs to be identified and eliminated in time.       The relevant measurement parameters In order to detect moisture damage, the following measurement parameters must be recorded:
Parameter Indicates
Air temperature …heating, ventilation and comfort in rooms.
Air humidity …mould damage, and important indicator in technical building drying. Air humidity indicates how much water vapour is present in the air.
Material temperature …the surface temperature of the material, and thus cold bridges, i.e. at which points heat is being drawn away from the material, allowing it to cool.
Material moisture …the water content in mineral building materials. Measurements both at the surface (non-intrusive), as well as measurements in the material using an equilibrium humidity measurement (intrusive), are possible.
Isolating the causes   Once mould is in the building, the tenant initially supposes that the damp is coming from the outside. Many legal battles have ensued from the question of who is responsible for mould damage. It is very difficult to determine who or what has caused mould: the inhabitants or defective building construction? This is where modern measurement technology comes in. Contractors, experts and assessors usually have such measuring instruments in use, and can carry out in-depth research into causes within a very short time.
Measuring instruments for research into tenantrelated causes Measuring instruments for research into construction-related causes
Air thermometers e.g. testo 610 Surface (contact) thermometers e.g. testo 905
Humidity measuring instruments e.g. testo 625 Infrared thermometers e.g. testo 830
Multi-function measuring instruments e.g. testo 635 Material moisture measring instruments, e.g. for stone and wood e.g. testo 616
Data loggers e.g. testo 175 H1 Thermal imagers e.g. testo 875
Detection of mould damage caused by tenants   The following measuring instruments are suitable: testo 610 for contractors in heating and sanitation Measurement of humidity and temperature in living quarters, bathrooms and new buildings   testo 610 is very small and handy, and can be carried with you conveniently at any time. testo 610 is simply held up in the room, and reliably, very accurately and at the touch of a button records the air humidity, temperature and dew point.       testo 625 for HVAC technology in buildings, quality assurance and production   Monitoring ambient indoor conditions testo 625 measures air humidity, temperature and dewpoint. In inaccessible points such as corners at ceiling height, the measurement values can be transferred wirelessly over great distances by the wireless module to the measuring instrument.       testo 635 for HVAC technology in buildings Testing of building substance and climatic conditions in and on buildings testo 635 measures air humidity, temperature, material moisture and U-value. The user can store the measurement results in the instrument, and later analyze and document them using the PC software. This makes uninterrupted documentary proof possible.       testo 175 H1 for use in industrial areas Long-term monitoring of air quality and indoor climate   testo 175 H1 continuously records temperature and humidity values and shows the dewpoint in the display. This allows the indoor climate to be monitored over a long period, underlining the necessity for a systematic exchange of air.       Detection of construction-related mould damage   The following measuring instruments are suitable:   testo 905-T2 for contractors in heating and sanitation   Contact measurement for the determination of surface temperature on radiators or heating systems testo 905-T2 adapts itself perfectly even to rough surfaces, achieving a high level of measurement accuracy. This allows the temperature on the surface of a wall, radiator, on valves or connections in a heatings system, to be measured quickly.       testo 830 for contractors in heating, sanitation and air conditioning Non-contact determination of surface temperature   testo 830 measures the surface temperatures of walls, ceilings and floors using infrared technology. This allows points which are too cold, at which humidity could precipitate, to be determined and if necessary countermeasures taken.       testo 616 for contractors in heating and sanitation Monitoring material moisture in building materials, e.g. after water damage   testo 616 measures material moisture non-intrusively using a contact probe in wood, screed, cement and concrete at a depth of up to 5 cm. The instrument simplifies the work of anyone who must observe the drying processes of floors, walls and surfaces as well as moisture damage.       testo 875 for the building trade and for energy consultation Identification of construction deficits on buildings   The thermal imager testo 875 shows deficits in materials and components, such as cold bridges, insufficient air-tightness, cracks in the brickwork or leaks, directly in the thermal image in the imager display. In the humidity mode, mould-risk areas are even shown up in red.     When the cause is incorrect heating or ventilation   Mould growth is in fact rarely caused by constructional deficits. The cause is more often the living habits of the tenants, for example incorrect or insufficient heating and ventilation of the living quarters. Because the humidity comes from the living quarters themselves, caused by the people, who automatically give off humidity to their surroundings. In colder places such as windows, this humidity leads to condensation, also referred to as “sweating”. For this reason, it must be extracted. In a four-person household, between 8 and 15 litres of water daily are given off into the ambient air in the form of vapour. The warmer the room, the more water can be absorbed by the air. If this water vapour now meets colder air, a part condenses back to water, which then precipitates, especially in colder areas such as corners of rooms, behind furniture and on outer walls. Heating the living room in the winter, and leaving lesser used rooms such as bedrooms or bathrooms cool does not save heating costs. It actually increases them more than if the complete apartment were to be continually heated. The higher the temperature difference between the rooms, the greater the danger that condensation can precipitate on critical areas. In addition to this, damp wall conduct heat energy more quickly to the outside. The result is mould fungus and mildew.     Humidity caused in living quarters daily: Cause Humidity in litres Humans sweating/breathing approx. 1.0 Cooking 0.5 – 1.0 Showering/bathing per person 0.5 – 1.0 Drying laundry – spin-dried 1.0 – 1.5 Drying laundry – dripping wet 2.0 – 3.5 Houseplants 0.5 – 1.0     Correct heating and ventilation   Observing a few simple heating and ventilation rules in the end not only prevents the development of mould in your apartment, it saves heating costs, protects the environment and ensures your own personal well-being.   Correct ventilation:  
  • Ventilate intensively several times a day with windows and doors open wide.
  • No long-term ventilation with windows only ajar, as this cools the brickwork too much.
  • Turn down radiators and/or thermostats.
  • Ventilate intensively immediately after cooking or showering.
  • Do not place furniture directly against outer walls, but pull them a few centimetres away.
  • The warmer the outside temperature, the longer the need for ventilation. Ventilate for a quarter of an hour on warmer days (over 12 °C), three minutes suffice on days with continuous temperatures below freezing.
    Correct heating:
  • Ensure as uniform a temperature as possible in all rooms.
  • Radiators must be freely accessible in order for the heat to be able to spread unhindered.
  • Close blinds and curtains at night in order to avoid heat loss.
  • Do not overheat the apartment. One degree Celcius of room temperature causes approximately 6% higher energy costs.
  • Never switch heating off completely, even during longer absences. The rooms would otherwise cool down too much.