Training Session on Energy
Equipment
Monitoring Equipment
Presentation from the
“Energy Efficiency Guide for Industry in Asia”
www.energyefficiencyasia.org
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© UNEP 2006
Training Agenda: Monitoring
Equipment
Electrical measuring instruments
Combustion analyzer
Manometers
Thermometers
Water flow meters
Speed measurement
Leak detectors
Lux meters
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© UNEP 2006
Monitoring Equipment:
Introduction
• Have you used any before?
• Why do we need them?
• Can we do without them?
• How accurate should they be?
• What properties should they posses?
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Electrical Measuring Instruments
What Do They Do?
• Measure electrical parameters: KVA,
kW, power factor, Hertz, KVAr, Amps
and Volts, harmonics
• Hand-held meters: instant
measurements
• Advanced facilitates: cumulative
readings with printouts at specified
intervals
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Electrical Measuring Instruments
What do they do?
• The HIOKI 3286-20 clamp on power hitester
measures:
- Voltage
- Reactivity
- Current
- Phase angle
- Voltage/current peak
- Frequency,
- Effective / reactive /
apparent power
(single-phase or 3phase)
- Phase detection(3-phase)
- Power factor
- Voltage/current harmonic
levels (up to 20th)
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Electrical Measuring Instruments
Where are they
used?
• These
instruments
are applied online to
measure
various
electrical
parameters
HIOKI 3286-20
clamp on power
hitester
www.hioki.co.jp
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Electrical Measuring Instruments
How to use them?
• Three leads with
crocodile clips:
red, yellow and
black (RYB)
• Used to measure
voltage
• Need naked wires
www.electricfence-online.co.uk/ishop/1047/shopscr91.html
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Electrical Measuring Instruments
How to use them?
• Clamp that can
open and close
• Used to measure
current
• Need insulated
wire
HIOKI 3286-20 clamp on power hitester
www.hioki.co.jp
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Electrical Measuring Instruments
How to use them?
• Only the combination of clamp and
crocodile clips give other
measurements
• Power
• Power factor
• Frequency
• Etc.
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Electrical Measuring Instruments
How to use them?
• Measurements are taken at the
junction or distribution box
• Electricity distribution to different
equipment
• Live and neutral wires visible
• Insulated and naked wires available
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Electrical Measuring Instruments
Current measurement
Clamp sensor
Live wire
Neutral wire
Display
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Electrical Measuring Instruments
Voltage measurement
Live wire
Neutral wire
Display
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Electrical Measuring Instruments
Measurement of all electrical
parameters on 3-phase, 4-wire circuit
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Electrical Measuring Instruments
Precautions
• Never attach the clamp to a circuit
operating > maximum rated voltage, or over
bare conductors
• Connect clamp on probe to the secondary
side of a breaker/fuse
• Use rubber hand gloves, boots, and safety
helmet to avoid electrical shocks
• Consult the operation manual before using
the equipment
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© UNEP 2006
Training Agenda: Monitoring
Equipment
Electrical measuring instruments
Combustion analyzer
Manometers
Thermometers
Water flow meters
Speed measurement
Leak detectors
Lux meters
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© UNEP 2006
Combustion Analyzer
What does it do?
• Measures the products of combustion:
• CO
• CO2
• NOx
• SOx
• O2
• Fly ash, soot, others…
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Combustion Analyzer
What does it do?
• Measures the composition of flue gases
after combustion in percentage
• Measure % oxygen or % CO2 in the flue
gases. If one is measured, the other can
most often be calculated
• Combustion efficiency can be calculated
with an inbuilt programme
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Combustion Analyzer
Fuel Efficiency Monitor
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www.fuelefficiencyllc.com/ feinc1.jpg
© UNEP 2006
Combustion Analyzer
Fyrite
omnicontrols.com/
lists/gifs/Bach5.gif
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Combustion Analyzer
Gas Analyzer
Bacharach Fyrite® Pro Combustion Gas Analyzer
www.apexinst.com/ assetsnew/Fyrite-pro.gif
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Combustion Analyzer
Where is it used?
• Any equipment where combustion
takes place: boilers, furnaces
• Measurements are taken in the duct
• Measurements are used to identify
efficiency, leakages
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Combustion Analyzer
How to use them: Gas Analyzer
Probe
Display
screen
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www.apexinst.com/ assetsnew/Fyrite-pro.gif
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Combustion Analyzer
Precautions
•
Always calibrate the instrument in open fresh air
before taking measurements
•
Check for clogging of the air filters
•
Ensure that the rubber tubing carrying the gases
to the instrument is not bended
•
Plug the open space of monitoring hole with
cotton rags
•
Use gloves, goggles and safety helmet
•
Consult the operating manual before use
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© UNEP 2006
Training Agenda: Monitoring
Equipment
Electrical measuring instruments
Combustion analyzer
Manometers
Thermometers
Water flow meters
Speed measurement
Leak detectors
Lux meters
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© UNEP 2006
Manometers
What does it do?
• Measure the differential pressure across two
points
•Positive pressure
•Negative pressure (vacuum)
• The liquid-column manometer is the oldest
type: a U-shaped tube half-full of liquid
• Liquid: oil, water, mercury
• A barometer is a manometer!!
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Manometers
What does it do - Principles
h
aa
bb
Source: Dwyer Instruments, www.dwyer-inst.com
h
c
c
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Manometers
Where is it used?
•
To measure pressure differential in air pipes,
water pipes, gas pipes
•
Of various equipment, mainly compressors,
pumps, and draft systems
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Manometers
How to operate them – main types
of manometers
1) Single-limb Liquid-column Manometer
2) Flexible Membrane Manometer
3) Coiled Tube Manometer
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Manometers
How to use a manometer: air pipes
and ducts
Flexible Membrane Manometer
Manometer
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Manometers
How to use a
manometer:
air pipes and
ducts
Probes
Display
screen
• Turn on
• Select measurement
unit
• Measured value
appears on screen
Dwyer Series 477 – Handheld Digital
Manometer, www.dwyer.co.kr
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Manometers
How to use a manometer: air pipes
and ducts
• Bournoulli equation to calculate velocity:
• Differential pressure = v2/2g, where
• Differential pressure: measured
• v = velocity
• g = gravity
• Velocity – air flow – efficiency
fans/blowers etc
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Manometers
How to use a manometer: water
pipes
a
b
c
10 m
Water pipeline
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Manometers
How to use a manometer: water pipes
• Differential pressure = f Lv2/2gD, where
• Differential pressure: measured
• f = friction factor of pipe
• L = distance between two tappings
• V = velocity
• D = pipe diameter
• g = gravity
• Velocity – flow rate – efficiency of pump
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Manometers
Precautions
• Do not expose the manometer to very
high pressures
• Always consult the operating manual
before use
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© UNEP 2006
Training Agenda: Monitoring
Equipment
Electrical measuring instruments
Combustion analyzer
Manometers
Thermometers
Water flow meters
Speed measurement
Leak detectors
Lux meters
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© UNEP 2006
Thermometers
What a thermometer does
• Measures temperatures of any
• Fluid
• Surface
• Gas
• Two types:
• Contact: clinical and thermocouple
• Non-contact or infrared
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Thermometers
Where thermometers are used
Measure the temperature of for example:
• Ambient air
• Refrigeration plant incl. compressors and
cooling towers: e.g. chilled water, air
• Boilers: surface, flue gases, steam pipes,
feed water, condensate water
• Furnaces: surface, flue gas, cooling water
• Waste heat recovery: gas, water
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Thermometers
Where a Thermocouple is used
• Measuring temperature of air, liquids and
gases
• Generally not used for surfaces
Type: AZ RS232, K, J, T thermometer
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Thermometers
How to operate a Thermocouple
• Turn on
• Insert probe
• Read
temperature
on display
• Wait 2 min for
stable reading
Type: AZ RS232, K, J, T thermometer
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Thermometers
Where is it used?
• Any equipment where combustion
takes place: boilers, furnaces
• Measurements are taken in the duct
• Measurements are used to identify
efficiency, leakages
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Thermometers
Where a non-contact / infrared
thermometer is used
• Measure temperature of surfaces only
• Used for:
• Moving objects
• Contamination, voltage, electromagnetic
field, vacuum
• Large distances/heights
• Too high temperatures for
thermocouples
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© UNEP 2006
Thermometers
How to operate
a non-contact /
infrared
thermometer
• Turn on
• Point to
surface
• Read on panel
Hioki Non-contact Temperature
Hi Tester, model 3415-01
www.tequipment.net
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Thermometers
Precautions
Thermocouple:
• Immere probe in fluid/gas and only read
measure after 1-2 minutes
• Note temperature range before you start
• Do not touch naked flame with the probe
Infrared:
• Set the emissivity for the surface where
temperature is measured
Always consult the operating manual before use43
© UNEP 2006
Training Agenda: Monitoring
Equipment
Electrical measuring instruments
Combustion analyzer
Manometers
Thermometers
Water flow meters
Speed measurement
Leak detectors
Lux meters
44
© UNEP 2006
Water Flow Meters
How water flow is measured
• Water meter: measures flow rate of a liquid
or a gas
• Time of fill method: tank volume is divided
by time to fill the tank
• Float method: distance ping pong ball
traveled divided by travel time
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Water Flow Meters
Where a water flow is used
• Water flow rate is measured to determine
the efficiency of
• Pumps
• Cooling towers
• Refrigeration / AC plant
• Heat exchangers
• Condensers
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Water Flow Meters
How to operate water flow meters
Water flow meters used to measure water flow
in open channels:
• Turbine flow meters
• Parallel wheels
• Positive displacement flow meters
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Water Flow Meters
How to operate water flow meters
Water flow meters that are permanently
installed on water pipelines:
• Rotameter
• Spring and piston flow meter
• Vortex meters
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Water Flow Meters
How to operate water flow meters
Water flow meters
that not permanently
installed on water
pipelines
• Ultrasonic flow
meters
www.rshydro.co.uk
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© UNEP 2006
Training Agenda: Monitoring
Equipment
Electrical measuring instruments
Combustion analyzer
Manometers
Thermometers
Water flow meters
Speed measurement
Leak detectors
Lux meters
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© UNEP 2006
Speed Measurement: Tachometers
and Stroboscopes
What tachometers and
stroboscopes do and where they
are used
• Measure speed of a rotating object in
revolutions per minute (RPM)
• Used for motors, fans, pulleys
• Tachometers: direct contact
• Stroboscopes: direct contact not possible
or not safe
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© UNEP 2006
Speed Measurement: Tachometers
and Stroboscopes
How to operate
a tachometer
display
panel
• Turn on
• Bring wheel in contact
with rotating body
• Read RPM on display
panel
Extech Contact/Laser Photo Tachometer,
model 461995-NIST.
www.mytoolstore.com/extech/tachndx.html
wheel
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Speed Measurement
How to operate
a stroboscope
• Mark line on rotating
object
• Point stroboscope at
object
• Change flashing
light until marked
line stops moving
• Read RPM on
display panel
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Source: Reliability Direct, Inc. © UNEP 2006
Speed Measurement
Precautions
• Be careful when bringing the wheel of the
tachometer in contact with the rotating
body
• Do not wear loose clothes while taking
measurements with a tachometers
• Avoid taking measurements alone
• Always consult the operating manual before
use
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© UNEP 2006
Training Agenda: Monitoring
Equipment
Electrical measuring instruments
Combustion analyzer
Manometers
Thermometers
Water flow meters
Speed measurement
Leak detectors
Lux meters
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© UNEP 2006
Leak Detectors
What does a leak detector do
• Detects the location of leaks
• Detects almost any leak because
•
Short distance/access not needed
•
High pressure not needed
•
Sensitive to sound
•
Filters background noises
• Does not measure the size of the leak
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Leak Detectors
Where is a leak detector used
For measuring
• Compressed air leaks
• Refrigerant leaks
But no leak detector will find every leak!!
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Leak Detectors
How to operate a leak detector
• Turn on and put
on headphones
• Move probe
along pipeline
monitoring
device
headphones
• Mark locations
where hissing
sound is heard
probe
Type: Accutrack Ultrasonic Leak
Detector, model VPE
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Leak Detectors
Precautions
• Dust or smoke should not come out of
the pipe
• Avoid measurement at places with high
sound levels
• Always consult operating manual
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© UNEP 2006
Training Agenda: Monitoring
Equipment
Electrical measuring instruments
Combustion analyzer
Manometers
Thermometers
Water flow meters
Speed measurement
Leak detectors
Lux meters
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© UNEP 2006
Lux Meters
What do Lux meters do and where
are they used
• Measures illumination (light) levels at
•
Offices
•
Industrial plants
• Streets
•
All other (work) places
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Lux Meters
How to operate
lux meters
• Consist of a
body, a photo
cell and a
readout/display
panel
• Lux meters
readings vary for
different light
sources
Display
panel
Body
Photo cell
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Lux Meters
Where & How It’s Used?
•
Turn on the lux meter
•
Place sensor where the light intensity
is to be measured
•
Read illumination levels on the display
panel
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Lux Meters
Precautions
•
Place sensor properly on the workstation
•
Store the sensor safely due its high
sensitivity
•
Always consult the operating manual
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© UNEP 2006
Training Session on Energy
Equipment

Monitoring Equipment
THANK YOU
FOR YOUR ATTENTION
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© UNEP GERIAP
Disclaimer and References
• This PowerPoint training session was prepared as part of
the project “Greenhouse Gas Emission Reduction from
Industry in Asia and the Pacific” (GERIAP). 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. © UNEP, 2006.
• The GERIAP project was funded by the Swedish
International Development Cooperation Agency (Sida)
• Full references are included in the textbook chapter that is
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available on www.energyefficiencyasia.org
© UNEP 2006