1. Installation safety

Electricians often have to perform a load analysis before new loads can be added to an existing panel. Why? These requirements are set by the electrical inspector, the electrical engineer who designed the project or the customer adding the new loads. The purpose is to determine whether there is sufficient capacity to add new loads.

In a load analysis, a power logger used to document existing load levels (three-phase power dissipation) over long periods of time. And this is where safety comes into play. On the one hand, load analysis can be used to ensure compliance with local safety regulations. On the other hand, failure to conduct a load analysis before adding new loads may result in the overloading of an existing electrical source or the creation of unsafe and unreliable electrical situations.

2. Managing energy costs and realising savings opportunities

Energy costs are a large part of total operational costs, and yet many companies do not have a good overview of where their energy money is going. They only get an overall monthly bill, with no indication of whether that consumption is normal or excessive for that month's operations.

By logging energy consumption at the main service input and then at large loads and secondary feeds, facilities can gain insight into how much energy is consumed when, by what and at what hourly rate. The data will actually always show energy wastage that can be corrected by changes in operations. For example, consider switching off certain loads, reducing loads during periods of high tariffs, or adjusting the schedule so that loads are operational during periods of off-peak tariffs.

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3. Electricity bill accuracy

Owners of large and medium-sized facilities often install submeters so they can bill tenants for their specific electricity consumption. However, these submeters are usually installed incorrectly, resulting in unreliable data. Installation problems range from power inverters placed incorrectly and power inverters on the wrong phase, to errors in submeter configuration.

A good practice is to check the measured value with a portable energy logger. The logger data provides an order-of-magnitude comparison of what is charged with what is consumed. A significant difference between the energy consumption charged and the logger data indicates that the submeter setting should be investigated.

4. Rebates and financial incentives

Utilities offer premiums and rebates to encourage their customers to reduce their energy consumption. The aim is to serve more customers with the same current energy supply, as building new power plants is not an option. Many premiums and rebates are aimed at retrofitting existing buildings, with energy-efficient lighting and high-efficiency motors, for example, or replacing motor starters with frequency-controlled drives.

To grant the financial incentive bonus, the utility first requires proof of energy savings - and for this, a load analysis is ideal. A load analysis performed before a retrofit identifies the current energy consumption for reference, a load analysis after a retrofit confirms the energy savings achieved by the retrofit.

5. Detecting problems with mains power quality

Often, the only way to solve a problem is to record and analyse data over a long period of time. For these more complex problems, energy loggers are invaluable, and they are much more affordable and easier to use than a complicated Power Analyzer.

A good example is when a circuit breaker trips randomly. Obvious situations, such as a heavy motor starting, are not always the cause. In reality, the cause of the tripping may be something that does not seem obvious, or may only occur when technicians are not present to notice it (e.g. at night). Having a maintenance technician monitor the load until the circuit breaker trips is impractical. Connecting an energy logger to the load side of the circuit breaker to record the current draw for an extended period of time can then help to solve the problem.

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Advanced power quality considerations

When power flows, some of the energy generated is inevitably lost in the form of heat.

The next step in reducing your energy consumption is to identify where energy wastage occurs. One area of concern is losses in conductors. When current flows through conductors, some of the energy generated is wasted as heat. If you want to solve this problem, apply the fundamental I2R equation indicating the current supplied. There are 2 possible solutions here: lower the current (I) for less kW or lower the resistance (R). Both create a problem:

• At a lower current (I), the load does not operate correctly
• Reducing resistance (R) may cost more, as copper or aluminium conductors need to be installed

So what is the best solution?

Consider the size of the conductor. In the National Electric Code (NFPA 70 or NEC 100) you will find a lot of advice on the size of a conductor and the ideal conductor size is described for almost all circumstances. The main consideration for the size of conductors is to ensure their safe operation with the most suitable insulation. The length, cross-sectional area and rated current expected to be required are decisive here. This will ensure minimal energy losses, typically 2% or less, and an acceptable voltage drop in the conductor. Another option is to install more efficient loads. Check whether the motors might be oversized for the current application.

Energy waste

These codes and guidelines are useful for new work, but once cabling is in place and loads are installed, the result is not always optimal. Over time, equipment can change due to additions, modifications, moves and age. This can have a major effect on energy waste. Key areas where energy waste can occur are related to your mains power quality: voltage regulation, harmonics, power factor and asymmetric loads.

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Voltage regulation

Voltage regulation aims to reduce energy consumption in loads that are voltage dependent. This is done by reducing or regulating voltage levels within the equipment manufacturer's specifications to yield energy savings. As more efficient loads are installed on a transformer, the voltage in the system may increase or be misregulated.

Use a Fluke 1777 Power Quality Analyzer to identify voltage regulation problems and detect transient voltages and voltage imbalances. Both problems can lead to failures, unplanned downtime and costly repairs.

Harmonischen

Harmonics distort voltage and current so that the ideal sine wave for voltage is not maintained. One of the most well-known effects of harmonics in electrical systems is the excessive heat they cause in conductors. This results in overheating in phase and neutral conductors, known as ‘triple harmonics.’

The extra heat causes problems in wiring, motor windings and transformers. The overheating can cause significant damage or catastrophic failure, resulting in unscheduled downtime and expensive repairs. To measure and diagnose harmonics, use aFluke 1770 series three-phase Power Quality Analyzer.

Benefits of power quality analysis

If, after power quality analyses, it is visible where energy is being wasted, you can take steps to solve the problems:

1. Perform preventive maintenance routinely so you can continue to measure against your benchmark and address problems as soon as they arise.
2. Install harmonic filters on loads that increase the harmonic distortion of your installation.
3. Address the causes of imbalance. This may mean setting up a repair or replacement schedule for large engines that have problems with mechanical imbalance.
4. Limit problems caused by asymmetrical loads. In some cases, this may mean adjusting single-phase loads to distribute them more evenly between phases.
5. Replace blown fuses if necessary. A blown fuse on a group of three-phase power factor upgrade capacitors may also be the cause of the problem; replacing the fuse may solve a major imbalance.

Mains power quality analyses show what can be done to save energy, reduce energy losses due to problems in an installation and reduce energy costs. Monitoring mains power quality can provide insight into the cause of problems and how to solve them.

Mains power quality analyses provide some other benefits besides energy savings:

• Discovery vhan potential weaknesses in assets that could cause a major disruption
• Discovery of equipment failures that could lead to worsening problems
• Discovery of improperly installed circuit breakers prone to inadvertent tripping

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Detecting and fixing leaks is not easy

Many factories and plants do not have a leak detection programme. Detecting and fixing compressed air, gas and vacuum leaks is not easy. Quantifying the amount of waste and determining the cost requires energy specialists or consultants who use energy analysers and loggers to monitor your air systems. By systematically calculating the annual cost savings from fixing leaks, they can make a strong business case for undertaking such a project.

Energy audits of compressed air systems are often carried out through partnerships of industry, government and non-governmental organisations (NGOs). One such partnership is the Compressed Air Challenge (CAC), a voluntary collaboration between these groups. Its sole purpose is to provide product-neutral information and educational materials to help industries generate and use compressed air with maximum sustainable efficiency.

The high cost of wasted air

According to the U.S. Department of Energy, a 1/8″ (3 mm) leak in a compressed air line can cost more than $2,500 a year. The Department of Energy estimates that an average US plant that is not properly maintained can waste 20% of its total compressed air production capacity due to compressed air, gas and vacuum leaks. The New Zealand government, as part of its Target Sustainability project, estimates that system leaks can account for 30 to 50% of a compressed air system's capacity. Rapid detection of compressed air, gas and vacuum leaks is a key factor in finding hidden profits. Air leaks can also lead to capital expenditure, rework, downtime or quality problems and higher maintenance costs.

To compensate for pressure loss due to leaks, business managers often tend to overcompensate by purchasing a larger compressor than necessary, which incurs significant capital costs and higher energy costs. System leaks can also lead to air equipment failure due to low system pressure. This can lead to production delays, unplanned downtime, quality problems, shorter lifespan and increased maintenance due to unnecessary switching compressors on and off.

For example, the maintenance manager of a manufacturer in the US says that low pressure in one of their air tools can lead to defects in their products. “Incorrect torque, either too low torque or too high torque, can result in recalls. This also leads to more man-hours in something that should be a very standard process,” he says. “It is throwing money down the drain through loss of profits and loss of products. At worst, demand may also be at risk because we could not deliver.”

It is no wonder that utilities, industry and government see compressed air systems as a potential source of cost savings. Compressed air, gas and vacuum leaks lead to waste. Fixing such leaks can save the company manager money and prevent the utility from having to build additional capacity into the system.

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Why ultrasonic leak detection is inefficient

Unfortunately, the most common leak detection practices are rather primitive. An old-fashioned method is to listen for hissing sounds, which are almost impossible to hear in many environments, and spray soapy water on the area of the suspected leak, which is messy and could potentially be a slip hazard.
The current tool for detecting compressor leaks is a ultrasound detector, a portable electronic device that recognises high-frequency sounds related to air leaks. Typical ultrasonic detectors help find leaks, but their use is time-consuming and repair staff can usually only use them during scheduled downtime, while servicing other critical machinery may be a better use of time. These instruments also require the operator to be close to the equipment to find leaks, making the instruments difficult to use in hard-to-reach places such as ceilings or behind other equipment.

In addition to the time required to detect leaks with suds or ultrasonic detectors, there may be safety issues with these techniques related to finding leaks above or below equipment. Climbing ladders or crawling around equipment can be hazardous.

Pioneering for compressed air leak detection

What if there was a leak detection technology that could determine the exact location of a leak up to 50 metres away, in a noisy environment, without having to turn off equipment? Fluke has developed an industrial acoustic camera that does just that. Industrial maintenance managers call the Fluke ii900 Sonic Industrial Imager“Pioneering” for compressed air leak detection.

Capable of detecting a wider frequency range than traditional ultrasonic devices, this new acoustic industrial camera uses new SoundSight™ technology to provide enhanced visual scans of air leaks, just as thermal imaging cameras detect hotspots.

The ii900 features an acoustic array of small, super-sensitive microphones that detect both sonic and ultrasonic sound waves. The ii900 recognises a sound source at a potential leak location and then applies algorithms that interpret the sound as a leak. The results produce a SoundMap™ image, a colour map overlaid on top of the visible-light image, - showing exactly where the leak is. The results are displayed on the 7-inch LCD screen as a still image or real-time video. The ii900 can store up to 999 image files or 20 video files for documentation or compliance.

Large areas can be scanned quickly, detecting leaks much faster than other methods. Filtering can also be done by intensity and frequency ranges. A team at a large factory recently used two ii900 prototypes and detected 80 compressed air leaks in one day. The maintenance manager said that using traditional methods it would have taken weeks to find that number of leaks. By quickly detecting and fixing leaks, the crew also avoided potential downtime, which can cost an estimated $100,000 an hour in lost productivity at this plant.

Where to find leaks:

• Links
• Snakes
• Tubes
• Fittings
• Threaded pipe connections
• Shortcuts
• FRLs (combinations of filter, regulator and lubricator)
• Condensate traps
• Valves
• Flanges
• Gaskets
• Air supply boilers

How much air do you waste?

The first step in controlling leaks in compressed air, gas and vacuum systems is to estimate the leakage rate. Some leakage (less than 10%) is to be expected. Anything more is considered wastage. The first step is to determine your current leakage load so that you can use it as a benchmark against which to compare improvements.

The best method for estimating leakage load is based on your control system. If you have a system with start/stop control, simply start your compressor when there is no demand in the system - after working hours or shifts. Then measure a number of compressor cycles to determine the average time before the loaded system is unloaded. If there is no equipment in operation, the unloading of the system is due to leakage.

Leakage (%) = (T x 100) ÷ (T + t)T = load time (minutes), t = relief time (minutes)

To estimate the leakage load in systems with more complex control strategies, place a pressure gauge downstream of the volume (V, in cubic metres), including all secondary boilers, mains and pipes. If there is no demand in the system, except for leakage, bring the system to normal working pressure (P1, in psig). Select a second pressure (P2, about half the value of P1) and measure the time (T, in minutes) it takes the system to drop to P2.

Leakage (cfm free air) = [(V x ( P1 - P2) ÷ (T x 14.7)] x 1.25

The multiplier 1.25 corrects leakage to normal system pressure, taking into account lower leakage as system pressure decreases.

Efficiently fixing and repairing leaks can lead to significant cost savings for air-dependent businesses. Companies can not only save on energy consumption by repairing leaks, but can also improve production and extend the life of equipment.

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Additel's new pressure controllers combine advanced control and measurement technology, modular design and user-friendly features in one powerful package. To achieve speed, control and accuracy in a wide range of applications, we have developed three different controller models: the ADT773 (LLP model, -0.95 to 1 bar), ADT783 (pneumatic model, -0.99 to 250 bar) and ADT793 (hydraulic model, 0 to 1000 bar). For users who want automated manufacturing, testing and calibration, our new pressure regulators can get the job done.

Thursday 22 June

One session at 10 a.m. and one at 1 p.m.

Optimising the consumption of electrical energy is a requirement today. With current energy price trends, perhaps as an additional incentive for companies. Not only for designers of new installations but also for owners of existing systems. ‘how do I make my installations operate as efficiently as possible with the lowest possible kWh consumption’. To determine efficiency, measurement is essential. ‘Measuring is still knowing’. The more parameters are measured, the more data there is to map energy flows, load profiles and efficiency. Potential improvements and corrections can be made after analysis.

A rewarding system in terms of energy savings is compressed air. With the compressor as the load and the application itself, this is so-called ‘low hanging fruit’ in terms of energy savings and efficiency increases. This example will also be taken into account to see how leaks can be efficiently identified and quantified.

This Webinar focuses on measuring the important parameters. To see, through some examples, how these can be measured and analysed.

In 45 minutes, we will review some test and measurement challenges with Fluke solutions. Test and measurement solutions that are ideal for measuring, collecting, analysing and reporting the desired parameter data.

Link for registration 10am webinar:

https://fluke-emea.zoom.us/webinar/register/6416847571656/WN_6RguJiR4SOqo6v-x12vOmw

Link for sign-up 1pm webinar:

https://fluke-emea.zoom.us/webinar/register/1116847578756/WN_dTA02swKRfyItnunvvESwg

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Take this unique opportunity to broaden your knowledge and strengthen your network. We look forward to welcoming you on 22 and 23 March in Antwerp Expo at our stand A2280.