Development and Testing of a Fan Monitoring System Using Induction Operated Current Switches

Emissions of gaseous compounds and particulate matter are the product of the pollutant concentrations and air exhausted from the fans of mechanically ventilated animal confinement buildings. Direct methods of monitoring exhaust fan operation (i.e., mercury tilt, limit or whisker, and vibration switches) have been reported to have limitations due to mechanical failure and/or the effect of the environment (dust, wind, moisture). Another method involves monitoring the control relay status at the fan system control box. A problem could occur at the fan but not in the signal at the control box, thereby giving a false operational signal. The objective of this project was to find a more reliable method of monitoring fan operation status. This paper describes the development, lab testing, and use of a fan monitoring system based on induction operated current switches (ICS). ICSs are unaffected by the environment and can provide direct measurement of real-time fan operational status by sensing AC current. A laboratory test of the ICS was performed to simulate a fan off/on duty cycle in a two-year emissions study; no ICS failure was recorded. The Southeastern Broiler Gaseous and Particulate Matter Emission study led by Iowa State University has been using 28 ICSs for over 190 days without a failure. At a unit cost as low as $19.50 this method offers a reliable, accurate, and economical way of measuring the real-time operational status of ventilation fans – a critical component of any air emissions monitoring in a mechanically ventilated confinement system

Development of a Wireless Sensor Network to Quantify Spatial and Temporal H2S Concentrations in Swine Houses (A Progress Report)

Transient hazards to human and animal health can occur in swine barns due to sudden bursts of high concentration hydrogen sulfide (H2S) gas released when manure slurry is agitated during removal from sub-floor pits. This project will quantify the concentration of hydrogen sulfide (H2S) that workers and swine in pork production facilities are typically exposed to in different production facility types during different operating conditions. Results from this study will be used to make recommendations to increase worker and animal safety by reducing risks of H2S poisoning

Validation of a Low Cost Flow Measurement System for Monitoring Vegetative Treatment System Performance

In 2006, the Iowa Department of Natural Resources issued National Pollution Discharge Elimination System (NPDES) permits to six feedlots participating in research on the use of vegetative treatment systems (VTSs) to control beef feedlot runoff. While Iowa State University monitors releases from the research portion of these sites, the producers are required to monitor releases from the non-research portions. Additionally, non-research site producers with VTSs and NPDES permits are required to monitor system releases. They are required to measure release volume and collect a sample for analysis. Automated, research oriented open channel flow measurement systems typically cost $7,500 to employ. Muhlbauer et. al (2007) developed a low cost monitoring system (LMS) designed to measure open channel flow from a VTS with a total cost of$1,600. Testing of the LMS by Muhlbauer et. al. (2007) across flow events ranging from one to six hours indicated a mean accuracy of 90.6% in comparison to a flow meter equipped ISCO 6712 portable sampler using a .46m (18”) fiberglass H-flume. Further cost reduction options for a producer include fabrication of a metal H-flume, reducing total system cost to $850. This paper compares the performance of the LMS for estimating both short and longer duration flow events and performance of the fabricated metal flume. The LMS flow measurements were compared to an ISCO 6712 portable sampler and a Krohne Optiflux 4000 flow meter in twelve field tests lasting one and six hours with an accuracy of 88.5% in comparison to the Krohne. Relative to a commercial fiberglass flume, the three fabricated flumes had a mean percent accuracy of 98%

Tyson Foods Air Pollutant Emission Monitoring

Iowa State University (ISU) is measuring air emissions from two Tyson broiler chicken houses in western Kentucky as part of a new air compliance agreement between the Environmental Protection Agency (EPA) and industry groups. The $1 million project in Kentucky, funded by Tyson Foods, was originally designed to monitor just ammonia. But the EPA agreed Iowa State could expand the project to include other items of interest - carbon dioxide, three types of particulate matter, hydrogen sulfide and nonmethane hydrocarbons

Technical Note: Development and Testing of an Induction-Operated Current Switch for Monitoring Fan Operation

Emissions of gaseous compounds and particulate matter are the product of the pollutant concentrations and air exhausted from the fans of mechanically ventilated animal confinements. Direct methods of monitoring exhaust fan operation (mercury tilt, limit/ whisker, and vibration switches) have been reported to have limitations due to mechanical failure and/or the effect of dust, wind, and moisture. The objective of this study was to find a reliable method of monitoring fan operation status. This article describes the development, lab testing, and field use of a fan monitoring system based on an induction-operated current switch (ICS). The ICS is unaffected by the environment and can provide direct measurement of real-time fan operational status by sensing the AC current drawn by the fan motor. A laboratory test of the ICS was performed to simulate a fan off/on duty cycle for a two-year field emissions monitoring study; no ICS failure was recorded. Three studies led by Iowa State University (Southeastern Broiler Gaseous and Particulate Matter Emission, Determining Ammonia and Particulate Matter Emissions from a Midwest Turkey Grow-Out Building, and Feeding DDGS and Other Altered Diets to Egg Laying Hens to Demonstrate Economically Viable Reductions in Ammonia Emissions) used a total of 28, 12, and 50 ICS systems for 24, 16, and 27 months, respectively, without a non-user error related failure. At a unit cost as low as $21.45 this method offers a reliable, accurate, and economical way of measuring the real-time operational status of ventilation fans – a critical component of any air emissions monitoring in a mechanically ventilated confinement.This article is from Applied Engineering in Agriculture 27, no. 2 (2011): 287–292.</p

Development and Testing of a Fan Monitoring System Using Induction Operated Current Switches

Emissions of gaseous compounds and particulate matter are the product of the pollutant concentrations and air exhausted from the fans of mechanically ventilated animal confinement buildings. Direct methods of monitoring exhaust fan operation (i.e., mercury tilt, limit or whisker, and vibration switches) have been reported to have limitations due to mechanical failure and/or the effect of the environment (dust, wind, moisture). Another method involves monitoring the control relay status at the fan system control box. A problem could occur at the fan but not in the signal at the control box, thereby giving a false operational signal. The objective of this project was to find a more reliable method of monitoring fan operation status. This paper describes the development, lab testing, and use of a fan monitoring system based on induction operated current switches (ICS). ICSs are unaffected by the environment and can provide direct measurement of real-time fan operational status by sensing AC current. A laboratory test of the ICS was performed to simulate a fan off/on duty cycle in a two-year emissions study; no ICS failure was recorded. The Southeastern Broiler Gaseous and Particulate Matter Emission study led by Iowa State University has been using 28 ICSs for over 190 days without a failure. At a unit cost as low as $19.50 this method offers a reliable, accurate, and economical way of measuring the real-time operational status of ventilation fans – a critical component of any air emissions monitoring in a mechanically ventilated confinement system.This is an ASAE Meeting Presentation, Paper No. 064159.</p

Validation of a Low Cost Flow Measurement System for Monitoring Vegetative Treatment System Performance

In 2006, the Iowa Department of Natural Resources issued National Pollution Discharge Elimination System (NPDES) permits to six feedlots participating in research on the use of vegetative treatment systems (VTSs) to control beef feedlot runoff. While Iowa State University monitors releases from the research portion of these sites, the producers are required to monitor releases from the non-research portions. Additionally, non-research site producers with VTSs and NPDES permits are required to monitor system releases. They are required to measure release volume and collect a sample for analysis. Automated, research oriented open channel flow measurement systems typically cost $7,500 to employ. Muhlbauer et. al (2007) developed a low cost monitoring system (LMS) designed to measure open channel flow from a VTS with a total cost of$1,600. Testing of the LMS by Muhlbauer et. al. (2007) across flow events ranging from one to six hours indicated a mean accuracy of 90.6% in comparison to a flow meter equipped ISCO 6712 portable sampler using a .46m (18”) fiberglass H-flume. Further cost reduction options for a producer include fabrication of a metal H-flume, reducing total system cost to $850. This paper compares the performance of the LMS for estimating both short and longer duration flow events and performance of the fabricated metal flume. The LMS flow measurements were compared to an ISCO 6712 portable sampler and a Krohne Optiflux 4000 flow meter in twelve field tests lasting one and six hours with an accuracy of 88.5% in comparison to the Krohne. Relative to a commercial fiberglass flume, the three fabricated flumes had a mean percent accuracy of 98%.This is an ASABE Meeting Presentation, Paper No. 084048.</p

Development and Testing of a Hydrogen Sulfide Detection System for Use in Swine Housing

Transient hazards to human and animal health can occur in swine barns due to sudden bursts of high concentration hydrogen sulfide (H2S) gas released when manure slurry is agitated during removal from sub-floor pits. Studies have shown that H2S levels can go from harmless to deadly in a matter of minutes during pit agitation (Patni and Clarke, 2003). From 1983 to 1990, H2S poisoning was responsible for the death of 24 swine workers in the Midwest alone and at least 15 more deaths since 1994 (Walinga, 2004). Swine slurry removal workers and producers report swine deaths every year from slurry agitation in sub-floor storage, or pits. Hence, a system that can reliably and promptly report H2S concentrations in swine housing without direct exposure of the operator(s) to the potentially hazardous environment is of socioeconomic importance to the swine producers. This paper describes the development and testing of a wireless, portable H2S detection system, followed by the use of the system under field conditions by slurry removal workers to monitor H2S levels during slurry agitation and removal in deep-pit swine housing systems in Iowa. The system developed in this study has a component cost of $2,735 and is based on a Pemtech PT-295 electro-chemical H2S sensor and a Phoenix Contact Wireless Transmitter / Receiver set. The portable H2S detection system has the following operational characteristics: a) 90% (t90) response to 10 - 500 ppm H2S within one minute, b) ± 5 % full scale accuracy, and c) This is an ASABE Meeting Presentation, Paper No. 084203.</p