“Plant Condition

Monitoring
By Using
Infrared Thermography”

Document By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
Engineeringpapers.blogspot.com
More Papers and Presentations available on above site

Abstract:
Infrared condition monitoring techniques offer an objective way of

assessing the condition of plant equipment. Infrared thermography is a condition

monitoring technique used to remotely gather thermal information from any object or

area, converting it to a visual image. The equipment is more compact, it is easier to

use, it provides better imagery, faster analysis and uses software that allows reports

to be written easily. Prices are also continually dropping in order to predict the need

for maintenance. Thermography also has the ability to generate information that can

be used to improve equipment and enhance operational and process modifications.

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 Temperature is a key variable in virtually any situation and for all

processes for example, if we have even the slightest deviation from normal body

temperature we feel sick. In industry, we have plenty of examples too. All this

radiation around us can be imaged, measured and stored by an infrared system for

analysis, Infrared thermography is the science of the acquisition and analysis of

thermal information from non-contact thermal imaging devices. Another area

where thermography can provide significant benefits is in the optimization of

preventive maintenance (PM). Preventive maintenance (PM) tasks are designed to

avoid unplanned failures by periodically inspecting, testing and replacing parts. In

many Cases, these time-based tasks result in unnecessary work and wasted parts or

materials, satisfactory preventive maintenance inspection can justify deferral or

elimination of some tasks, reducing plant manpower requirements and part

expenditure.

Introduction:
All electrical components have a tendency to heat up as their physical
condition worsens or their electrical properties deteriorate. In 1965 the Swedish Power
Board began inspecting approximately 1,50,000 components a year. In 1986 the UK
Electrical Generation Board began utilizing infrared thermography for predictive
maintenance on transmission lines. However, thermography was revolutionized with the
introduction of image type thermovision cameras in the Nineties.
As this is a non –contact technique, it is safe and shutdown is not
required. It helps to record and documents the thermal characteristics of almost any
object that emits infrared radiation. Thermal images can quickly and easily locate
abnormal sources of heat, which in electrical systems often indicate potential problems.

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Portable infrared cameras are used to convert this infrared radiation energy into high
resolution thermal images that are displayed on conventional video screens for
quantitative and qualitative analysis. Temperature is the single most measured parameter
for a condition monitoring exercise. Temperature is simply crucial and having control
over it will mean higher quality, better safety and money saved. Thermography spans
many subject areas like electrical power generation, transmission, and distribution
systems. An Infrared Camera is designed to detect this overheating and interpret it as
early warning signs of imminent failure.

Infrared energy:
Our environment contains many different forms of energy that are
propagated through space at the speed of light. These forms of energy are differentiated
as a function of their wavelength. Infrared radiation begins just above the visible light
spectrum and continues up to wave lengths of one thousand of a meter. Above infrared
are radio waves. All objects above absolute zero in temperature emit infrared radiation
.This natural occurrence is caused by thermal agitation of the object’s molecules
.Because molecules are composed of electrical charges, the oscillations of the molecules
created radiation emitted by an object is directly related to its temperature. The Infrared
spectrum is divided In to four common regions. These are 0.75 to 2 micron referred to as
near infrared, 2 to 5 microns referred to as short wave Infrared, 8 to 14 microns referred
to as long wave Infrared. Radiation in the 5 to 8 micron range is almost completely
absorbed by the atmosphere. Infrared Thermography spans many subject areas like
electrical power generation, transmission, and distribution systems and various fields
like mechanical and medicine fields as follows:

Long wave systems are theoretically more sensitive to low temperature

emission, whereas short wave has in theory better capabilities to detect a broader band of
higher temperatures. However the short wave region has areas of signal attenuation

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caused by the absorption of the signal by CO2 H20 and 03. The long wave system is not
sensitive to reflections, which are normally a problem for a short wave system. The
choice of using a short wave system over a long wave system, or a long wave system
over a short wave system, should not be based on theoretical detection but on actual
detectability of the particular system.

Basic Thermal Science:

One must know the basic concepts of temperature, heat, heat transfer
and direction of heat transfer, to understand infrared thermography. Thermal energy is
transferred from one body to another body by any or all of the following mechanisms:
1. Conduction 2. Convection 3. Radiation 4. Evaporation / Condensation
with infrared imaging, the sensor or the scanner is only detecting radiated energy. Heat
transfer by radiation is achieved by emission and absorption of thermal radiation. All
objects will emit and absorb thermal ration at the same time. The net heat transfer is the
difference between what an object absorbs and emits Exitant radiation is all the radiated
energy that leaves the surface of an object regardless of its original sources:
1. Emitted, from the object itself
2. Reflected from a source in front of the object
3. Transmitted, from a source behind the object

The target fig -2 has a temperature and an emissivity, which the power of the radiation
coming from the target depends upon the radiation power of the other two radiation
component does not depend on the target temperature, but on the temperature and
emissivity of the reflection and the transmission heat sources, respectively.
How is A Visual Light is Image Created From Infrared energy ?

An infrared imaging device contains one or more detectors that convert energy
in the infrared spectrum into an electrical signal. The more energy detected the greater
the electrical signal output. The electrical signals are typically formatted into a video

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signal and displayed on a CRT/LCD. The amplitudes of the electrical signals are then
displayed as varying intensities on the CRT/LCD thus creating a contrast in the image in
different pallets such as Grey, Iron and Rainbow etc. depending upon the applications,

In thermography, there are many factors apart from the surface temperature of
the object s that affect and disturb the temperature measurements for accurate
temperature measurements it is crucial to know which those factors are, and how the
equipment compensates for them. Before the measured radiation can be transformed
into temperature all other radiation sources have to be compensated for by the equipment
so that the measured temperature is a function of the object temperature and not of the
distance, emissivity or the internal equipment temperature.
If any if the Electrical components deteriorate there is an increase in
resistance to the flow of electrical current. With increase in resistance comes the increase
in radiant energy output as the component gets heated a thermal imaging system detects
this radiant energy. In case of an overloading conductor or imbalance in a three phase
system the more current flowing through the line the greater the temperature of that line
and the brighter the thermal pattern appears.
Visual v/s Infrared Image:
There are to fundamental differences between looking in the infrared and in the visual.
 Visual is mainly reflections, while infrared is mainly a combination of object
emission and reflection.
 Visual is color and intensity, while infrared is only intensity.
 If two objects are at same temperature, the object with higher emissivity radiates
more than the object with low emissivity. Hence the first object looks brighter
than the second.
 Emissivity causes the contrast in both the thermal images

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  Though both receive radiation from the surroundings, which is also reflected, but
more by the second object with low emissivity and high reflectivity and less by
first object with high emissivity and low reflectivity.
Quantitative v/s Qualitative Analysis:
In planning for an infrared inspection is normally looking to obtain the best
service for the amount of money spend. Unfortunately, due to many mis-representations
by infrared service companies the customers are confused about the “facts of infrared
operations” and often pay for meaningless date. This problem is especially prevalent in
conducting infrared inspections for the electrical utility industries. Infrared as a
technology is not new! In fact, quality infrared systems have been in service for over 30
years and continue to evolve.

Thermal Image Analysis Techniques:

• Thermal Gradient - It is a gradual change in temperature over distance. It
Indicates presence of conductive heat transfer which is the only mode in opaque solids.
• Thermal Tuning: It means adjusting the scale of the image in order to optimize
contrast. For this level and span controls of the camera are used
• Isotherm: It replaces certain colors in the scale with a contrasting color. It marks an
interval of equal apparent temperature. The feature is used to find out if there is any
heat floe e.g. thermal gradient.
• Palettes: The color palettes of the image assigns different colors to mark specific
levels of apparent temperature they can give more or less contrast depending on the
colors used in them for electrical installation, generally an iron palette is used which is
a low contrast palette.
Factor Affecting the Measurement:
• Atmosphere:- Though it is a transmissive object between camera and the
target the even some factors affect the measurement they are Distance, Ambient
temperature, and Relative humidity.
• Reflected radiation: - Reflection from nearby objects apparent temperature
of these objects that result in radiation that is reflected by the target into the camera is
known as reflected apparent temperature.

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 • Emissivity: - A low emissivity target will always try to look like the
surroundings if the target is hotter than the surroundings it will look colder than it is and
if it is colder than the surrounding it will look warmer than it is. It can be said that a low
emissivity target tries to camouflage its real temperature to the thermal imager for high
emissivity targets apparent t temperature is very close to real temperature.

• Calibration: - The calibration of the camera is performed in a lab under

controlled environmental conditions with a large number of black body reference sources
within emissivity approaching 1.0.
• Spatial resolution and target size:- Ideal equipment would of course
measure the same object temperature even when looking at an object that is very small
compared to the whole field of view. Relation between Field Of View and Distance (240
Lens)

.
Infrared Applications: Electrical Distribution Systems

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 What Can Be Detected:

• Loose/deteriorated connections
• Overloads
• Imbalanced Loads
• Open Circuits
Improperly Closed • Inductive Heating
Air Switch • Harmonics
• Defective Equipment

Benefits:

• locate problems quickly, without

interrupting service
• drastically reduce costly, unscheduled
Load Imbalance
power outages
on Bus Duct
• minimize preventive maintenance time and
maximize troubleshooting effectiveness
• prevent premature failure and extend
equipment life

Mechanical Systems

What Can Be Detected:

• Misalignment of coupled equipment

• Over/under lubrication of bearings
• Over/under tension of belted systems
• Excessive friction
Uneven Heating Caused • Defective Equipment
by Misalignment
Benefits:

• quickly locate misaligned coupled

equipment
• increase equipment reliability and life
• increase production and efficiency while
saving energy
Defective Pillow • increase quality of product
Block Bearing • minimize downtime by planning the

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 required manpower and materials before
shutdown
Overheated
Shaft Bearing • improve worker productivity and morale
by correcting potential problems

Structural Energy Loss

What Can Be Detected:

• Missing, damaged, or improperly installed

insulation
• Energy losses caused by air infiltration and
exfiltration
Q/A Inspection Detects • Water infiltration
Missing Insulation in • Damaged refractory
New Building
Benefits:

• help reduce heating and cooling energy

costs
• evaluate thermal performance of retrofits
• identify areas of latent moisture
• detect conditions conducive to mold or
insect problems

Compromised Refractory • provide hardcopy proof of problems

in Steel Ladle

Conventional Maintenance Procedures:

Generally a fairly uniform set of maintenance procedures are adopted in many
organizations. These include:-
• Visual inspections
• Cleaning equipment
• Tightening connections
• Over current device testing
• Insulation quality testing

Advantages of Thermographic Approach:

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 • Infrared inspection is non-contact. It uses remote sensing. Firstly, it
keeps the user out of danger i.e. away from live electrical components.
Secondly, it does not intrude upon or affect the target as well
• Infrared thermography is two dimensional. We can measure temperature of many
points in the same image and compare them. Thus analysis of image is very
effective and simple.
• Infrared thermography is real time. It allows us to do over fast scanning
• Electrical equipment is inspected during operation, so the power doesn’t have to
be interrupted.
• Reduced inspection costs as large quantities of equipment can be scanned in a
short period of times finding the trouble spot quickly, saving labour time and
money over regular trouble shooting.
• Faults can be pinpointed before maintenance is carried out, so maintenance
resources are directed where they are most needed and prioritized, resulting in
significant labour and cost savings.

Infrared Program :

In order to profit from the benefits of infrared thermography, regardless of the

technology chosen, much consideration should be given to establishing an infrared
inspection program. One that is properly initiated is guaranteed to provide users with a
quick return on investment. Typically this will occur within 3 months of purchasing and
using the equipment, but many companies claim receiving a payback the very first day
on which they performed an infrared inspection.

The first of several steps in setting up a successful thermography program is:

The interest in this technology is that it promises major advances for infrared focal plane
arrays:

 Excellent pixel uniformity, imaging and sensitivity performance.

 Large pixel format capability, up to 640 x 480

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  QWIPs are tunable and can be made responsive from about 3 to 25 microns, can
be made for broad band and dual band applications.

 Can be produced at relatively low cost and in large quantities.

Education: The very first step is to find out some more about the products and
technology that are available and how they can be used.

 Go to introductory seminars and conferences.

 Request product data sheets and application literature from equipment vendors

 Browse the internet. This is a little time consuming, but there is a wealth of
information on the web.
 Contract in an independent consultant to assist in the assessment and education
process.
 Hire an experienced infrared service company and learn from their employees
while they are performing an inspection in the field.

Conclusion:

Hence conventional cleaning and tightening procedures can overlook

many problems these overlooked problems as well as those that may have been
remedied by the preventive maintenance program will be identified by a competent
infrared survey. Infrared thermography is capable to instantly identify all resistive type
problem, that are the object of the conventional cleaning and tightening procedures in
addition poor connections that are not readily accessible during conventional
maintenance can be checked connection contact and calibration problems in thermal
overload devices and fuses can be instantly spotted. The most costly component of
many preventive maintenance program is equipment cleaning and connection tightening
this is appropriate since these procedure are directed towards correcting deficiencies in
terminations, joints and contact points the location of most electrical failures also these

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procedures are highly labour intensive since substantial component disassembly and
reassembly is required to access all the major contact points and terminations.

Thermo-graphic imaging and infrared temperature measurements have

been used extensively by POWERGRID for maintenance related activities.
Improvements in the sensitivity and selectivity of infrared imaginary now allow more
meaningful observational comparisons of substation equipments the team of
thermographers with skills and capabilities have allowed to uncover a number of
impending problems that could have led to catastrophic failure and unscheduled outages.
The increased sensitivity of newer designs rejection of unwanted reflections
.improvements of specific point resolution and in depth training have contributed to
“Infrared Imaging as an Effective Condition Monitoring System ”.

Document By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
Engineeringpapers.blogspot.com
More Papers and Presentations available on above site

12