Thermo Imaging for condition

Monitoring

By
M S N Sastry
 Thermal Imaging
The Technology to help Prevent Damages
before they happen
 Agenda

• Basicsof Infrared!!!
• What is thermography?
• How is it different than the single beam infrared thermometer
• Applications.
• About Testo
 Thermal imaging

• Is the science of seeing heat patterns using special electronic cameras

Rather than seeing light, these remarkable instruments create pictures of
heat. They measure infrared (IR) energy and convert the data to images
corresponding to the temperature.
 History of thermography
In nature some of the animals have the vision of objects in thermal
form and not as normally as we see ! ! !
e.g. a Rattle snake does not see the world as we normally see it but it
sees the object / its prey thermally.

Further as the technology flourished this found

applications in Medical applications to find out
problematic areas in animal & Human bodies.

This technology was for years being used for

military application to view objects and
infiltrations at the borders and so on.
 The electromagnetic spectrum
The electromagnetic (EM) spectrum is just a name that
scientists give a bunch of types of radiation when they want to
X-rays 10-4
talk about them as a group.
10-2

Wavelength in Microns (µm)

Ultra-
violet
0.28
0.40

Infrared radiation, like light and radio 0.70

Near Infrared
waves, is a form of electromagnetic Short Wave
2.00
energy. Infrared
6.00
Middle
Infrared
8.00
Thermal Long Wave
Infrared

15.00

Microwave 104
The inspected object

Blackbody (perfect emitter)  Real body

Absorbs and emits 100% (Emissivity A part of the radiation is reflected

= 1) as well as transmitted (Emissivity <
1)
An Infrared System

IR Energy
IR Collected
Windows IR Sensor
and Optics

S 453¡C

T SP1 470¡C
EMS ¯.85

Electronics
Object Environment Detector Electronic Display
or Other Output
 Transformer Radiator

Cool components may indicate problems:

Low oil or restricted flow in cooling tube
Blown fuses
Single-phasing
 Thermography
Interpretation
34.7°C

34

32

30

28

26

24

22
InfraredInstitute.com InfraredInstitute.com 21.8°C

Lower Temp. Higher Temp.

 Thermal imaging
Benefits
•Is non-contact
•Applies to most types
of equipment and
conditions
•is obtained without
disturbing production
•quickly identifies
specific locations
•allows for detection of
problems before failure
•can scan large areas
quickly to identify areas
of concern
 CONDITION MONITORING

Condition Based Maintenance is the

maintenance initiated as a result of
knowledge of the condition of an item
from performing inspections with
condition monitoring technologies.
 CONDITION MONITORING
TECHNIQUES
Rotating Equipments Electrical
Stationary Equipments
Chillers Transformers Insulation

Motors Circuit Breakers Tanks

Pumps Capacitors Refractory

Fans High-Voltage Switches Roofs

Equipment to be Generators Motors Steam traps
Inspected
Compressors Controls Building envelope

Gear Boxes Panels Furnace interiors

Cables Piping leaks

Generators Heat exchangers

HV Terminations Valves

Thermography Thermography Thermography

Vibration Measurement Oil Analysis Ultrasound

Inspection Alignment/balancing Ultrasound Combustion analysis

Technology Oil testing (ferrography) Corona Testing Air flow

Ultrasound Volt/amp Levels Ultrasound

Motor circuit evaluation Power factor test

 Advantages of a
Thermography
• Find the problem before it finds you!
• Improved less expensive maintenance
• Consistent and improved availability
• Increase in production rate
• Reduced maintenance costs
• Extend asset life (less need for capitol expenditure)
• Reduce asset base i.e. spare parts
• Increased product quality and consistency.
Let’s put the Thermal Imager to work

Just a few of the applications

• Electrical
• Mechanical / Electromechanical
• Automotive
• Process
• Others
 Thermal Imaging
Applications
• Thermography covers a broad range of applications:
Industrial maintenance
Research and development
Building diagnostics
Fire and security
Heath care: humans as well as animals

And many more ………

 Electrical
Commonly inspected Typical reasons for temperature
components hotspots or deviations
• (3 phase) Power distribution • Unbalanced loads
• Fuse boxes • Harmonics (3rd harmonic current in Neutral)
• Cables & connections • Overloaded systems/excessive current
• Relays/Switches
• Insulators • Loose or corroded connections increased
resistance in the circuit (typically one side of
• Capacitors components heats up)
• Substations • Insulation failure
• Circuit breakers • Component failure
• Controllers • Wiring mistakes
• Transformers • Underspecified components (like fuses)
• Motors would heat up on both side of the fuse
• Battery banks
Hot fuse and connections
 Pad mount transformers

are designed for mounting on a

concrete pad with underground
connecting cables

• Look for problems in both internal

and external connections
Sub-station connections
Utility
 Utility sub-stations
9

1. Switches of all types

2. Transformers
3. Bushings
4. Cooling fans

3
 Mechanical / Electromechanical
Commonly Typical reasons for
inspected temperature hotspots or
components deviations
• Motors • Bad cooling- due to reduced airflow
• Pumps
• Heat exchangers • PQ problems like unbalance, overload
or 5th harmonic (voltage) will cause heat
• Bearings dissipation
• Gearboxes • Bad alignment
• Drive belts • Insulation problems with motor windings

• Bearing problems – lubrication, wear,

etc.
• Friction due to wear, misalignment or
inadequate lubrication
 Motors Bearing, Shafts
restrictions

• Overall motor temperature increases

• Overheating causes failures
• IR provide fast monitoring even at a distance
Automotive Applications

Automotive Climate Control

 Process
Commonly Typical reasons for
inspected temperature hotspots or
components deviations
• Refractory insulation • Damaged structures caused by worn
• Tanks and vessels pipes etc
• Steam systems/traps • Abnormal heat flow/heat gradients
• Pipes and valves • Gas or steam leakage
• Heaters/Furnaces
• Manufacturing equipment
• Plastics Industry (Molding)
• Pulp & Paper (Rollers,
handling equipment, etc)
• Metal Foundry
• Boilers and Reactors
• Research & Development
 Predictive Maintenance
4

Locate fluid, solid,

and “floater” levels

-
LI
 Refractory & cement kiln insulation
3
Look for
Hot areas associated
with refractory
thinning or failure
Cold areas
associated with
internal product build-
up

1
Steam traps

Working Steam Trap

 Energy Loss- Insulation Deficiency

New installation. Insulation was poorly installed. Without infrared the

deficiencies would not have been discovered for years. The system was repaired
under warranty.
 Example images: Hot-Spot effect

Defective solar modules,

identifiable in the thermal
imager as a Hot-Spot
(approx. 15K above mean
temperature)

Defective cell:
 Converts power from the adjacent cells into heat!
 Converts all incoming solar energy into heat
 Known as the Hot-Spot effect

Loss of performance of the system - danger

of fire from overheating!
 Medical Thermography

Useful for:
- Sports injuries
- Stress fractures
- Vascular disorders
- Spinal pain syndromes
- Shoulder injuries
- Foot pain syndromes
- Neuromuscular problems
- Acupuncture facilitation
- Cancer detection
- breast cancer
Know the hidden truth!!
INFRARED THERMAL IMAGING SYSTEM
Main Features of Thermal Camera
• Measurement
 Temp. range -10 to 450 deg.C
 Extended Temp. range up to 1500 deg.C

 Accuracy of Measurement 0.1deg.C

 Operating Temp. range -15 to +50 deg. C

• Atmospheric Correction
 Inputs for Air Temperature, Distance and
Relative Humidity
• Field of View
 17.0 deg. Horizontal,15.6 deg. Vertical
 Focus Range 0.9 inch to 2km
 Image Specification
• Size: 150KB without voice comments
• *.img extension
• Naming as per date
e.g. A0512-13.img i.e. 13th image of a
directory stored on 12.05.2000
• Cannot be opened without IRWIN Report 5.21
software package
 IR – Thermal Imaging System
• Scans the Temperature profile of the area
being focused
• Generates a coloured thermal image of the
area being focused on the view-finder
• Color profile indicates the temperature profile
of the area
 IR – Thermal Imaging System
• The temperature at any spot of the area can
be measured in the camera view finder (
Field measurement)
• Also the thermal image can be stored in
inbuilt PCMCIA Removable Disc Drive
• The image can subsequently be analyzed in
the computer
 IR – Thermal Imaging System
• The Software Package : IRWIN Report 5.21
allows image processing
• Customized report can be generated
• The report shows coloured thermal image, hot
spots, temperature profile along any line on
thermo gram
CONFIDANCE DOSENT COME WHEN YOU HAVE ALL THE ANSWERS,
BUT IT COMES WHEN YOU ARE READY TO FACE ALL QUESTIONS.