Incredible Applications of Themography in Condition Monitoring
Infrared Thermography Cameras work on the principle of converting infrared energy signals radiating from all the surface of all objects into heat / temperature information and using the same to have extensive knowledge of behavior of the objects. We in National Productivity Council (NPC), India have been using infrared thermography in our Plant Engineering Consultancy projects to help all types of industries identify the condition of mechanical and process machineries for Predictive Maintenance.
A simple portable infrared thermal camera is used by the consultant to scan the surface conditions and obtain a Thermal picture on the LCD screen. Using simple navigation features built into the camera, it is then possible to identify the thermal profile and abnormal hot or cold spots. Based on the information about average temperatures, design parameters, visual observations, etc it we report the present condition of those machineries and provide suggestions for corrective actions. We complement the numerical information of temperatures with the print of the thermal pictures, sometime super imposed on the real pictures of the machineries.
Our clients have been immensely benefited by our Infrared Thermography studies and the fees that they have paid to us have been heavily compensated by the recurring savings they achieve by preventing abnormal failures. For complex machinery problems which require detailed thermal and energy analysis, we also make use of Software's provided along with the infrared thermography camera, which uses the 'Digital Thermography' concepts. Using these concepts, it would be possible to analyses not only steady state thermal conditions but also transient thermal changes.
The following are some of the incredible applications we found in clients' workplaces. In a fertilizer factory, we used infrared thermography camera to scan the end portion of a heat exchanger which had number of passes inside. Their problem was to find out the reasons for poor thermal efficiency they were facing lately. Presto! our scanning identified passing leaks from one pass to another which was clearly seen in the thermal profile and subsequent digital thermography pictures. The company could save much money from an accurate prediction of their problems.
In an Oil pumping station of a major Oil Company, we scanned the cylinders of a diesel engine which was the prime mover for pumping of crude. We could identify misfiring in one of the cylinders from the transient thermal profiles as the engine was started and brought to its loaded conditions. This type of exact identification of the faulty cylinder would not be possible by any other method.
In a paper factory, some of the drum drivers are located in inaccessible places and can't be reached easily. We use the infrared thermography camera from the ground level to check the heating of their bearings. This way it is possible to locate faulty bearing points long before they become dangerously hot which can cause breakdown for the entire plants.
Sometimes, we combine Thermography inspection and the digital thermography information for additional reliability to predict mechanical component failures. For example, when the Vibration Analysis of Motor Bearings indicate high frequency random vibration amplitudes signifying bearing faults, we also try to scan the bearings' thermal profiles to compare conditions of various bearings in the motors before we can conclude about their conditions and report to the clients. No doubt, infrared thermography inspections with the infrared cameras have given an 'Incredible' and distinct competitive edge to NPC's condition monitoring services in 'incredible India'.
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About the Author: Mr. Krishnan has performed numerous Thermographic Inspections for Condition Monitoring at major facilities in India.
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