Fluke Seminar Manual.pdf

Infrared Introduction Seminar

Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

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GLOBAL LEADERS OF INFRARED THERMOGRAPHY EDUCATION

www.InfraredInstitute.comwww.InfraredInstitute.com

Facilitator: Ron NewportLevel III Thermographer, BSc. Elect.Eng., F.I.Diag. Eng., Certified Trainer.

Seminar ObjectiveSeminar Objective

The objective of this workshop is to provide information to gain a better understanding of infrared condition monitoring. What it is, what it is not, and what is required to perform a concise and accurate inspection.

Services Offered: Inspection Services Certification Courses

- ASNT, BINDT, ISO- Level I, II and III

Application Courses- Building, Electrical, Process

IR Camera Operator Courses: Fluke, plus all other manufacturers

Tailored On-Site Courses Procedures and Standards Writing

Institute of Infrared ThermographyInstitute of Infrared Thermography



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Over the past 30 years maintenance has Over the past 30 years maintenance has changed, possibly more so than any changed, possibly more so than any other management discipline. The other management discipline. The changes are due to the increase in the changes are due to the increase in the amount and variety of physical assets amount and variety of physical assets (plant, equipment, and buildings) which (plant, equipment, and buildings) which must be maintained, increased must be maintained, increased automation requirements, more automation requirements, more complex machinery and control complex machinery and control designs. designs.

Industry ChangesIndustry Changes

Repair / overhaulat failure

Riskof

FailureStart-up Life

There was a belief that there is a relationship between the age of a component and how likely it is to fail. This is called the Bathtub reliability Curve.

HistoryHistory-- Failure with AgeFailure with Age

PM, Fact or Fantasy?PM, Fact or Fantasy?

New findings contradict the belief that there is always a connection between reliability and operating age.

The conclusion was: PM provides increased reliability with more maintenance.

This is rarely true!This is rarely true!



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New FindingsNew Findings

Riskof

Failure Life

Today it is understood there is little relationship between age and failure. Studies now show that only 4% of items will conform to the bathtub curve. And, that 68% of the items conformed to the curve below.

Preventive Maintenance and Failure RatesPreventive Maintenance and Failure Rates

It has now been proven in most industries and situations, that the removal and replacement of parts, which are still in good condition, no matter how carefully done,can actually increase overall failure rates.

Preventive MaintenancePreventive Maintenance-- RealityReality

Periodic disassembly is expensive and time consuming

Period or interval is difficult to determine

Potential for maintenance induced problems

Unavailability of process or equipment due to PM tasks may outweigh gain in reliability



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Industrial Maintenance TechnicianIndustrial Maintenance Technician

Fact: 1.Technicians spend most of

their time fixing problems On average, 4x more

doingrepairs than on the Prevention of problems

2. Reactive maintenance provides the highest level of maintenance cost

adds to cost-of-goods sold

reduced company profitsM t f ti t

Riskof

Failure

Start-up Life

Maintenance / overhaulprior to failure

Test and inspection instrumentation are used to identify and monitor potential failure.Corrective action is taken when measurements are about to go outside the equipment operating limits.

Predictive Maintenance (PdM) Predictive Maintenance (PdM)

PdMPdM-- Advantages Advantages

Essential tool to assure maximum safety and improved reliability

Detects possible system or equipment failures in the early stages

Reduces risk of catastrophic failures Minimizes repair time Improved and lower cost Maintenance Reduce asset base i.e. spare parts Lets healthy machines keep

running



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Predictive Maintenance (PdM)Predictive Maintenance (PdM)

Predictive Maintenance removes the need for unnecessary preventative maintenance - partially reducing expenditure.

Typically 50% of the maintenance costs can be realized when performing predictive maintenance methods.

Condition MonitoringCondition Monitoring

These predictive inspection tasks are called Condition Monitoring because the inspection techniques employed are evaluating the operating condition of the items being inspected. The majority of the techniques rely upon the fact that most failures give warning of the fact that they are about to occur.

CM techniques include: Vibration Monitoring & Analysis Lubricant and Oil Analysis Wear Particle Analysis Ultrasonic Noise Detection Motor Circuit Evaluation Electrical Condition Monitoring Nondestructive Testing Infrared Thermography

CM Techniques CM Techniques



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CM Techniques CM Techniques

The most diverse inspection technique is Infrared Thermography. No other instrument provides the diversity of applications and inspection capabilities in the industrial and commercial setting.

#1 The PdM Program#1 The PdM Program

find the problem before it finds you!improved less expensive maintenanceconsistent and improved availability increase in production rate reduced maintenance costs extend asset life (less need for capitol

expenditure)reduce asset base i.e. spare partsincreased product quality and consistency

Advantages of a IRT ProgramAdvantages of a IRT Program



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A ten year study by a billion dollar Insurance company, Hartford Steam Boiler Insurance Company, determined that a proper infrared predictive maintenance program produces a 400% Return on Investment.

Return on InvestmentReturn on Investment

Within industry, no other measurement method is more frequently used!

WHY?WHY?Because temperature measurement provides valuable information regarding the condition of a process, component and the operating environment.

Why Temperature?Why Temperature?

What is Infrared?What is Infrared?



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For the most part, infrared cameras can only see the energy from the surface of a material. We cannot se through enclosure doors.

However, the energy we are interested in originates from the inside.Doors must be opened when possible

IR cannot see through most materialsIR cannot see through most materials

Be sure to comply with safety regulations when opening and working around active panels.

Conduction is transfer of thermal energy actual molecular vibration in solidsFor instance, when an iron rod is heated, thermal energy travels by conduction through the metal to the other endConvection is heat transfer within a gas or LiquidRadiation is heat transfer by electromagnetic wavesAll objects emit infrared radiation

How does thermal energy get to the surface?How does thermal energy get to the surface?

Heat Transfer TheoryHeat Transfer Theory

Thermal ImagingThermal ImagingIs the science of imaging radiant thermal energy using special electronic camera.The infrared camera detect and measure infrared (IR) energy and convert the information to images corresponding to the thermal energy levels from the surface of the object.



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For objects that are:moving or very hotdifficult to reach impossible to shut-

offdangerous to

contactContaminated/

altered or destroyed through contact

Fast, safe and accurate measurementsFast, safe and accurate measurements

Applications for infrared thermography amazingly diverse.The limitation is your imagination!

ApplicationsApplications

- Electrical: generation to low voltage- Mechanical: motors, bearings, gears- Process: product flow, piping, vessels- Manufacturing: electronics, glass,

plastics, pharmaceutical, textiles- Energy Conservation: missing or

damaged insulation - Building Thermography- Pest Management

Application Diversity?Application Diversity?



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Electrical Condition MonitoringElectrical Condition Monitoring

A major portion of a facilitys capital investment is in electrical equipment. From generation to power distribution to electric motors and lighting, the efficient operation of the electrical system is critical to maintaining total operational capability of any facility.

No electrical power = No operation!


Therefore monitoring key parameters such as temperature, load, high resistance and insulation breakdown are major concerns for any facility.

These faults are costly as they can stop operations, increases energy usage, present safety concerns (fires and explosions) and life cycle cost issues (premature replacement of equipment).

Faults in electrical systems are serious concerns and yet are seldom obvious!


Electrical CM encompasses several technologies but infrared thermography is the #1 chosen non-contact, NDT instrument for electrical inspections in all industrial and commercial sectors



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-A Thermography program can virtually eliminate this disaster.

Zurich Risk Engineering reports that 25-30% of all large fire losses are caused by electrical faults.

Insurance Companies fully support the use of Infrared Thermography!

Insurance CompaniesInsurance Companies

In urban areas, electrical systems account for 33% of residential fires.

Fire PreventionFire Prevention

A ten year study by a billion dollar Insurance company, Hartford Steam Boiler Insurance Company, determined that a proper infrared predictive maintenance program produces a 400% Return on Investment.

Return on InvestmentReturn on Investment



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The investment in an infrared electrical inspection program can be paid back from the discovery of one major electrical fault.

Electrical Thermography ROIElectrical Thermography ROI

Where is IR/T Applied?Where is IR/T Applied?

GenerationTransmissionDistributionSub-StationsTransformersSwitchesCapacitorsIn-PlantLow VoltageUPS Electronics

InfraredInstitute.comInfraredInstitute.com

Will provide valuable information on the entire electrical system!

Problems Found on Electrical System:Problems Found on Electrical System:

1. High Resistance2. Load Imbalance3. Open Circuits4. Insulation

degradation5. Short Circuits6. Induction Currents7. Undersized or

specified components

8. Live Grounds9. Corona10.Harmonics



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Normal Thermal SignaturesNormal Thermal Signatures

First the technician must understand what the normal thermal signature on the equipment under inspection.

InfraredInstitute.com

Normal Load and Resistance Relationship.

ConnectionsConnections

The most frequent problems found during a thermographic investigation are thermal anomalies related to connections. It is not unusual to have 75% of the anomalies detected during an infrared inspection to be a connection problem of some sort.

Localized ResistanceLocalized Resistance

The thermal energy trailing away from the bolted connection suggests localized connection problem.



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Load conditions such as overload, load imbalance or undersized components will be apparent.This thermal image shows a higher temperature and an even temperature distribution on Bphase, this suggests an unbalanced load.

LoadLoad

Temperature on electrical components is critical to safe operating conditions. Because this is well understood, associations like IEEE, ANSI, IEC and all Manufacturers publish temperature ratings for electrical components.

Temperature RatingsTemperature Ratings

Transmission/Distribution ApplicationsTransmission/Distribution Applications

Splices Line Clamps Bolted Connections Insulator Connections Insulator problems Current Leakage



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230 Kv Bolted Connector

Aerial ThermographyAerial Thermography

SubstationsSubstations


Switches of all typesBreakersCurrent TransformersCapacitorsTransformersBushingsCooling fans



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TransformerTransformer

Utility SubUtility Sub--StationsStations

An IR Inspection detected a 450C temperature rise on a high voltage bushing on a transformer.

Avoided cost $332,300.00

Transformer FinsTransformer Fins

Note the temperature differential between the top and bottom. This indicates correct operation.

Fluid Restrictions: Note the thermal variations. This indicates restrictions to the fluid flow.



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Electrical ConnectionsElectrical Connections

Both qualitative and quantitative inspections are possible with most IR Cameras. This depends on the program and the application.

The connections on this connection is over 50C higher than A phase. Temperature rise is a method to determine problem severity.

Breaker ContactBreaker Contact-- ExposedExposed



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Breaker ContactBreaker Contact-- HiddenHidden

Internal breaker contacts

Low Voltage Electrical MaintenanceLow Voltage Electrical Maintenance

Poor Primary Breaker Connector

This shows a problem with the breaker contact to the bus.

ConductorsConductorsInfrared thermography on conductors is used to indicate general overheating due to overloading or undersized cables, high resistance, poor connections and bad splices.

Image courtesy of ACMT Overheated splice



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UPS System and BatteriesUPS System and Batteries

Induction HeatingInduction Heating

Logo can be changed from file

Inputs for:Company NameProblem NumberLocation Name and EquipmentProblem DescriptionWeather ConditionsRoute DataMaintenance Action InformationRepair Priority AssignmentReinspection SignoffPre /Post Thermal Image or Pre Thermal /Post Digital Image

Thermographic ReportingThermographic Reporting



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AC/DC MotorsPumps, FansCompressorsEnginesGearsCouplings

BearingsHydraulicsValvesDrivesConveyors

MechanicalMechanical

Mechanical InspectionsMechanical Inspections-- MotorsMotors

High Operating Temperatures Winding Insulation BreakdownCooling BlockagesBearingsAlignmentMechanical LoadMotor ConnectionsPower Quality Issues

-Harmonics-Voltage Unbalance-Overload-Load Imbalance

MotorsMotors

For each 10C rise over maximum rated temperature, motor life will be reduced by approximately 50%.



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Motor SignaturesMotor Signatures

1. Normal Signature2. Localized hot spot3. Severe Overheating2.

3.

The most common cause of motor failure is bearings. It has been estimated that up to 50% of all motor burnouts are a result of bearing failure. Yet, there are many causes of bearing failure.

Motor BearingsMotor Bearings

48.7C

InfraredInstitute.comOverheated bearing due to lack of lubrication. Once lubricated, the temperature returned to normal.

Motor BearingsMotor Bearings



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Process applications include the flow of a product, fluids, steam, chemicals, hot gases, or solids through any system typically display a particular thermal signature. When this signature changes such as with corrosion, cracking, thinning, erosion, leaks, blockages, varying fluid levels, coking, scale build-up, etc. may cause detectable variations in infrared energy patterns.

Process ApplicationsProcess Applications


Typical reasons for temperature hotspots or deviationsDamaged structures caused by worn

pipes etcAbnormal heat flow, heat gradients,

blockagesGas or steam leakageTank LevelsSludge LevelsBroken Valves, closed or bypassingGas and Steam LeakagePipe Thinning

Commonly inspected componentsRefractory'sTanks and vesselsSteam systems/trapsPipes and valvesHeaters/FurnacesManufacturing equipmentPlastics Industry (Molding)Pulp & Paper (Rollers,

handling equipment, etc)Metal FoundryBoilers and ReactorsResearch & Development

Pipe Leaks & Blockages

Pipes can become blocked from deposition of heavier materials from the product flowing through the pipes. The flow can become restricted slowing down the process, or blocked, shutting it down.




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RefractoryRefractory

Refractory is high temperature insulation. Thinning, cracked or missing refractory areas can be spotted easily.Temperature measurements may be used to estimate refractory lining thickness

Inspect for:Hot areas

associated with refractory thinning or failureCold areas

associated with internal product build-up

Refractory & Cement Kiln insulationRefractory & Cement Kiln insulation

Steam SystemSteam System-- Steam TrapsSteam Traps

When the trap is operating correctly there should be a definitive change between the inlet temperature and outlet.



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Working TrapFailed Trap

Single failed trap in school building caused $170 loss per day

That is $62,000a year loss from 1 failed trap!

Steam traps Steam traps failures are costlyfailures are costly

Leakage in Boiler


Pulp and Paper IndustryPulp and Paper Industry

Paper machine moisture variation across the paper roll



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Glass Industry: Quality ControlGlass Industry: Quality Control

Monitoring glass mold and product uniformity

Process Quality Control & EfficiencyProcess Quality Control & Efficiency

Ensure package seal integrity

Plastic IndustryPlastic Industry-- Quality ControlQuality Control

Plastic Injection Molding, Part

Uniformity



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MBuildings- Structure- energy audits- Insulation - air in/exfiltration- moisture ingress &

leaksMRoof moisture and

leak detectionMHeating & AC

systems

Building ThermographyBuilding Thermography

Energy Loss: Conduction Losses- insulation inspections, missing, misplaced, inadequate insulation.

Convection Losses-air infiltration/exfiltrationair movement into and through the envelope.

Building ThermographyBuilding Thermography

Conduction LossesConduction Losses



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Air ExfiltrationAir Exfiltration

The window seals are damaged and cooled are is escaping. This reduces the energy efficiency of the building and if not repaired will deteriorate the structure.

Air ExfiltrationAir Exfiltration

Envelope integrity- Moisture Moisture development due to condensation within the envelope due to vapour retarder and air sealing problems moisture intrusion- due to cracks, openings, water pipe leakssick building syndrome, mold growth and other health issues

Building EnvelopeBuilding Envelope



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The entry point of infiltrating water is often difficult to determine because water normally does not enter a building in a way that is predictable.

Buildings Buildings Water LeaksWater Leaks

roof inspections- moisture intrusion and locating water leaks, energy loss.

Roof Inspections-


moisture damage due to leaks or condensation, especially in the walls or roofs

poor HVAC distribution or performance





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Exfoliation check of wall tile (south faced)Exfoliation check of wall tile (south faced)

Under the sunlight, temperature was rising in the outer wall of the mortar. Higher temperature was shown in the exfoliated outer wall of mortar.

Concrete Void PrincipleConcrete Void Principle

Concrete Exfoliation Diagnosis Concrete Exfoliation Diagnosis Bridge railing concrete exfoliation may cause serious disaster if there is a pedestrian path under the bridge. The thermography test is an effective method for general inspection due to its remote capability.

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