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Application Notes:
Applying Infrared Thermography to Predictive Maintenance |
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Is your facility running too hot?Heat is often an early symptom of equipment damage or malfunction, making it a key performance parameter monitored in predictive maintenance (PdM) programs. |
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Technicians who practice infrared predictive maintenance regularly check the temperature of critical equipment, allowing them to track operating conditions over time and quickly identify unusual readings for further inspection.
By monitoring equipment performance and scheduling maintenance when needed, these facilities reduce the likelihood of unplanned downtime due to equipment failure, spend less on "reactive" maintenance fees and equipment repair costs, extend the lifespan of machine assets, and further maximize maintenance and production.
Cost savingsStudies by the Federal Energy Management Program (FEMP), estimate that a properly functioning predictive maintenance program can provide a savings of 30 % to 40 % over reactive maintenance.
Integrating thermography into PdMInfrared thermography cameras are the first line of defense in a predictive maintenance program. Technicians can quickly measure and compare heat signatures for each piece of equipment on the inspection route, without disrupting operations.
For best results, integrate all of your maintenance technologies into the same computer system, so that they share the same equipment lists, histories, reports and work orders.
Applications
- Monitor and measure bearing temperatures in large motors or other rotating equipment.
- Identify "hot spots" in electronic equipment.
- Identify leaks in sealed vessels.
- Find faulty insulation in process pipes or other insulated processes.
Inspection process
- Begin by using existing lists of equipment from a computer managed maintenance system (CMMS) or other inventory tool.
- Eliminate items that aren't well suited for infrared measurement.
- Review maintenance and production records.
- Use a database or spreadsheet to group the critical equipment together, either by area or function, into roughly 2-3 hour inspection blocks.
- Use your thermal imager to capture baseline images of each piece of critical equipment.
To capture the best thermal images, follow these best practices:
- Verify that the target system is operating at a minimum 40 % of load (lighter loads don't produce much heat, making it hard to detect problems).
- Get close to your target and don't "shoot" through doors, especially not through glass.
- When safety procedures allow, electrical enclosures must be opened or infrared windows or viewports utilized.
- Account for wind and air currents. These powerful convective forces cool the abnormal hot spots, often below the threshold of detection.
- Account for ambient air temperatures, especially outdoors.
Example 1: Motor bearingsStart with a newly commissioned and freshly lubricated motor and take a "snap shot" of the motor bearing housing while the motor is running.
Example 2: Spotting leaky gaskets and sealsFinding leaks in sealed vessels is a "snap" when using thermal imagers. Most leaks develop in or around a gasket or seal.
Either way, in infrared imager can diagnose the problem. To find a leaky gasket or seal...
Click here to download the full pdf: Applying thermography to predictive maintenance » | |