Industrials
Predictive and Preventative Maintenance
Predictive Maintenance is a maintenance strategy that uses technologies to determine the early stages of faults and predict failure by evaluating the rate of degradation, e.g; Infrared Thermography.
Preventative Maintenance is a maintenance strategy designed to prevent failure by inspection, cleaning and component replacement.
The use of Infrared Thermal imaging is now recognised as an essential diagnostic tool throughout industry. Using a temperature calibrated infrared camera, overheating in mechanical and electrical plant can be detected indicating an anomaly which, if allowed to persist, may cause an expensive shutdown and possibly the risk of fire. The primary advantages of thermal imaging in industry are:
- It's non contactable keeping the user out of danger.
- It's two dimensional - we can measure temperature in two points or a hundred points in the same image for comparison.
- It's real time - allowing us to see many potentially dangerous situations immediately.
The most common areas of inspection for Thermography are:
Mechanical Plant such as Pumps and Motors
Electrical Switchgear
Pipe Insulation and Blockages
Furnace Insulation
Boiler Maintenance
Bearings
Valves
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Figure 1.13 shows a typical three phase electrical connection. The infrared image, figure 1.14, reveals an annomoly on the center phase which is overheating. Note the reflection in the infrared image from the galvanised rear panel.
Machinery that doesn't operate efficiently can in some cases significantly increase energy costs and recent advances in infrared technology have made some traditional diagnostic tools redundant.
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The electric motor, in figure 1.15, is a typical problem where cooling ducts get blocked. This is a common problem in plants such as paper mills, or where sticky products, such as resins, are produced. These may spill on to the motor and solidify. Although the motor can be cleaned, deposits are still left under the cooling fan cowling, figure 1.16, causing it to overheat.
Figure 1.17
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The visual image figure 1.17, is an image of a steam control valve. Figure 1.18 shows an infrared image of a correctly operating steam control valve, while figure 1.19 shows a defective valve.
The software and control signals for the 'defective' reactor were examined but nothing out of the ordinary was found. This type of investigation continued for a few weeks with no useful outcome. Within minutes from the start of the thermagraphic survey, it became immediately apparent what was causing the problem - a blockage in the main steam supply of the 'defective' reactor, figure 1.19. When the valve was replaced, the problem was solved.
Please note that Infrared Thermography can only be undertaken when all mechanical and electrical plant is running at full load.
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