Did you know that regular inspections using infrared cameras can help keep your facility’s systems running efficiently? Using thermal imagers is also a safer way to detect system failures, especially in hazardous environments.
Whether you’re looking for hot or cold spots, or the apparent surface temperature of a component or target area, using infrared cameras help you find problems quickly and safely.
In this article, we’re discussing the use of infrared cameras in industry for preventive maintenance and the promotion of safety. Let’s start by taking a glance at how infrared cameras work, the benefits of using them, and their role in preventive maintenance and safe inspection.
How do infrared cameras work?
All objects emit infrared energy, known as a heat signature. An infrared camera (also known as a thermal imager) detects and measures the infrared energy of objects. The camera converts that infrared data into an electronic image that shows the apparent surface temperature of the object being measured.
An infrared camera contains an optical system that focuses infrared energy onto a special detector chip (sensor array) that contains thousands of detector pixels arranged in a grid. Each pixel in the sensor array reacts to the infrared energy focused on it and produces an electronic signal. The camera processor takes the signal from each pixel and applies a mathematical calculation to it to create a colour map of the apparent temperature of the object. Each temperature value is assigned a different colour. The resulting matrix of colours is sent to memory and to the camera’s display as a temperature picture (thermal image) of that object.
Many infrared cameras also include a visible light camera that automatically captures a standard digital image with each pull of the trigger. By blending these images it is easier to correlate problem areas in your infrared image with the actual equipment or area you are inspecting.
Why use infrared cameras?
Infrared thermography helps detect subtle problems before they result in failures. In industrial applications, some equipment problems can be spotted through unusual vibration or sounds, but many other problems do not present such obvious symptoms. Many electrical problems can be detected by their thermal patterns, which, if not identified, could either lead to equipment failure or a more serious electrical hazard. Moisture problems in ceilings and walls can be very difficult to find before they become serious enough to damage or destroy building contents.
In all of these cases, an infrared camera can speed up diagnosis, reduce (or perhaps even avoid) unscheduled downtime, and minimize damage to structures and contents. Infrared thermography offers a variety of advantages, because it can be used for:
- Most types of equipment
- Collecting data in a hazardous environment from a safe distance
- Scanning large areas such as walls, ceilings, and roofs quickly
- Gathering data without disrupting production
- Quickly identifying irregularities in specific locations
- Detecting problems before failure
These advantages produce several specific benefits for troubleshooting and preventive and predictive maintenance, including:
Increased safety. Technicians can often inspect without directly contacting equipment or interrupting its operation. They also can potentially inspect ductwork and ceilings without having to climb ladders or use a lift.
Improved reliability. More accurate information makes it easier for maintenance teams to fix problems before they result in large-scale losses, thus significantly reducing unscheduled downtime.
Better assurance of repairs. Using an infrared camera to quickly scan a repaired component or structural area allows a technician to verify that the repair was successfully completed, or identify subtle signs that further repair is needed.
Successful commissioning of new installations. Thermography can be used to document the condition of equipment at the time of acceptance, to verify manufacturer performance specifications or provide a basis for comparison at a later time. A thermal image can also indicate potential faults in installation, so that if a problem is found it can be immediately corrected or monitored until a repair can be scheduled.
Monitor equipment deterioration. You can use a thermal imager to monitor the condition and characteristics of your equipment against predetermined tolerances. This will help predict possible malfunctions or failures, allowing you to repair or replace the deteriorating components before they fail completely and potentially cause unplanned downtime.
Infrared inspection promotes safety...
From a health and safety perspective, the ability to scan industrial equipment and processes from a distance it is of vital importance. Reduced exposure to hazards is especially helpful for:
1. Electrical system inspection
Electrical inspections usually involve energized equipment. Currently, most electricians perform these inspections by de-energizing the system, opening the panel door, re-energizing the system, and scanning the panel with a thermal imager.
One of the biggest danger points, particularly with electrical systems of 480 V and higher, occurs as the enclosure is opened. That can trigger a phase-to-phase or phase-to-ground arc flash, which is an extremely high-temperature discharge (up to 19,427°C).
Inspecting with an infrared camera can help reduce the risk of arc flash and increase your efficiency by:
- Allowing you to inspect the equipment from outside the arc flash zone.
- Avoiding the need to open the enclosure by accurately scanning equipment through special infrared transparent windows or viewports in enclosure doors or covers.
- Reducing the amount of personal protective equipment (PPE) you need to wear based on your distance from the inspection target
2. Potentially explosive environments
Any industrial environment where a mixture of gases, dust, or vapour could ignite and cause an explosion is especially hazardous. Some of the most common are petrochemical processing, oil platforms and refineries, and pipelines.
The most obvious way to minimize the risk of an explosive event occurring is to avoid those environments wherever possible. While that is not always possible, there are situations where you can get the information you need by scanning the process or equipment from a safe distance with an infrared camera that provides the appropriate resolution and distance-to-spot ratio.
In some cases, you may need to add a 2x or 4x infrared telephoto lens to see enough detail from a safe distance. In addition to keeping technicians out of the most extreme danger zones, this long distance scanning can save a lot of climbing, and allow you to inspect areas that you wouldn't be able to get close enough to otherwise, without shutting down production.
3. Building inspection thermography
Using an infrared camera equipped with a telephoto lens can help you avoid having to climb up into the rafters of a warehouse or factory to inspect ceilings, walls, and ductwork. With a wide angle or standard lens you can inspect a lot of roof area quickly from one position, and avoid having to get too close to the edge or move around too much on a weakened structure. This can reduce your risk of falls and expedite your inspections.
In closing…
Heat is often an early symptom of equipment damage or malfunction, making it important to monitor in preventive maintenance programs. Using infrared preventive maintenance regularly to check the temperature of critical equipment allows you to track operating conditions over time and quickly identify unusual readings for further inspection. By monitoring equipment performance and scheduling maintenance when needed, facilities can reduce the likelihood of unplanned downtime due to equipment failure, spend less on “reactive” maintenance fees and equipment repair costs, and extend the lifespan of machine assets. Thermal imaging also presents a safer means of detecting system failure, especially in harsh environments.
Do you need a thermal imaging solution for your facility? Click here to chat to us about infrared cameras and our thermography services.
Source:
https://www.fluke.com/en/learn/best-practices/measurement-basics/thermography