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Predictive maintenance using Predictive maintenance using thermography in industrial thermography in industrial environments and the effect on environments and the effect on revenue protectionrevenue protection

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What do we know What do we know about about temperature?temperature?

•Most frequently made Most frequently made measurement °C,°F and Kmeasurement °C,°F and K

•Key condition indicatorKey condition indicator•Can be used to determine Can be used to determine

state of health of equipmentstate of health of equipment

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Developments in Developments in scheduled scheduled maintenancemaintenance

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Industry trendsIndustry trends

•Growing concern for personal Growing concern for personal safetysafety

• Increased attention for power Increased attention for power related issuesrelated issues

•Shift from reactive Shift from reactive maintenance to preventive maintenance to preventive maintenancemaintenance

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Economics: Cost Economics: Cost savingssavings

• Half of the electrical failures could be Half of the electrical failures could be prevented with regular maintenanceprevented with regular maintenance

• Unplanned downtime due to Unplanned downtime due to equipment failure costs equipment failure costs manufactures up to 3% of their manufactures up to 3% of their revenuerevenue

• Predictive maintenance can save 6-Predictive maintenance can save 6-12% over reactive maintenance12% over reactive maintenance

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Types of Types of maintenancemaintenance

• Reactive maintenance Reactive maintenance repair it when it failsrepair it when it failsrun to failure run to failure maintenancemaintenance

• Preventive maintenance Preventive maintenance Maintenance at regular Maintenance at regular intervalsintervals

• Predictive maintenance Predictive maintenance problem detected before problem detected before failure, maintenance failure, maintenance planned aheadplanned ahead

Break-down

Time

Cost

Time

Cost

Time

Cost

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Reactive Reactive Maintenance Maintenance Break-down Break-down MaintenanceMaintenanceReactive maintenance leads to:Reactive maintenance leads to:

• Secondary damageSecondary damage• Safety riskSafety risk• Unplanned downtimeUnplanned downtime• Unplanned maintenanceUnplanned maintenance• Product wasteProduct waste• Spares inventorySpares inventory

Time

Cost

Notrecommended

for criticalequipment

Break-down

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Preventive Preventive MaintenanceMaintenanceTime-based Time-based maintenancemaintenanceTime based maintenance involves:Time based maintenance involves:

• More frequent overhaulsMore frequent overhauls• Risk of early failuresRisk of early failures• Tampering with good equipmentTampering with good equipment• Time consuming overhaulsTime consuming overhauls• Experts needed for each overhaulExperts needed for each overhaul

Time

Cost

Notrecommended

for criticalequipment

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Bath tub curveBath tub curve

• Detect early defectsDetect early defects• Prolong life time of equipmentProlong life time of equipment• Prevent costly aging failuresPrevent costly aging failures

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Predictive Predictive MaintenanceMaintenanceCondition based Condition based maintenancemaintenance

• Monitor the condition of Monitor the condition of the equipment and predict the equipment and predict when it would failwhen it would fail

• Plan maintenance ahead of Plan maintenance ahead of time and save moneytime and save money

• Repair the equipment only Repair the equipment only when it needs to be when it needs to be repairedrepaired

• Focus overhauls only on Focus overhauls only on faulty partsfaulty parts

• Higher plant availability, Higher plant availability, performance and reliabilityperformance and reliability

• Greater safetyGreater safety• Better product qualityBetter product quality• Longer equipment lifeLonger equipment life• Greater cost effectivenessGreater cost effectiveness

Time

Cost

Break-downRecommended

for criticalmachines

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Predictive Predictive maintenance maintenance proceduresprocedures

• InspectionsInspections requires site knowledgerequires site knowledge Requires inspection tools Requires inspection tools

and instrumentsand instruments• AdjustmentsAdjustments• TestingTesting• CalibrationsCalibrations• RebuildsRebuilds• ReplacementsReplacements

• A list of tools, parts or A list of tools, parts or instruments required for instruments required for predictive maintenancepredictive maintenance

• A form in case of taking A form in case of taking measurements or readingsmeasurements or readings

• On this form include a limit On this form include a limit or range of values for or range of values for indicating indicating normal/abnormal readingsnormal/abnormal readings

• Safety considerations Safety considerations should be listed, such as should be listed, such as lock out or hot work lock out or hot work proceduresprocedures

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MeasurementsMeasurements

• Insulation resistance of cables and motorsInsulation resistance of cables and motors• Temperature of motor housings and hot spots of Temperature of motor housings and hot spots of

electrical panelselectrical panels• Voltage stability of variable speed drivesVoltage stability of variable speed drives• Resistance of connectionsResistance of connections• Harmonics and unbalance of phases on motors, Harmonics and unbalance of phases on motors,

pumps, fans, coolers etc.pumps, fans, coolers etc.

• And if you don’t document it you didn’t do it!And if you don’t document it you didn’t do it!

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ThermographyThermography

• Thermography is a non contact technology that Thermography is a non contact technology that measures infra red wavelengths to determine an measures infra red wavelengths to determine an object’s thermal radiation distribution at a safe object’s thermal radiation distribution at a safe distance and in real timedistance and in real time

• We are measuring the thermal representation of We are measuring the thermal representation of an object as well as 1000’s of temperature points an object as well as 1000’s of temperature points in real timein real time

• Thermal images can be taken while production is Thermal images can be taken while production is running without any contact running without any contact safe!safe!

• Analysis requires some IR knowledge about IR Analysis requires some IR knowledge about IR principlesprinciples

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It is easy to It is easy to understand the IR understand the IR image…image…

ΔT

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Electromagnetic Electromagnetic SpectrumSpectrum

Gamma X rays UV Visible Infrared Microwaves Radio

.4 .7 2 6 8 15

ShortWave IR

LongWave IR

Wavelength in Microns

Near IR

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• Predictive Maintenance ApplicationsPredictive Maintenance Applications Electrical applicationsElectrical applications Mechanical applicationsMechanical applications ProcessProcess BuildingBuilding MedicalMedical

Common Common thermography thermography applicationsapplications

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Electrical Electrical connectionsconnections

• The temperature The temperature readouts show that readouts show that connections on both connections on both phases A and B on this phases A and B on this main lighting main lighting disconnect are hot, disconnect are hot, suggesting an suggesting an unbalanced loadunbalanced load

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Predictive Predictive maintenancemaintenanceElectrical Electrical inspectionsinspections• As a rule , during an electrical inspection the load As a rule , during an electrical inspection the load

should be at least 40% of max load, for at least should be at least 40% of max load, for at least the last ½ hour!the last ½ hour!

• Never make an electrical inspection with loads Never make an electrical inspection with loads under 20%!under 20%!

• If the load changes rapidly check the average If the load changes rapidly check the average load in the last 2 hours!load in the last 2 hours!

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Maintenance Maintenance routingrouting

• The primary criteria that should be considered The primary criteria that should be considered when developing routes are:when developing routes are:

• Travel TimeTravel Time• Logical sequence of inspectionLogical sequence of inspection• SafetySafety• Criticality of machineCriticality of machine

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Maintenance Maintenance routingrouting

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• Location NameLocation Name• CommentsComments• Low and High Low and High

AlarmAlarm• EmissivityEmissivity• RTCRTC

Specify route-Specify route-datadata

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Take new pictures and compare to see if composition and distance etc is the same

Load route into imager

Upload new data to PC

Inspection Inspection RoutingRouting

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Thank youThank you