Transcript Predictive maintenance using thermography in industrial

Predictive maintenance using thermography in
industrial environments and the effect on
revenue protection
Brendan Campbell
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What do we know about
temperature?
•Most frequently made
measurement °C,°F and K
•Key condition indicator
•Can be used to determine state of
health of equipment
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Developments in
scheduled maintenance
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Industry trends
•Growing concern for personal
safety
•Increased attention for power
related issues
•Shift from reactive maintenance to
preventive maintenance
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Economics: Cost savings
• Half of the electrical failures could be
prevented with regular maintenance
• Unplanned downtime due to equipment
failure costs manufactures up to 3% of their
revenue
• Predictive maintenance can save 6-12%
over reactive maintenance
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Types of maintenance
Break-down
• Reactive maintenance
repair it when it fails
run to failure maintenance
Cost
Time
• Preventive maintenance
Maintenance at regular
intervals
Cost
Time
• Predictive maintenance
problem detected before
failure, maintenance
planned ahead
Cost
Time
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Reactive Maintenance
Break-down Maintenance
Reactive maintenance leads to:
• Secondary damage
• Safety risk
• Unplanned downtime
• Unplanned maintenance
• Product waste
• Spares inventory
Not
recommended
for critical
equipment
Break-down
Cost
Time
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Preventive Maintenance
Time-based maintenance
Time based maintenance involves:
• More frequent overhauls
• Risk of early failures
• Tampering with good equipment
• Time consuming overhauls
• Experts needed for each overhaul
Not
recommended
for critical
equipment
Cost
Time
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Bath tub curve
• Detect early defects
• Prolong life time of equipment
• Prevent costly aging failures
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Predictive Maintenance
Condition based
maintenance
Break-down
Recommended
for critical
machines
Cost
• Monitor the condition of the
equipment and predict when it
would fail
• Plan maintenance ahead of
time and save money
• Repair the equipment only
when it needs to be repaired
• Focus overhauls only on faulty
parts
Time
• Higher plant availability,
performance and reliability
•
•
•
•
Greater safety
Better product quality
Longer equipment life
Greater cost effectiveness
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Predictive maintenance
procedures
• Inspections
 requires site knowledge
 Requires inspection tools and
instruments
• Adjustments
• Testing
• Calibrations
• Rebuilds
• Replacements
• A list of tools, parts or
instruments required for
predictive maintenance
• A form in case of taking
measurements or readings
• On this form include a limit or
range of values for indicating
normal/abnormal readings
• Safety considerations should be
listed, such as lock out or hot
work procedures
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Measurements
• Insulation resistance of cables and motors
• Temperature of motor housings and hot spots of electrical
panels
• Voltage stability of variable speed drives
• Resistance of connections
• Harmonics and unbalance of phases on motors, pumps,
fans, coolers etc.
• And if you don’t document it you didn’t do it!
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Thermography
• Thermography is a non contact technology that measures
infra red wavelengths to determine an object’s thermal
radiation distribution at a safe distance and in real time
• We are measuring the thermal representation of an object
as well as 1000’s of temperature points in real time
• Thermal images can be taken while production is running
without any contact  safe!
• Analysis requires some IR knowledge about IR principles
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It is easy to understand
the IR image…
ΔT
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Electromagnetic
Spectrum
Gamma X rays UV
Visible
Infrared
Long
Wave IR
Short
Near IR Wave IR
.4
.7
2
Microwaves
6
8
15
Wavelength in Microns
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Radio
Common thermography
applications
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Predictive Maintenance Applications
Electrical applications
Mechanical applications
Process
Building
Medical
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Electrical connections
• The temperature readouts
show that connections on
both phases A and B on
this main lighting
disconnect are hot,
suggesting an unbalanced
load
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Predictive maintenance
Electrical inspections
• As a rule , during an electrical inspection the load should
be at least 40% of max load, for at least the last ½ hour!
• Never make an electrical inspection with loads under 20%!
• If the load changes rapidly check the average load in the
last 2 hours!
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Maintenance routing
• The primary criteria that should be considered when
developing routes are:
• Travel Time
• Logical sequence of inspection
• Safety
• Criticality of machine
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Maintenance routing
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Specify route-data
• Location Name
• Comments
• Low and High
Alarm
• Emissivity
• RTC
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Inspection Routing
Load route
into imager
Upload new
data to PC
Take new
pictures and
compare to see
if composition
and distance
etc is the same
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Thank you
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