Project II

1
Project II

• IET-120 Technology Systems
• Steve Napier
• November 6, 2008

2
Infrared Thermography

• Plant Predictive Maintenance Program

3
Introduction

• What is thermography?
• Why is thermography needed?
• Infrared cameras
• Examples of thermal imaging
• Program investment and downtime reduction
• Benefits
• Conclusion

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What is infrared thermography?

• Infrared thermography uses special cameras that
  can detect radiation in the infrared range of the
  electromagnetic spectrum and produce an image of
  that radiation.
• An infrared camera is a non-contact device that
  detects infrared energy (heat) and converts it
  into an electronic signal, which is then
  processed to produce a thermal image on a video
  monitor and performs calculations to indicate the
  temperatures.

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What is infrared thermography?

• Heat sensed by an infrared camera can be
  precisely measured enabling the user to monitor
  thermal performance and evaluate the severity of
  heat-related problems.
• Infrared thermography is the only diagnostic
  technology that can instantly visualize and
  verify thermal performance.

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Why is thermography needed?

• Infrared thermography has become a standard
  predictive maintenance practice to check
  electrical circuitry for loose connections.
• The technology is now being used to scan pumps,
  steam traps, steam lines, refrigeration systems,
  manufacturing processes, manufacturing
  facilities, and HVAC systems.
• The technology can provide instant feedback on
  unsafe or wasteful conditions.

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Cameras - FLIR i60
Courtesy FLIR Systems
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Cameras - FLIR T250
Courtesy FLIR Systems
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Examples of thermography
This is a busbar connection that is loose. The
scale on the left is the temperature range. The
loose connection is producing temperatures close
to 175 Fahrenheit. Courtesy FLIR Systems
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Examples of thermography
This is an example of a 120VAC breaker with a
loose connection. Courtesy FLIR Systems
11
Program investment and downtime

• The initial cost of a camera may be high, but
  cost justification is evident when the cost of
  downtime is realized.
• The average cost of downtime in a manufacturing
  environment has been estimated at greater than
  20,000 per hour.

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Program investment and downtime

• Unplanned downtime due to equipment failure cost
  manufacturing plants up to 3 of their annual
  revenue. Predictive maintenance can save 8 to
  12 over reactive maintenance.
• The U.S. Federal Energy Management Program
  estimates that half of electrical failure that
  occurs in manufacturing environment facilities
  could have been prevented with a routine
  maintenance program.

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Benefits of a thermography program

• Early indication of faults and undesirable
  conditions.
• Enable a proactive work-flow model.
• More efficient planning and scheduling.
• Increased wrench time for maintenance
  technicians.
• Decrease in equipment failures.
• Higher production efficiency, better quality, and
  lower maintenance costs.

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Conclusion

• Thermography is a predictive maintenance tool
  that when properly used can save money within
  days of the first scan.
• The program has saved many companies thousands of
  dollars annually.
• One of the best programs a manufacturing facility
  can invest in to improve production, quality,
  worker environment, and save money.

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Works Cited

• Campbell, Kevin. Plant Engineering. 7 April 2007.
  6 November 2008 lthttp//www.plantengineering.com/a
  rticle/CA6431534.htmlgt.
• FLIR Systems. 18 April 2008. 6 November 2008
  lthttp//www.goinfrared.com/news/news_item/1126/gt.
• Stockton, Gregory R. Stockton Infrared
  Thermographic Services. 10 June 2000. 6 November
  2008 lthttp//www.stocktoninfrared.com/PUBLISHED/PD
  F/low-hang.pdfgt.
• Wikipedia - The Free Encyclopedia. 10 July 2008.
  6 November 2008 lthttp//en.wikipedia.org/wiki/Ther
  mographygt.