FIRM SYNERGY SDN.

BHD

CHAPTER 4

COMPANY PROJECT

4.1 Thermography

Thermography is a method of inspecting electrical and mechanical equipment

by obtaining heat distribution pictures. This inspection method is based on the fact
that most components in a system show an increase in temperature when
malfunctioning. The increase in temperature in an electrical circuit could be due to
loose connections or a worn bearing in the case of mechanical equipment. By
observing the heat patterns in operational system components, faults can be located
and their seriousness evaluated.

Thermography, also called infrared inspection, is based upon the sensing of heat
emitted from the surface of an object in the form of infrared radiation. Test
instruments are used to detect and convert the infrared radiation into either a
temperature value or a thermal image, which can be used to assess the thermal
condition of the object at the time of measurement. An infrared camera is one common
type of an infrared thermal imaging device.

The inspection tool used by Thermographers is the Thermal Imager. These are
sophisticated devices which measure the natural emissions of infrared radiation from a
heated object and produce a thermal picture. Modern Thermal Imagers are portable
with easily operated controls. As physical contact with the system is not required,
inspections can be made under full operational conditions resulting in no loss of
production or downtime.
Potential applications include:
i. Infrared Inspection Of Electrical System
ii. Infrared Inspection Of Mechanical System
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iii. Infrared Inspection Of Refractory Lined Structures

4.1.1 Types of Inspections

a) Infrared Inspection of Electrical System

Thermography is a non-destructive test (NDT) method that may

be used to detect poor connections, unbalanced loads, deteriorated
insulation, or other potential problems in energized electrical
components. These problems may lead to excess power use, increased
maintenance costs, or catastrophic equipment failure resulting in
unscheduled service interruptions, equipment damage, or other
problems.

Energized electrical systems generate heat because of electrical

resistance. The amount of heat generated is related to the amount of
current flowing through the system and the resistance of the individual
system components and connections within the system. As components
deteriorate, their resistance increases, causing a localized increase in
heat. Similarly, a poorly made connection will have higher resistance
than a well-made connection, along with a higher temperature profile.
Thermography may be used to detect these temperature differences.

i) Advantages of Inspection of Electrical system

The National Fire Protection Association (NFPA)

estimates that ten percent of the fires occurring in manufacturing
properties are related to electrical system failures, such as failure
of electrical insulation, terminals, and related components.
Additionally, failures can cause employees to be exposed to live
electrical circuits, making them susceptible to serious injury or
death from electrocution. By detecting high-resistance
connections and repairing them, the likelihood of a breakdown
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of the electrical wires and related components should be

reduced.

Other advantages to detecting and repairing these faults are the

cost savings from energy conservation and lower outage and
repair costs. High resistance in circuits causes an increase in
current flow. When current flow is increased, the resulting
power consumption will increase. Further, high current draw can
cause critical electrical circuit components, such as fuses, circuit
breakers, and transformers, to fail prematurely. These failures
result in higher maintenance and repair costs, and resultant
business interruptions.

ii) Electrical Defects Detectable By Thermography

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No Defects Descriptions
1
 High resistance causes hot
spots
 Hot spot localized to
connection
 Splices
 Fuse clips
 Mechanical

Loose/ Deteriorated Connection connections

2
 Uneven loading causes
conductor to heat unevenly
 Conductors warm throughout
entire length
 Each phase a different
temp

Unbalanced loads
3
 Excess current causes
conductors to warmer
 Conductors warm throughout
entire length
 Each phase a different
temperature.

Overloaded Circuits

Table 4.1: Electrical defects

b) Infrared Inspection Of Mechanical System

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With both rotating equipment and machinery, infrared

thermography is often used to find immediate failures and critical
problems. Perhaps an even greater benefit, however, is in trending
equipment in conjunction with other maintenance technologies such as
vibration analysis, acoustics, and oil analysis. All of these monitoring
methods should work together in a comprehensive predictive
maintenance program. If the data is gathered and correlated
consistently, the cost benefits are phenomenal.

As with all infrared inspections it is also important to understand the

theories involved in how infrared radiation works and how heat transfer
is affecting the objects in a thermal image. Concepts such as emissivity,
thermal reflections, thermal conductivity, and indirect temperature
measurement are crucial to the identification and diagnosis of
mechanical problems.

i) Mechanical Defects Detected By Thermography

No Defects Descriptions
1
During a routine electrical survey, this motor
was identified as having a damaged inboard
bearing. Infrared imaging can quickly
identify bearings, motor windings, gears, and
other elements of rotating equipment that
overheat due to misalignment, wear,
under/over lubrication, and misuse.
Electric Motor Bearing
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2
An understanding of heat transfer and the
ability to obtain a good thermal focus with
an infrared camera allows a thermographer
to clearly identify a failing component, such
as this motor inboard bearing.

Overheating Inboard Bearing

3
This image shows a leaking seal on a turbine
enclosure around a cooling airline.

Turbine Enclosure
4
The far right belt in this belt drive assembly
is twisted and appears hotter than the belts to
the left. The undersides of all of the belts
appear hotter due to friction with the sheave.

Twisted Drive Belt

Table 4.2: Mechanical defects
4.1.2 List of Inspection Tools and Equipment

4.1.2.1 Ferroscope 308 with Adept Pro MC™ Software

The Ferroscope 308 is the latest in a distinguished line of
electromagnetic testing instruments which have revolutionized
equipment maintenance in such industries as oil and gas, power,
petrochemical, and pulp and paper.
The Ferroscope 308 employs
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Remote Field Testing (RFT)

technology; a method well
suited to detection of corrosion,
erosion and other flaws in ferrous
and non-ferrous tubes such as
those found in tubular heat
exchangers, boilers, well casings
and pipelines.
The Adept Pro family of software uses Phase Angle analysis (similar to
standard eddy current analysis) and Voltage Plane analysis, (a method
of extracting the maximum amount of information from RFT absolute
coil data more than can be extracted from the Phase Angle method
alone). Voltage Plane analysis reveals the depth and circumferential
extent of metal loss, and allows one-sided metal loss to be distinguished
from circumferential loss.

4.1.2.2 Bracelet Probe

Used with Ferroscope 308 for rapid corrosion screening of piping.
Works for detection of:
• Corrosion Under Insulation
• Near & Far Surface Wall Loss
• Localized & Clustered Pitting
• Piping and plate applications
• Interfaces to standard 16
channel Ferroscope RFT
instrument
4.1.2.3 Imperium FirstMAP

Imperium has developed a product

specifically designed to address these
problems, the FirstMap™ Corrosion
Mapping system. Designed specifically for
the Petrochemical industry, specialized
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modifications have been incorporated to

facilitate scanning curved pipelines with
greater accuracy and to quickly and easily
evaluate the large surfaces of storage tank
bottoms.

For the first time, users can immediately see a

complete picture of the area being inspected.
Technicians can see corrosion problems on
the spot and generate a comprehensive data
and visual representation of the problem.

The final report will give customer the

necessary data plus images and allowing
clients to see defects/corrosion clearly. Using
the newest enhancement to scan multiple images
and stitch them together creating a
comprehensive large area scan. By incorporating
a wheel encoder into the camera head,
continuous images can recorded. This mapping
technology also generate details thickness
reading identical to those from a flaw detector.

4.1.2.4 Acoustic Eye Dolphin G3

Featuring patented Acoustic Pulse Reflectometry (APR) technology,

AcousticEye Dolphin G3™ is an advanced, yet easy-to-use tool
that overcomes the limitations of many conventional inspection
techniques. With its simple operation, automated analysis and
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report generation, there is far less dependency on operator

expertise. Providing reliable inspection of even the most challenging
tube sizes and configurations, AcousticEye increases inspection
cycle efficiency and operational cost saving.

Any tube size up to 4” diameter, regardless of

shape or material.
 Boilers, Fin Fans other heat exchangers
 U-bends, twisted and spiral wound
tubes
 Ferrous and non-ferrous metals,
graphite and plastics
Ultra-fast, non- invasive inspection
 Less than 10 seconds per tube
 Fast enough for 100% inspection when
needed
 Ideal for emergency situations
 No need for inventory of consumable
probes of standards
Less expertise required
 Testing is easily performed by any
operator with minimal training
 Computer-based data interpretation and
report generation

4.2 Vibration Condition Monitoring

Vibration monitoring is conducted to assist in the evaluation of the health of

the machine during sustained operation. Depending on the machine type and the
critical components to be monitored, one or more measurement parameters and a
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suitable monitoring system have to be selected. The objective of such a programmed is

to recognize an unhealthy condition in sufficient time to take remedial action before
certain defects in the machine parts significantly decrease equipment operation or
projected machine life or fail completely, thereby establishing a cost-effective
maintenance plan.
Several types of condition monitoring system are described below depending on the
machine, the machine condition and other factors.

4.2.1 Types of Vibration Condition Monitoring

Condition monitoring system take many forms. They utilize

permanently installed, semi-permanent or portable measuring equipment. A
decision to select the appropriate measuring system depends upon a number of
factors, such as:
i. Criticality of the machine operation
ii. Cost of machine down-time
iii. Cost of catastrophic failure
iv. Cost of the machine
v. Rate of progress of the failure mode
vi. Accessibility for repair/maintenance (nuclear plants or other remote
locations)
vii. Accessibility of the appropriate measurement positions
viii. Quality of the measurement/diagnostic system
ix. Operational modes of the machine (speed, power)
x. Cost of the monitoring system
xi. Safety, and environmental impacts

4.2.1.1 Permanently Installed Systems

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This types of system is one in which the transducers, signal

conditioners, data processing and data storage equipment are
permanently installed. Data collected either continuously or
periodically. The application of permanently installed systems is
usually limited to costly and critical machinery or to machines with
complex monitoring tasks. Figure 1 and 3 show a typical permanently
installed on-line systems.

4.2.1.2 Semi-Permanent Systems

The semi-permanent system is a cross between the permanent and

portable systems. In this type of system the transducers are generally
installed, whereas the electronic data acquisition components are
intermittently connected.

4.2.1.3 Portable Monitoring Systems

A portable monitoring system performs similar functions as the

continuous on line system but it is less elaborate and normally less
expensive. With this arrangement, the data are recorded periodically
either automatically or manually, with a portable data collector.
Portable systems are to record manually measurements at preselected
locations on the machine at periodic intervals. The data are usually
entered and stored locally on a portable data collector. A preliminary
cursory analysis can be done immediately, however for more in depth
processing and analysis, the data is downloaded to a personal computer
that has the appropriate software. The type of system show in figure 2.
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Figure 4.1: Permanently Installed On-Line Systems

The mechanism of this system is begin with the installation sensor on the area of inspected.
The sensor collect any source of vibration from the machine that read in form of micron then
transfer to the signal conditioner. From the signal conditioner, the source was converted to the
electrical form before transfer to VibroSmart monitor systems to collected data.
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Figure 4.2: Portable Monitoring Systems Figure 4.3: Permanently On-Line Systems

4.2.2 Periodic Data Collection

Periodic data collection can be done with either permanent on-line or

portable systems. On-line periodic systems may include automatic vibration
monitoring system with multiplexer connections. In this case all channels are
cyclically scanned one after the other with respect to off limit conditions. The
measuring system is permanently in actions but there are gaps in monitoring
the individual measuring points, which are dependent on the number of
channels monitored and the measuring period per channel. These systems are
sometimes referred to as scanning or intermittent systems. For machines for
which permanent on-line systems cannot be justified, portable systems are
usually used and they are in most cases suitable for periodic monitoring.
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Front view Back view

Figure 4.4: Vibration Monitoring systems at SJ Patau-Patau

Figure 4.5: Monitoring systems Figure 4.6: Monitoring systems

SJ Tenom Pangi SJ Melawa

4.2.3 Condition Monitoring Programme Flowchart

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