CONDITION MONITORING

AURAL METHOD

Hearing ("auditory" or "aural") is the ability to

perceive sound by detecting vibrations through an organ
such as the ear.

It is one of the traditional five senses.

In humans and other vertebrates, hearing is performed

primarily by the auditory system: vibrations are detected
by the ear and transduced into nerve impulses that are
perceived by the

Like touch, audition requires sensitivity to the movement

of molecules in the world outside the organism. Both
hearing and touch are types of mechanosensation.

Frequencies capable of being heard by humans are

called audio or sonic. The range is typically considered to
be between 20 Hz and 20,000 Hz.

Frequencies higher than audio are referred to

as ultrasonic, while frequencies below audio are referred to
as infrasonic.

In common use, the word noise means any

unwanted sound.

Can be used in condition monitoring

Noise reduction with distance

When one doubles the distance from a noise

source the recorded noise level is reduced by 6
dB. This is also called the Rule of 6
NASAresearchersat
GlennResearchCenterconducting
testsonaircraftenginenoisein1967
ULTRASONIC TESTING

n ultrasonic testing (UT), very

short ultrasonic pulse-waves with center frequencies
ranging from 0.1-15 MHz and occasionally up to
50 MHz are launched into materials to detect internal
flaws or to characterize materials.

The technique is also commonly used to determine the

thickness of the test object, for example, to monitor
pipework corrosion.

Ultrasonic testing is often performed on steel and

other metals and alloys, though it can also be used on
concrete, wood and composites, albeit with less
resolution..
At a construction site, a technician tests a pipeline weld for
defects using an ultrasonic phased array instrument. The
scanner, which consists of a frame with magnetic wheels,
holds the probe in contact with the pipe by a spring. The wet
area is the ultrasonic couplant that allows the sound to pass
into the pipe wall.
PRINCIPLE OF WORKING

In ultrasonic testing, an
ultrasound transducer connected to a diagnostic
machine is passed over the object being
inspected.

The transducer is typically separated from the

test object by a couplant (such as oil) or by water,
as in immersion testing.

There are two methods of receiving the

ultrasound waveform, reflection and attenuation.
REFLECTION METHOD

In reflection (or pulse-echo) mode, the transducer

performs both the sending and the receiving of
the pulsed waves as the "sound" is reflected back
to the device.

Reflected ultrasound comes from an interface,

such as the back wall of the object or from an
imperfection within the object.

The diagnostic machine displays these results in

the form of a signal with
an amplitude representing the intensity of the
reflection and the distance, representing
the arrival time of the reflection
ATTENUATION

In attenuation (or through-transmission) mode,

a transmitter sends ultrasound through one
surface, and a separate receiver detects the
amount that has reached it on another surface
after traveling through the medium.

Imperfections or other conditions in the space

between the transmitter and receiver reduce the
amount of sound transmitted, thus revealing
their presence. Using the couplant increases the
efficiency of the process by reducing the losses in
the ultrasonic wave energy due to separation
between the surfaces
ADVANTAGES

High penetrating power, which allows the detection of

flaws deep in the part.

High sensitivity, permitting the detection of extremely

small flaws.

Only one surface need be accessible.

Greater accuracy than other nondestructive methods in

determining the depth of internal flaws and the
thickness of parts with parallel surfaces.

Some capability of estimating the size, orientation,

shape and nature of defects.

Nonhazardous to operations or to nearby personnel and

has no effect on equipment and materials in the vicinity.

Capable of portable or highly automated operation.

DISADVANTAGES

Manual operation requires careful attention by experienced

technicians

Extensive technical knowledge is required for the development of

inspection procedures.

Parts that are rough, irregular in shape, very small or thin, or not
homogeneous are difficult to inspect.

Surface must be prepared by cleaning and removing loose scale,

paint, etc., although paint that is properly bonded to a surface need
not be removed.

Couplants are needed to provide effective transfer of ultrasonic wave

energy between transducers and parts being inspected unless a non-
contact technique is used. Non-contact techniques include Laser and
Electro Magnetic Acoustic Transducers .

Inspected items must be water resistant, when using water based

couplants that do not contain rust inhibitors.
TEMPERATURE MONITORING

Defects - tribological reasons energy wasted in

heat energy heats the connected component.

Equipment operating at ambient conditions.

Temperature rise is monitored to detect any

fault.

Different techniques are adopted to detect this

rise

Temperature crayons and tapes

Thermometers and Optical Pyrometers

Softening cones/Wax/Paints

Thermocouples and fusible plugs

Infrared Meter

Thermography (Infrared Radiation scanner)

Bimetallic Strips

Theristors

Vapour Pressure in Bulb

Mercury in Glass etc.

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.
CAMERAS - FLIR I60
Courtesy: FLIR ystems
CAMERAS - FLIR T250
Courtesy: FLIR ystems
APPLICATIONS

Industrial

Process Control

Predictive Maintenance

Energy Audits

Roofing Diagnostics
APPLICATIONS

Predictive Maintenance

Electrical
ELECTRICAL
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Connection
ELECTRICAL
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Corroded Contact
ELECTRICAL
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ELECTRICAL
$otor tarter Connection
ELECTRICAL
#attery Inspection
APPLICATIONS

Predictive Maintenance
Mechanical
MECHANICAL
%ulley Rubbing a hroud
MECHANICAL
Coupling Alignment
MECHANICAL
!&erheated $otor
APPLICATIONS

Energy Audits
APPLICATIONS
-Energy Audit
Blocked Heat
Exchanger Tubes
APPLICATIONS

Energy Audits
Refractory Damage
APPLICATIONS

Energy Audits
Process Flow
Heat Loss
APPLICATIONS

Energy Audits
Insulation Damage
APPLICATIONS

Roofing Diagnostics
Roof Leaks (Moisture)
INFRARED LIGHT
Discovered in 1800 by Sir
Fredrick Herschel
Light Beyond Red
All objects above the
temperature of
Absolute Zero emit
Infrared light.
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.
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.

Light or visible light is electromagnetic

radiation that is visible to the human eye, and is
responsible for the sense of sight.

Visible light has wavelength in a range from

about 380 nanometres to about 740 nm, with a
frequency range of about 405 THz to 790 THz.

In physics, the term light sometimes refers to

electromagnetic radiation of any wavelength,
whether visible or not.

Infrared (IR) light is electromagnetic

radiation with a wavelength longer than that
of visible light, measured from the nominal edge
of visible red light at 0.74 micrometres ( m), and
extending conventionally to 300 m.

These wavelengths correspond to a frequency

range of approximately 1 to 400 THz, and include
most of the thermal radiation emitted by objects
near room temperature.

Microscopically, IR light is typically emitted or

absorbed by molecules when they change
their rotational-vibrational movements.
THERMOGRAPHY

Infrared thermography, thermal imaging,

and thermal video are examples of infrared imaging
science.

Thermal imaging cameras detect radiation in the

infrared range of the electromagnetic spectrum (roughly
900014,000 nanometres or 914 m) and produce images
of that radiation, called thermograms.

Since infrared radiation is emitted by all objects above

absolute zero according to the black body radiation law,
thermography makes it possible to see one's environment
with or without visible illumination.

The amount of radiation emitted by an object increases

with temperature; therefore, thermography allows one to
see variations in temperature.

When viewed through a thermal imaging camera, warm

objects stand out well against cooler backgrounds; humans
and other warm-blooded animals become easily visible
against the environment, day or night
FACTORS AFFECTING
THERMOGRAPHY

Possible obstruction between sensor and target

(which is to be monitored) in the form of object,
particles, steam and gas molecules, which may
absorb, reflect or scatter the radiation before it
reaches the sensor.

Background radiations from object, other than

target.

Low emissivity
BENEFITS OF INFRARED
THERMOMETRY

Can be used for

Moving objects

Non-contact
applications where
sensors would affect
results or be difficult to
insert or conditions are
hazardous

Large distances

Very high temperatures

BENEFITS OF A THERMOGRAPHY
PROGRAM

Quick problem detection without interrupting services

Prevention of premature failure and extention of

equipment

Identification of potentially dangerous or hazardous

equipment

Wide temperature range from (-17)oC to 900oC with

filters

Can monitor targets in motion and also fragile target

Can monitor target electrically charged.

Can monitor small and remote items

More efficient planning and scheduling.

Increased wrench time for maintenance technicians.

Decrease in equipment failures.

Higher production efficiency, better quality, and lower

maintenance costs.
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.
THERMOGRAPHY
Thermography is the
use of an infrared
imaging and
measurement
camera to "see" and
"measure" thermal
energy emitted from
an object.
APPLICATIONS

Roofing Diagnostics
CONCLUSION

Is there a need for an Infrared Energy Audit

Scheduling of the Survey

Questions??????
INFRARED
THERMOGRAPHY
Plant Predictive Maintenance Program
INTRODUCTION

What is thermography?

Why is thermography needed?

Infrared cameras

Examples of thermal imaging

Program investment and downtime reduction

Benefits

Conclusion
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.
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.
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.
CAMERAS - FLIR I60
Courtesy: FLIR ystems
CAMERAS - FLIR T250
Courtesy: FLIR ystems
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 '()* Fahrenheit.
Courtesy: FLIR ystems
EXAMPLES OF THERMOGRAPHY
This is an e+ample of a ',-.AC brea/er with a loose connection.
Courtesy: FLIR ystems
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.
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.
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.
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.
WORKS CITED

Campbell, Kevin. Plant Engineering. 7 April 2007. 6

November 2008
<http://www.plantengineering.com/article/CA643153
4.html>.

FLIR Systems. 18 April 2008. 6 November 2008

<http://www.goinfrared.com/news/news_item/1126/>.

Stockton, Gregory R. Stockton Infrared

Thermographic Services. 10 June 2000. 6 November
2008
<http://www.stocktoninfrared.com/PUBLISHED/PD
F/low-hang.pdf>.

Wikipedia - The Free Encyclopedia. 10 July 2008. 6

November 2008
<http://en.wikipedia.org/wiki/Thermography>.