• Refractory
• Steam Systems
• Petrochemical Processes
• Automotive Industry Process
• Metal and Plastic Processing

• Electronics design, verification, mass screening, diagnostics
• Mechanical Assemblies -malfunction and failure analysis

• Cavities and Inclusions in Solids
• Composite Delamination
• Subsurface Corrosion Detection
• Moisture Detection
• Concrete Bridge Deck Delamination

• Security
• Surveillance
• Search & Rescue

• Heat Plow Studies
• Biological Studies
• Air Movement Studies
• New Product Evaluation

• Lower maintenance and production costs
• Reduced unscheduled production downtime
• Extends maintenance repair intervals
• Lower probability of catastrophic failure
• Increased personnel safety
• Reduced insurance rates
• Reduced spare parts inventory
• Unnecessary repairs minimized
• Maximize plant availability
• Maintenance or repairs can be planned for non-peak production periods
• Improved coordination of maintenance efforts
• Optimizes staff size
• Biutilization
• Improved production quality
• Speeds up production output
• Improved communication and decision making
• Improved equipment design
• Competitive advantage

• 28% increase in maintenance productivity
• 19% decrease in material cost
• 18% reduction in spare parts inventory

IR/T is currently experiencing rapid growth as more and more electric utilities and industrial sectors are embracing the technology. The reason for this growth is that company personnel are understanding the benefit of this non-contact, nondestructive method. The primary benefit is to find deteriorating components prior to catastrophic failure. Thermography provides a "different set of eyes" allowing a whole new level of diagnostic aid and problem solving.

INFRARED CONDITION MONITORING

Temperature and thermal behavior of power generation and distribution equipment as well as industrial machinery and processes are the most critical factors in the maintenance of operations. Temperature is one of the first observable parameters that will indicate the operating condition of a component, and is by far the most measured quantity in an industrial environment. For this reason, monitoring the thermal operating condition of electrical and mechanical equipment is considered to be the key to any successful predictive maintenance program.

Infrared Thermography (IR/T) is a condition monitoring technique used to remotely gather thermal information for monitoring the condition of the entire electrical system from generation, distribution to end user.

Since all equipment (when operating) has a normal operating thermal signature, IR/T allows this signature to be recorded as a baseline measurement. Once this is established, IR/T over time will reveal the thermal differences deviating from the norm. This abnormally localized radiation (anomaly) can either be an over heated condition or lack of heat. This information is then reviewed and the decision is made to plot the temperature change with time and/or the repair can be initiated at the most efficient time. The information gathered can be stored and Illy analyzed, providing complete predictive maintenance capabilities.

CONDITION MONITORING PROGRAM

A condition monitoring program, properly implemented, is an important tool for modem facilities. The total maintenance cost in most plants will range from 15 to 40 percent of the total cost of goods produced. It is the single largest contributor to controllable cost in most manufacturing and process plants. It also has the largest potential for improved availability and profit in industry today.

Independent surveys indicate that North American industry spends more than $200 billion dollars each year on maintenance and that more than one third, or $60 billion, is wasted as a result of unnecessary or improper maintenance These surveys also confirm that reactive (after the machine failure) maintenance will cost an average of three times more than the same repair performed using the advance notice provided by condition monitoring techniques. The forewarning of incipient machine or system problems provided by a condition based predictive maintenance program is invaluable in saving money.

IR/T Electrical Inspections - A Brief History

The main application for thermography has always been electrical system inspections. In 1965, the Swedish Power Board began IR/T inspections. In 1976, the UK Electrical Generation Board began utilizing IR/T for predictive maintenance on their transmission lines. Canadian companies such as Ontario Hydro and B.C. Hydro also became involved with IR/T during this period.

Over the years, IR/T has proved itself as valuable tool for electrical inspections. Electrical problems manifest themselves by emitting increased heat energy. The new generation of IR scanners can easily detect and image this information. IR/T has now been implemented in virtually every major industrial setting to provide valuable information for condition monitoring and preventive maintenance.

Return on Investment

The costs involved in implementing an 11~ITT condition monitoring program are dependant on several factors. These include:

• Facility size.
• Facility type.
• Complexity of monitoring program desired. IR equipment and training either contracted out or acquired internally.

Conclusion

The benefits of a properly implemented IR/T inspection program are hard to ignore. Companies hoping to maintain a competitive edge must stay current with technology. While certainly not new, IR/T is just beginning to reveal how useful it can be to all areas of industry. By reducing maintenance costs, down-time and catastrophic failure, IR/T customers will continue to enjoy a strong bottom line.