Fluke Seminar Manual PDF

Infrared Introduction Seminar
GLOBAL LEADERS OF INFRARED

THERMOGRAPHY EDUCATION
www.InfraredInstitute.com
Facilitator: Ron Newport
Level III Thermographer, BSc. Elect.Eng., F.I.Diag. Eng., Certified Trainer.
Seminar Objective
The objective of this workshop is

to provide information to gain a
better understanding of
infrared condition
monitoring. What it is,
what it is not, and what
is required to perform a
concise and accurate
inspection.
Institute of Infrared Thermography
Services Offered:
Inspection Services
Certification Courses
- ASNT, BINDT, ISO
- Level I, II and III
Application Courses
- Building, Electrical, Process
IR Camera Operator Courses:

Fluke, plus all other manufacturers
Tailored On-Site Courses
Procedures and Standards Writing
Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

Industry Changes
Over the past 30 years maintenance has

changed, possibly more so than any
other management discipline. The
changes are due to the increase in the
amount and variety of physical assets
(plant, equipment, and buildings) which
must be maintained, increased
automation requirements, more
complex machinery and control
designs.
HistoryHistory- Failure with Age
There was a belief that there is a

relationship between the age of a
component and how likely it is to fail.
This is called the Bathtub reliability
Curve.
Repair / overhaul
at failure
Risk
of
Failure
Start-up
Life
PM, Fact or Fantasy?
The conclusion was: PM

provides increased
reliability with more
maintenance.
This is rarely true!

New findings contradict
the belief that there is
always a connection
between reliability and
operating age.

New Findings
Today it is understood there is little

relationship between age and failure.
Studies now show that only 4% of items
will conform to the bathtub curve. And,
that 68% of the items conformed to the
curve below.
Risk
of
Failure
Life
Preventive Maintenance and Failure Rates
It has now been

proven in most
industries and
situations, that the
removal and
replacement of parts,
which are still in good
condition, no matter
how carefully done,
can actually increase
overall failure rates.
Preventive MaintenanceMaintenance- Reality
Periodic disassembly is expensive

and time consuming
Period or interval is difficult to
determine
Potential for maintenance induced
problems
Unavailability of process or equipment
due to PM tasks may outweigh gain in
reliability

Industrial Maintenance Technician
Fact:
1. Technicians spend most of
their time fixing problems
On average, 4x more
doing
repairs than on the
Prevention of problems
2. Reactive maintenance
provides the highest level
of
maintenance cost
adds to cost-of-goods
sold
reduced company profits
M t
f
ti t
Predictive Maintenance (PdM)
Test and inspection instrumentation

are used to identify and monitor
potential failure.
Corrective action is taken when
measurements are about to go outside
the equipment operating limits.
Maintenance / overhaul
prior to failure
Risk
of
Failure
Start-up
Life
PdMPdM- Advantages
Essential tool to assure maximum

safety and improved reliability
Detects possible system or
equipment failures in the early stages
Reduces risk of catastrophic failures
Minimizes repair time
Improved and lower cost Maintenance
Reduce asset base i.e. spare parts
Lets healthy machines keep
running

Predictive Maintenance (PdM)
Predictive Maintenance removes the

need for unnecessary preventative
maintenance - partially reducing
expenditure.
Typically 50% of the maintenance costs
can be realized when performing
predictive maintenance methods.
Condition Monitoring
These predictive inspection

tasks are called Condition
Monitoring because the
inspection techniques employed
are evaluating the operating
condition of the items being
inspected.
The majority of the techniques
rely upon the fact that most
failures give warning of the fact
that they are about to occur.
CM Techniques
CM techniques include:
Vibration Monitoring & Analysis
Lubricant and Oil Analysis
Wear Particle Analysis
Ultrasonic Noise Detection
Motor Circuit Evaluation
Electrical Condition Monitoring
Nondestructive Testing
Infrared Thermography

CM Techniques
#1 The PdM Program
The most diverse

inspection technique
is Infrared
Thermography. No
other instrument
provides the diversity
of applications and
inspection capabilities
in the industrial and
commercial setting.
Advantages of a IRT Program
find the problem before it finds

you!
improved less expensive maintenance
consistent and improved availability
increase in production rate
reduced maintenance costs
extend asset life (less need for capitol
expenditure)
reduce asset base i.e. spare parts

increased product quality and
consistency

Return on Investment
A ten year study by a

billion dollar Insurance
company, Hartford Steam Boiler
Insurance Company, determined that a
proper infrared predictive maintenance
program produces a
400% Return on Investment.
Why Temperature?
Within industry, no other

measurement method is
more frequently used!
WHY?
Because temperature
measurement provides
valuable information
regarding the condition
of a process, component
and the operating
environment.
What is Infrared?

IR cannot see through most materials
For the most part, infrared
cameras can only see the energy
from the surface of a material. We
cannot se through enclosure
doors.
However, the energy we are
interested in originates from the
inside.
Doors must be opened when
possible
Be sure to comply with safety
regulations when opening and
working around active panels.
Heat Transfer Theory

How does thermal energy get to the surface?
Conduction is transfer of thermal

energy actual molecular vibration in
solids
For instance, when an iron rod is heated,
thermal energy travels by conduction
through the metal to the other end
Convection is heat transfer within a gas
or Liquid
Radiation is heat transfer by
electromagnetic waves
All objects emit infrared radiation
Thermal Imaging
Is the science of imaging radiant thermal
energy using special electronic camera.
The infrared camera detect and measure
infrared (IR) energy and convert the
information to images corresponding to the
thermal energy levels from the surface of the
object.

Fast, safe and accurate measurements
For objects that are:

moving or very hot
difficult to reach
impossible to shutoff
dangerous to
contact
Contaminated/
altered or destroyed
through contact
Applications
Applications for
infrared
thermography
amazingly diverse.
The limitation is
your imagination!
Application Diversity?
- Electrical: generation to low voltage

- Mechanical: motors, bearings, gears
- Process: product flow, piping, vessels
- Manufacturing: electronics, glass,
plastics, pharmaceutical, textiles
- Energy Conservation: missing or

damaged insulation
- Building Thermography
- Pest Management

A major portion of a facilitys capital

investment is in electrical equipment.
From generation to power distribution
to electric motors and lighting, the
efficient operation of the electrical
system is critical to maintaining total
operational capability of any facility.
No electrical power = No operation!
Faults in electrical systems are serious

concerns and yet are seldom obvious!
These faults are costly as they can stop
operations, increases energy usage,
present safety concerns (fires and
explosions) and life cycle cost issues
(premature replacement of equipment).
Therefore monitoring key parameters
such as temperature, load, high
resistance and insulation breakdown
are major concerns for any facility.
Electrical CM encompasses several

technologies but infrared
thermography is the #1 chosen noncontact, NDT instrument for electrical
inspections in all industrial and
commercial sectors
10

Insurance Companies
Insurance Companies fully support the use of
Infrared Thermography!
Zurich Risk
Engineering reports
that 25-30% of all
large fire losses are
caused by electrical
faults.
A Thermography program can virtually eliminate
this disaster.
-
Fire Prevention
In urban areas, electrical systems

account for 33% of residential fires.
Return on Investment
A ten year study by a

billion dollar Insurance
company, Hartford Steam Boiler
Insurance Company, determined that a
proper infrared predictive maintenance
program produces a
400% Return on Investment.
11

Electrical Thermography ROI
The investment in an infrared electrical

inspection program can be paid back
from the discovery of one major
electrical fault.
Where is IR/T Applied?
Generation
Transmission
Distribution
Sub-Stations
Transformers
Switches
Capacitors
In-Plant
Low Voltage
Will provide valuable
information on the entire UPS
Electronics
electrical system!
InfraredInstitute.com
Problems Found on Electrical System:
1. High Resistance
2. Load Imbalance
3. Open Circuits
4. Insulation
degradation
5. Short Circuits
6. Induction Currents
7. Undersized or
specified
components
8. Live Grounds
9. Corona
10.Harmonics
12

Normal Thermal Signatures
First the technician must understand

what the normal thermal signature on
the equipment under inspection.
Normal Load and Resistance Relationship.
Connections
The most frequent problems found

during a thermographic investigation
are thermal anomalies related to
connections.
It is not unusual to
have 75% of the
anomalies detected
during an infrared
inspection to be a
connection problem
of some sort.
Localized Resistance
The thermal energy trailing away from the

bolted connection suggests localized
connection problem.
13

Load
Load conditions such

as overload, load
imbalance or
undersized components
will be apparent.
This thermal image
shows a higher
temperature and an
even temperature
distribution on B
phase, this suggests an
unbalanced load.
Temperature Ratings
Temperature on electrical components is

critical to safe operating conditions.
Because this is well understood,
associations like IEEE, ANSI, IEC and all
Manufacturers publish temperature ratings
for electrical components.
Transmission/Distribution Applications
Splices
Line Clamps
Bolted
Connections
Insulator
Connections
Insulator
problems
Current
Leakage
14

Aerial Thermography
230 Kv Bolted Connector
Substations
Substations
Switches of all types

Breakers
Current Transformers
Capacitors
Transformers
Bushings
Cooling fans
15

Transformer
Utility SubSub-Stations
An IR Inspection
detected a 450C
temperature rise on a
high voltage bushing
on a transformer.
Avoided cost
$332,300.00
Transformer Fins
Note the temperature

differential between
the top and bottom.
This indicates
correct operation.
Fluid Restrictions:
Note the thermal
variations. This
indicates restrictions
to the fluid flow.
16

Substations
Electrical Connections
Both qualitative and quantitative inspections

are possible with most IR Cameras. This
depends on the program and the application.
The connections on this connection is over

50C higher than A phase. Temperature rise
is a method to determine problem severity.
Breaker ContactContact- Exposed
17

Breaker ContactContact- Hidden
Internal breaker contacts
Low Voltage Electrical Maintenance
Poor Primary Breaker Connector
This shows a problem with the breaker

contact to the bus.
Conductors
Infrared thermography on conductors is used to
indicate general overheating due to overloading
or undersized cables, high resistance, poor
connections and bad splices.
Image courtesy of ACMT
Overheated splice
18

UPS System and Batteries
Induction Heating
Thermographic Reporting
Logo can be changed from file
Inputs for:
Company Name
Problem Number
Location Name and Equipment
Problem Description
Weather Conditions
Route Data
Maintenance Action Information
Repair Priority Assignment
Reinspection Signoff
Pre /Post Thermal Image or
Pre Thermal /Post Digital Image
19

Mechanical
AC/DC Motors
Bearings
Pumps, Fans
Hydraulics
Compressors
Valves
Engines
Drives
Gears
Conveyors
Couplings
Mechanical InspectionsInspections- Motors
High Operating Temperatures

Winding Insulation Breakdown
Cooling Blockages
Bearings
Alignment
Mechanical Load
Motor Connections
Power Quality Issues
-Harmonics
-Voltage Unbalance
-Overload
-Load Imbalance
Motors
For each 10C rise over

maximum rated temperature,
motor life will be reduced by
approximately 50%.
20

Motor Signatures
3
.
InfraredInstitute.c
om
2.
1. Normal Signature
2. Localized hot spot
3. Severe Overheating
Motor Bearings
The most common

cause of motor failure
is bearings.
It has been
estimated that up to
50% of all motor
burnouts are a result
of bearing failure.
Yet, there are many
causes of bearing
failure.
Motor Bearings
48.7C
Overheated
bearing due to lack of
lubrication. Once lubricated, the
temperature returned to normal.
21

Process Applications
Process applications include the flow of

a product, fluids, steam, chemicals, hot
gases, or solids through any system
typically display a particular thermal
signature.
When this signature changes such as
with corrosion, cracking, thinning,
erosion, leaks, blockages, varying fluid
levels, coking, scale build-up, etc. may
cause detectable variations in infrared
energy patterns.
Commonly inspected
components
Refractory's
Tanks and vessels
Steam systems/traps
Pipes and valves
Heaters/Furnaces
Manufacturing equipment
Plastics Industry (Molding)
Pulp & Paper (Rollers,
handling equipment, etc)
Metal Foundry
Boilers and Reactors
Research & Development
Typical reasons for temperature

hotspots or deviations
Damaged structures caused by worn
pipes etc
Abnormal heat flow, heat gradients,
blockages
Gas or steam leakage
Tank Levels
Sludge Levels
Broken Valves, closed or bypassing
Gas and Steam Leakage
Pipe Thinning
Pipe Leaks & Blockages
Pipes can become blocked from deposition of

heavier materials from the product flowing through
the pipes. The flow can become restricted slowing
down the process, or blocked, shutting it down.
22

Refractory
Refractory is high
temperature
insulation. Thinning,
cracked or missing
refractory areas can
be spotted easily.
Temperature
measurements may
be used to estimate
refractory lining
thickness
Refractory & Cement Kiln insulation
Inspect for:
Hot areas
associated with
refractory
thinning or
failure
Cold areas
associated with
internal product
build-up
Steam SystemSystem- Steam Traps
When the trap is operating correctly there

should be a definitive change between the
inlet temperature and outlet.
23

Steam traps failures are costly
Single failed trap

in school
building caused
$170 loss per
day
That is $62,000
a year loss
from 1 failed
trap!
Working Trap
Failed Trap
Leakage in Boiler
Pulp and Paper Industry
Paper machine moisture variation

across the paper roll
24

Glass Industry: Quality Control
Monitoring glass mold and product

uniformity
Process Quality Control & Efficiency
Ensure package
seal integrity
Plastic IndustryIndustry- Quality Control
Plastic Injection
Molding, Part
Uniformity
25

Building Thermography
MBuildings
- Structure
- energy audits
- Insulation
- air in/exfiltration
- moisture ingress &
leaks
MRoof moisture and

leak detection
MHeating & AC
systems
Building Thermography
Energy Loss:
Conduction Losses- insulation
inspections, missing, misplaced,
inadequate insulation.
Convection Lossesair infiltration/exfiltration- air movement

into and through the envelope.
Conduction Losses
26

Air Exfiltration
Air Exfiltration
The window seals

are damaged and
cooled are is
escaping. This
reduces the
energy efficiency
of the building and
if not repaired will
deteriorate the
structure.
Building Envelope
Envelope integrity- Moisture

Moisture development due to
condensation within the envelope
due to vapour retarder and air
sealing problems
moisture intrusion- due to cracks,
openings, water pipe leaks
sick building syndrome, mold
growth and other health issues
27

Buildings Water Leaks
The entry point of infiltrating water is often

difficult to determine because water normally
does not enter a building in a way that is
predictable.
Building Envelope
Roof Inspections roof inspections- moisture intrusion

and locating water leaks, energy loss.
Building Envelope
moisture damage due to leaks or

condensation, especially in the
walls or roofs
poor HVAC distribution or
performance
28

Exfoliation check of wall tile (south faced)
Under the sunlight, temperature was rising in

the outer wall of the mortar. Higher
temperature was shown in the exfoliated outer
wall of mortar.
Concrete Void Principle
Concrete Exfoliation Diagnosis
Bridge railing concrete exfoliation may cause

serious disaster if there is a pedestrian path
under the bridge. The thermography test is
an effective method for general inspection
due to its remote capability.
29

Fluke Seminar Manual PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Fluke Seminar Manual PDF

Uploaded by

Copyright:

Available Formats

Infrared Introduction Seminar

GLOBAL LEADERS OF INFRARED

Facilitator: Ron Newport

Level III Thermographer, BSc. Elect.Eng., F.I.Diag. Eng., Certified Trainer.

The objective of this workshop is

Institute of Infrared Thermography

IR Camera Operator Courses:

Tailored On-Site Courses

Procedures and Standards Writing

Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

Infrared Introduction Seminar

Over the past 30 years maintenance has

HistoryHistory- Failure with Age

There was a belief that there is a

PM, Fact or Fantasy?

The conclusion was: PM

This is rarely true!

Infrared Introduction Seminar

Today it is understood there is little

Preventive Maintenance and Failure Rates

It has now been

Preventive MaintenanceMaintenance- Reality

Periodic disassembly is expensive

Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

Infrared Introduction Seminar

Predictive Maintenance (PdM)

Test and inspection instrumentation

Essential tool to assure maximum

Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

Infrared Introduction Seminar

Predictive Maintenance removes the

These predictive inspection

Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

Infrared Introduction Seminar

#1 The PdM Program

The most diverse

Advantages of a IRT Program

find the problem before it finds

reduce asset base i.e. spare parts

Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

Infrared Introduction Seminar

A ten year study by a

Within industry, no other

Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

Infrared Introduction Seminar

Heat Transfer Theory

Conduction is transfer of thermal

Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

Infrared Introduction Seminar

For objects that are:

- Electrical: generation to low voltage

- Energy Conservation: missing or

Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

Infrared Introduction Seminar

A major portion of a facilitys capital

Electrical Condition Monitoring

Faults in electrical systems are serious

Electrical Condition Monitoring

Electrical CM encompasses several

Copyright. Institute of Infrared Thermography. All rights reserved. www.InfraredInstitute.com

Infrared Introduction Seminar

In urban areas, electrical systems

The most common