Professional Documents
Culture Documents
Maintenance strategy
There is no strict rule as to the application
of an appropriate maintenance strategy.
This is very much dependent on the economics of machine operation, that is, the
criticality of machine. As plants tend to
have many machines with varying
criticality, it is envisaged that the maintenance strategy also will reflect this, that is,
a possible mix of breakdown, regular and
predictive maintenance strategies. A predictive maintenance strategy requires the
application of machine condition monitoring, commonly known as condition-based
maintenance, as shown in Table 1.
Maintenace
strategy
Breakdown
Regular planned
PREDICTIVE
Unit
parameters
failure based
timed based
CONDITION BASED
Machine Fault
short time and display a picture of the temperature distribution. There are a variety of
thermal imaging instruments available including devices that have the ability to store and
recall images. This ability to retrieve and
analyse previous thermal data is crucial to
the development of predictive maintenance.
Modern portable monitoring systems (thermal imagers) have been developed by a
number of companies and a typical system is shown in Figure 1. The instruments
(5) look very similar to portable video cameras or Camcorders.
Advantages and
disadvantages
The major advantage of thermography is
that it can be put to a large number of industrial uses, which range from machine
condition monitoring and predicting fail-
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Energy systems
Thermography
Non-contact thermal monitoring, or thermography as it is commonly called, is primarily
concerned with the transfer of infrared heat
radiation from an object, and it is an
extremely versatile and powerful condition
monitoring tool. There are many valid
Electronic systems
Discrete components, printed
circuit boards and bonding
X
Table 2. Temperature condition indicators and faults.
11
Using thermography
Electrical systems
There are many documented uses of infrared monitoring particularly in the steel,
power generation, building services, auto-
electrical;
mechanical;
electronic;
energy; and
medical and research.
DESIGN
Process plant: Steam and water lines, heating units (ovens, furnaces, boilers) kilns,
process pipes, containers, ducts, vents, exhaust stacks, flue pipes, buildings e.g., installation of refractory insulation.
Intelligent machine design: Cooling design on electrical machines,
PLANT AND MACHINE MAINTENANCE
Maintenance planning, procedures and reporting: implementing timely, appropriate
maintenance on mechanical and electrical plant and machines.
Efficiency monitoring: cooling towers, doors, windows, ventilators, heat exchangers,
steam traps, foam and refractory insulation.
MACHINE AND COMPONENT FAILURE
Analysis of mechanical component condition: bearings, seals, gears, actuators,
hydraulic rams
Analysis of electrical component condition: fuses, switches, insulators, relays, busbars,
commutators, brushgear
Table 3. Advantages of thermography.
COST
Hardware: Cameras and lenses can be expensive.
Software: Software limitations on some systems.
PRACTICAL CONSIDERATIONS
Object source: Emissivity, transmission and size of detail.
The objects emissivity must be known or calculated.
Object surroundings: The object surroundings should have a homogeneous (ambient)
temperature and should not include hot areas so positioned, that the radiaition can be
reflected by the object.
Atmospheric influences/attenuation: Distance, composition (clear, misty, etc) and
ambient temperature can affect quality of detail
Table 4. Disadvantages of thermography.
12
January/February 1999
r = m
Ir
Im
EQUATION 2
1.67
Ir
Im
r = m
45
40
35
30
25
20
15
10
5
0
0
50
90
120
160
180
200
DAYS
220
232
285
320
340
Figure 3. Trend
monitoring
of
a faulty busbar
connection using
spot measurements.
13
Mechanical systems
Mechanical systems represent a large
proportion of equipment that is used
by most industries. This equipment
includes rotating and reciprocating
machines such as large turbines and
compressors. Thermography can be used
to monitor this complex machinery, which
invariably is composed of a large number
of components.
One thing that all rotating and reciprocating
machines have in common is that in
operation they generate heat through
friction, which is the result of normal or
excessive wear. Friction can lead to
catastrophic failure, caused by defective
components such as bearings, seals,
pulleys, conveyors, pumps, couplings,
shafts, gears and chain drivers, and it
is often linked to inadequate maintenance,
a lack of lubrication or even misuse.
This wear information combined with
the vibration data can prove to be a
most accurate indication of machine component condition as both measurements are
related to wear and can be trended against time.
Possible reasons for mechanical machine
problems include:
increased loading on the bearings
thereby reducing bearing life;
increased stress on the machine
components leading to fatigue problems;
increased forces applied to a machine,
such as loose foundations; and
effects of inertia which lead to imbalance
in rotating parts.
Some examples of machine deterioration
are misalignment, unbalance, looseness,
damaged vanes and blades, damaged bearings and gears, eccentricity, aerodynamic
and hydraulic problems.
Machine systems that make use of bearings, gears and other mechanical components are subject to many of the problems
identified in Table 6. Misalignment can
cause expensive energy losses in rotating
machinery which can lead to problems
such as looseness, a bent shaft, imbalance,
even catastrophic failure. Thermography
can be used to identify gross misalignment
as significant temperature rises occur
across the couplings. Other examples include chains, couplings, belt wear and slippage, fluid leakage, pneumatic actuators
flywheels, clutches, and tank level measurement.
Hydraulics
Monitoring the condition of hydraulic
components using thermography is
generally not common. Perhaps this is
because the high flow speed, fast pressure
changes and fast movements make
diagnosis complex and difficult. However,
temperature in hydraulic systems can vary
to some degree during the cycle of the
system because of wear, a malfunction and
increases in leakage. These problems can
be detected using thermography and have
been documented (8) as:
leakage;
clogging of moving parts in components;
component failures (even small leakages
can be detected); and
the design or installation of component
parts.
The detection of faulty hydraulic
components in the steel industry has
proven to be quite successful (9). For
example, a defective seal with a small
axial incision was installed in a hydraulic
cylinder which was then used in an
experiment to prove the accuracy of
thermography. The fault was quickly
picked up on the thermal image as a hot
spot resulting from a high-pressure
(around 500 psi) fluid escaping from
the incision. This was conclusively proven
by rotating the hot spot. The most common
Electronic systems
Electronic and microelectronic systems,
particularly printed circuit boards (PCBs)
and their components, have benefited
greatly from the development of various
thermographic methods of inspection. This
has arisen mainly because PCBs contain
many small components whose individual
temperatures are difficult to monitor by
conventional means.
Initially, temperature measurement devices
were produced to monitor the individual
temperature patterns which are associated
with single components (11). This has progressed to more complex computerised
thermographic systems for automatic inspection of complete electronic printed circuit boards (12).
It is a well known fact that high operating
temperatures of electronic components result in a reduced service life, with the failure rate increasing almost exponentially
(Figure 5) with a thermal acceleration factor determined by Equation 4.
EQUATION 4
= Failure rate at T
Failure rate at 75C
In sophisticated systems, placing components
in racks can sometimes lead to additional
overheating problems. This can be checked
in situ by varying the ambient temperature
for a complete system and monitoring the
thermal effect on the electronics (13).
The conceptual bathtub curve (14)
(Figure 6), based on reliability studies,
shows that initially a new component has
Hydraulic component
Thermal problem
Cylinder
Valves:
Pressure valves
Directional valves
Check valve
Valve packages
Valve blocks
Leakage, clogging.
Complete system
14
January/February 1999
Figure 5. The failure rate of
a carbon composite resistor
increases by a factor of 22.
7
6
5
4
3
2
1
0
20
34
48
62
76
90
104
118
132
45
Monitoring Parameter
35
30
25
20
15
10
5
0
100
400 600
800
Time (Days)
990
Energy systems
40
15
Refractory insulation
Refractory structures such as kilns and furnaces
are required to operate at temperatures as
high as 1500C. Using thermography an
inspection can be carried out while the
plant is operating. Thermal patterns reveal
internal problems, and are used to predict condition and to plan any remedial maintenance.
The temperature distributions from furnaces
and sometimes the product itself can indicate
furnace and product condition. In the steel
industry, the location of steel strip within
a furnace is monitored by fixed thermal
cameras, while the insulation of the furnace
walls are monitored using portable thermal
imaging cameras. Other examples include
checking the integrity of insulation,
Step
Procedure
Take the PCB out of the rack and start recording a series of thermograms, noting
the time that elapses from removal to taking the first thermogram.
Check back to the time of removal (t=0) and establish the correct temperature of
the components in its normal thermal environment.
Table 7. Procedures that can be used to identify thermal problems on printed circuit boards (16).
brickwork and poor joints on furnaces
and kilns;
refractory lined duct;
blast furnace stoves;
burner operation;
operation of water-cooled elements; and
product temperature measurement.
Medical systems
There appears to be a resurgence of medical applications that use thermography as
a diagnostic tool. In dermatology, for example, thermographic systems with high
spatial resolution allow subcutaneous features of cooled skin to be visualised. Fine
vascular structures and the underlying
pathological processes can directly affect
surface temperature patterns. Other medical examples include:
thermal monitoring of patients during
transplant operations, and temperature
patterns in operating theatres;
cardiac surgery, skin grafting and mi
cro-vascular surgery (wound healing;
research into the impact of physical
training, neuromuscular disorders; and
research into hypothermia treatments
and diabetic care.
References
1. Mobley, R.K. (1990) An Introduction
to Predictive Maintenance.
2. Ross, W.H. (1995) Condition monitoring of electrical machines in Scottish Power.
IEE Colq. On Cond. Mon. of Elect.
Machs., Digest No. 95/019.
16
Customers Purchase
Order Number
Order
Form
PO Box 72, Chipping Norton, Oxford, OX7 6JU, UK
Tel: +44(0)1451 830261 Fax: +44(0)1451 870661
E-mail: mail@coxmoor.com Web: www.coxmoor.com
Title*
The Vibration Monitoring Handbook
The Wear Debris Analysis Handbook
The Thermography Handbook
The Corrosion Handbook
The Noise & Acoustics Handbook
The Oil Analysis Handbook
The Appearance & Odour Handbook
The Acoustic Emission & Ultrasonics Handbook
The Level, Leakage & Flow Handbook
The Power, Performance & Efficiency Handbook
The Steady State Handbook
Technical Data Monitoring & Control
Subscription to Condition Monitor
Subscription to Condition Monitor (Pdf)
Condition Monitoring 99 (Proceedings)
COMADEM 99 (Proceedings)
ISSN or ISBN
Publication
Date
1 901892 00 X
1 901892 02 6
1 901892 01 8
1 901892 03 4
1 901892 04 2
1 901892 05 0
1 901892 06 9
1 901892 07 7
1 901892 08 5
1 901892 09 3
1 901892 10 7
1 901892 10 5
0268 - 8050
0268 - 8050
1 901892 11 5
1 901892 131
May 1998
January 1999
June 1999
January 2000
August 2000
January 2001
TBA
March 2000
August 2000
March 2001
June 2001
TBA
Monthly
Monthly
April 1999
July 1999
Price*
Quantity
35/US$60
35/US$60
35/US$60
35/US$60
35/US$60
35/US$60
35/US$60
35/US$60
35/US$60
35/US$60
35/US$60
35/US$60
259/US$415
175/US$282
65/US$110
65/US$110
Total Price
Method of Payment
Delivery details
Name:
Position:
Total Payment:
Address:
Post/
Zip Code:
Country:
County/
State:
Tel:
Fax:
Cardholder name:
E-mail:
Card number:
Web Site:
Expiry date:
The nature of your business (any information you give will enable
us to ensure only relevant new title information is sent to you).
Todays date:
Signature: