Practical Thermography for Mechanical Applications Pub ITC 110 H Infrared Training Center
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1 Practical Thermography for Mechanical Applications Pub ITC 110 H Infrared Training Center 1
2 Pub ITC 110 H Infrared Training Center 2
3 Lesson Objectives Learn basics of what to look at in a mechanical IR survey Understand importance of a baseline IR survey Understand effect of environmental conditions Understand occasional need for other technologies Pub ITC 110 H Infrared Training Center 3
4 Pub ITC 110 H Infrared Training Center 4
5 Why Use IR to Inspect Mechanical Equipment? Mechanical systems generate thermal energy during normal operation Excessive temperatures can be generated by: Friction Cooling degradation Material loss Blockages Pub ITC 110 H Infrared Training Center 5
6 Pub ITC 110 H Infrared Training Center 6
7 Causes of Excessive Friction Friction Causes Wear Misalignment Over or under lubrication Misuse Heat energy will travel from generation points to surface to be imaged Pub ITC 110 H Infrared Training Center 7
8 Pub ITC 110 H Infrared Training Center 8
9 Mechanical Applications Motors and their associated driven components Gasoline and Diesel engines Heat exchangers Piping systems Boilers and furnaces Steam Traps Valves Gear boxes Vessels and Tanks Automotive, Marine, and Aeronautical Multiple bearing transport systems (conveyors) Energy delivery systems Air handling systems Pub ITC 110 H Infrared Training Center 9
10 Pub ITC 110 H Infrared Training Center 10
11 Familiarity with Equipment is Key Simply identifying a thermal pattern does not mean a problem has been located Once a normal thermal signature is obtained and understood, any deviation from this normal signature can provide evidence of a suspect problem Understand temperature limits of mechanical equipment Pub ITC 110 H Infrared Training Center 11
12 Pub ITC 110 H Infrared Training Center 12
13 Thermography s Use More useful for locating a problem area than for indicating the cause of the overheating Other technologies such as vibration analysis, oil analysis, and ultrasound can be employed to find root causes Pub ITC 110 H Infrared Training Center 13
14 Pub ITC 110 H Infrared Training Center 14
15 Thermography s Advantages Non-contact and non-invasive technique Fast Image easier to understand than many other NDT techniques Versatile Other NDT methods often necessary to pinpoint problems discovered with IR Pub ITC 110 H Infrared Training Center 15
16 Pub ITC 110 H Infrared Training Center 16
17 Mechanical Applications Baseline IR surveys very important Variables include: Environmental conditions, especially temperature Equipment type, mfr Equipment load Pub ITC 110 H Infrared Training Center 17
18 Pub ITC 110 H Infrared Training Center 18
19 Mechanical Applications Compare, compare, compare Time trending Same equipment over time Equipment comparisons Similar equipment under similar load and environmental conditions in a different location at about the same time F F F F Pub ITC 110 H Infrared Training Center 19
20 Pub ITC 110 H Infrared Training Center 20
21 Baseline example-normal operation C Courtesy, David Gleaton 15.0 C Pub ITC 110 H Infrared Training Center 21
22 Pub ITC 110 H Infrared Training Center 22
23 Mechanical Applications Often use other condition monitoring technologies to verify and isolate findings Vibration Oil analysis MCSA (motor current signature analysis) Ultrasonics Pub ITC 110 H Infrared Training Center 23
24 Pub ITC 110 H Infrared Training Center 24
25 Steam Traps More difficult than other valve or piping systems to diagnose Pressure has effect on temperature of steam in a saturated system As pressure decreases, the temperature of the steam decreases as well Improperly operating traps may go unnoticed Pub ITC 110 H Infrared Training Center 25
26 Pub ITC 110 H Infrared Training Center 26
27 How to Inspect Steam Traps Inspect exit of trap. Should see temperature fluctuation as trap dumps condensate If you don't see it, can mean: Failed open or closed Undersized for condensate load Have not waited long enough to see trap cycle If you see any of these conditions, use an ultrasonic tester to verify trap s condition Pub ITC 110 H Infrared Training Center 27
28 Pub ITC 110 H Infrared Training Center 28
29 Steam Trap A float and thermostatic trap before dumping condensate (left) and after. Note the temperature increase in the outlet pipe (lower left) Pub ITC 110 H Infrared Training Center 29
30 Pub ITC 110 H Infrared Training Center 30
31 Steam Trap Trap cycling live steam, not dumping condensate 314 F F 350 SP F SP F Pub ITC 110 H Infrared Training Center 31
32 Pub ITC 110 H Infrared Training Center 32
33 Valves Leaks 38.7 C C The thermal pattern on the right valve indicates leakage Pub ITC 110 H Infrared Training Center 33
34 Pub ITC 110 H Infrared Training Center 34
35 Valve leakage Pub ITC 110 H Infrared Training Center 35
36 Pub ITC 110 H Infrared Training Center 36
37 Valve condition F Dropped sealing disk Valve in open position F F Courtesy, Robert Bonin, Motiva Leaking valve? IR says NO F Pub ITC 110 H Infrared Training Center 37
38 Pub ITC 110 H Infrared Training Center 38
39 Pipe Blockage Pub ITC 110 H Infrared Training Center 39
40 Pub ITC 110 H Infrared Training Center 40
41 Duct Blockage Dust drum duct blockage Pub ITC 110 H Infrared Training Center 41
42 Pub ITC 110 H Infrared Training Center 42
43 Vacuum Leak 84.4 C C A vacuum leak causes the bolt (left) to cool Pub ITC 110 H Infrared Training Center 43
44 Pub ITC 110 H Infrared Training Center 44
45 Refractory Losses A decrease in the insulation refractory has caused this hotspot on this molten metal transfer ladle Pub ITC 110 H Infrared Training Center 45
46 Pub ITC 110 H Infrared Training Center 46
47 Lime Kilns Pub ITC 110 H Infrared Training Center 47
48 Pub ITC 110 H Infrared Training Center 48
49 Welded Joints Pub ITC 110 H Infrared Training Center 49
50 Pub ITC 110 H Infrared Training Center 50
51 Heat Exchangers 45.4 C C Pub ITC 110 H Infrared Training Center 51
52 Pub ITC 110 H Infrared Training Center 52
53 Heat exchanger Pub ITC 110 H Infrared Training Center 53
54 Pub ITC 110 H Infrared Training Center 54
55 Bearings and Belts Some mechanical targets too numerous to continuously monitor *>133.3 F *>141.2 F *<30.5 F Hot Spot Conveyor System Roller Bearings *<63.7 F Pub ITC 110 H Infrared Training Center 55
56 Pub ITC 110 H Infrared Training Center 56
57 Bearing *>88.8 C IN-board sleave bearing should be warmer! *<51.9 C Overhead Industrial Fan Bearing Pub ITC 110 H Infrared Training Center 57
58 Pub ITC 110 H Infrared Training Center 58
59 Pillow block bearing problem *>205.2 F *<-4.0 F Courtesy Frank Vereb, ISI Pub ITC 110 H Infrared Training Center 59
60 Pub ITC 110 H Infrared Training Center 60
61 Belts loose and worn F Courtesy, David Gleaton F Pub ITC 110 H Infrared Training Center 61
62 Pub ITC 110 H Infrared Training Center 62
63 Tank levels Pub ITC 110 H Infrared Training Center 63
64 Pub ITC 110 H Infrared Training Center 64
65 Tank Level Typical thermogram of an actively heated tank. The area containing gas at the top has cooled faster than the heated liquid in the bottom causing a temperature difference Pub ITC 110 H Infrared Training Center 65
66 Pub ITC 110 H Infrared Training Center 66
67 Tank levels Floating roof 22 ft Crude level F F AR F F 70 Outlet Pub ITC 110 H Infrared Training Center 67
68 Pub ITC 110 H Infrared Training Center 68
69 Spheres (BRT) Natural Gas 7.9 C Vapor Butane 5 Liquid Butane C Pub ITC 110 H Infrared Training Center 69
70 Pub ITC 110 H Infrared Training Center 70
71 Tank sludge removal -- almost F 100 Before F F 120 After Courtesy, Robert Bonin, Motiva 47.6 F Pub ITC 110 H Infrared Training Center 71
72 Pub ITC 110 H Infrared Training Center 72
73 Motors Temperatures generally compared test period to test period Other factors affecting temperatures Ambient temperature Motor environmental conditions Application heat transfer Frame size/mass Casing type (enclosed/ribbed/interior location) Pub ITC 110 H Infrared Training Center 73
74 Pub ITC 110 H Infrared Training Center 74
75 But Remember! Casing temperature is NOT the motor s true temperature Indirect measurement Estimates are that internal motor temperature, depending on the above listed factors, could increase by 40 F (22 C) minimum Pub ITC 110 H Infrared Training Center 75
76 Pub ITC 110 H Infrared Training Center 76
77 Case Study Tested two separate ways Comparison to ambient temperature If motor case temperature is 40 F (22 C) over ambient temperature, it is considered overheating Increase of 80 F (44 C), serious heat problem is noted Comparison to spot or reference temperature If marked reference points indicate rise of 20 F (11 C), motor is overheating At 40 F (22 C), a serious heat problem is noted (Courtesy Missouri River Energy Services) Pub ITC 110 H Infrared Training Center 77
78 Pub ITC 110 H Infrared Training Center 78
79 Case Study Analyze this IR Image Infrared image of motor bank (Courtesy Missouri River Energy Services) Pub ITC 110 H Infrared Training Center 79
80 Pub ITC 110 H Infrared Training Center 80
81 Case Study Not testing actual interior winding temperatures Customers, to date, have not demanded pinpointing problems IR can give first warning sign Customers addressing smaller problems before outages occur In the case of larger problems, they can plan for maintenance downtime Pub ITC 110 H Infrared Training Center 81
82 Pub ITC 110 H Infrared Training Center 82
83 Bearings Pub ITC 110 H Infrared Training Center 83
84 Pub ITC 110 H Infrared Training Center 84
85 Bearings Severity Criteria for Bearings Desirable: Component is C (18-75 F) above ambient (normal) Important: Component is C ( F) above ambient (normal) Mandatory: Component is C ( F) above ambient (normal) Immediate: Component is 70 C (158 F) or more above ambient (normal) Pub ITC 110 H Infrared Training Center 85
86 Pub ITC 110 H Infrared Training Center 86
87 If you see a thermal anomaly in the bearing area, investigate further with vibration analysis Motors Pub ITC 110 H Infrared Training Center 87
88 Pub ITC 110 H Infrared Training Center 88
89 Bearings F F Pub ITC 110 H Infrared Training Center 89
90 Pub ITC 110 H Infrared Training Center 90
91 Gear reducers F After 20 minutes of operation 75.0 F F After 30 seconds of operation 75.0 F Pub ITC 110 H Infrared Training Center 91
92 Pub ITC 110 H Infrared Training Center 92
93 Bearings and Belts Some mechanical targets too numerous to continuously monitor *>133.3 F *>141.2 F *<30.5 F Hot Spot Conveyor System Roller Bearings *<63.7 F Pub ITC 110 H Infrared Training Center 93
94 Pub ITC 110 H Infrared Training Center 94
95 Bearing *>88.8 C IN-board sleave bearing should be warmer! *<51.9 C Overhead Industrial Fan Bearing Pub ITC 110 H Infrared Training Center 95
96 Pub ITC 110 H Infrared Training Center 96
97 Pillow block bearing problem *>205.2 F *<-4.0 F Courtesy Frank Vereb, ISI Pub ITC 110 H Infrared Training Center 97
98 Pub ITC 110 H Infrared Training Center 98
99 Belts loose and worn F Courtesy, David Gleaton F Pub ITC 110 H Infrared Training Center 99
100 Pub ITC 110 H Infrared Training Center 100
101 Overheating Air Compressor Motor Pub ITC 110 H Infrared Training Center 101
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