Practical Thermography for Mechanical Applications Pub ITC 110 H Infrared Training Center

Practical Thermography for Mechanical Applications 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 1

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 2

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 3

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 4

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 5

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 6

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 7

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 8

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 9

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 10

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 11

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 12

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 13

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 14

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 15

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 16

Mechanical Applications Baseline IR surveys very important Variables include: Environmental conditions, especially temperature Equipment type, mfr Equipment load 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 17

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 18

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 150.0 F 150.0 F 140 140 120 120 100.0 F 100.0 F 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 19

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 20

Baseline example-normal operation 112.0 C 100 80 60 40 Courtesy, David Gleaton 15.0 C 20 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 21

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 22

Mechanical Applications Often use other condition monitoring technologies to verify and isolate findings Vibration Oil analysis MCSA (motor current signature analysis) Ultrasonics 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 23

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 24

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 25

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 26

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 27

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 28

Steam Trap A float and thermostatic trap before dumping condensate (left) and after. Note the temperature increase in the outlet pipe (lower left). 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 29

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 30

Steam Trap Trap cycling live steam, not dumping condensate 314 F 355.0 F 350 SP01 300 250 314 F SP02 200 197.6 F 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 31

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 32

Valves Leaks 38.7 C 35 30 25 21.2 C The thermal pattern on the right valve indicates leakage. 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 33

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 34

Valve leakage 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 35

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 36

Valve condition 102.5 F 100 80 Dropped sealing disk Valve in open position 60 40 36.0 F 118.2 F Courtesy, Robert Bonin, Motiva Leaking valve? IR says NO. 66.8 F 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 37

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 38

Pipe Blockage 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 39

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 40

Duct Blockage Dust drum duct blockage 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 41

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 42

Vacuum Leak 84.4 C 80 75 70 65 58.3 C A vacuum leak causes the bolt (left) to cool 60 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 43

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 44

Refractory Losses A decrease in the insulation refractory has caused this hotspot on this molten metal transfer ladle. 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 45

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 46

Lime Kilns 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 47

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 48

Welded Joints 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 49

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 50

Heat Exchangers 45.4 C 45 40 35 30 25 20.5 C 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 51

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 52

Heat exchanger 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 53

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 54

Bearings and Belts Some mechanical targets too numerous to continuously monitor *>133.3 F 130.0 120.0 110.0 100.0 90.0 80.0 70.0 60.0 50.0 40.0 *>141.2 F 140.0 *<30.5 F 130.0 120.0 Hot Spot 149.0 110.0 100.0 90.0 Conveyor System Roller Bearings 80.0 70.0 *<63.7 F 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 55

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 56

Bearing *>88.8 C 85.0 80.0 75.0 70.0 80.5 55.1 65.0 60.0 55.0 IN-board sleave bearing should be warmer! *<51.9 C Overhead Industrial Fan Bearing 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 57

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 58

Pillow block bearing problem *>205.2 F 200.0 150.0 100.0 50.0 0.0 *<-4.0 F Courtesy Frank Vereb, ISI 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 59

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 60

Belts loose and worn 100.0 F 100 95 Courtesy, David Gleaton 90 85 2010-05-27 80.0 F Pub ITC 110 H - 2010 Infrared Training Center 61

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 62

Tank levels 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 63

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 64

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. 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 65

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 66

Tank levels Floating roof Sludge @ 22 ft Crude level 119.3 F 119.3 F 110 110 100 100 90 90 80 80 AR01 64.5 F 70 64.5 F 70 Outlet 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 67

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 68

Spheres (BRT) Natural Gas 7.9 C Vapor Butane 5 Liquid Butane 0-5 -11.1 C -10 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 69

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 70

Tank sludge removal -- almost 116.4 F 100 Before 80 60.2 F 130.9 F 120 After 100 80 Courtesy, Robert Bonin, Motiva 47.6 F 60 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 71

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 72

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) 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 73

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 74

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 75

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 76

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) 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 77

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 78

Case Study Analyze this IR Image Infrared image of motor bank (Courtesy Missouri River Energy Services) 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 79

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 80

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 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 81

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 82

Bearings 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 83

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 84

Bearings Severity Criteria for Bearings Desirable: Component is 10-24 C (18-75 F) above ambient (normal) Important: Component is 25-39 C (77-102 F) above ambient (normal) Mandatory: Component is 40-69 C (104-156 F) above ambient (normal) Immediate: Component is 70 C (158 F) or more above ambient (normal) 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 85

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 86

If you see a thermal anomaly in the bearing area, investigate further with vibration analysis Motors 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 87

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 88

Bearings 192.6 F 128.9 F 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 89

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 90

Gear reducers 100.0 F 100 95 90 85 80 After 20 minutes of operation 75.0 F 100.0 F 100 95 90 85 80 2010-05-27 After 30 seconds of operation 75.0 F Pub ITC 110 H - 2010 Infrared Training Center 91

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 92

Bearings and Belts Some mechanical targets too numerous to continuously monitor *>133.3 F 130.0 120.0 110.0 100.0 90.0 80.0 70.0 60.0 50.0 40.0 *>141.2 F 140.0 *<30.5 F 130.0 120.0 Hot Spot 149.0 110.0 100.0 90.0 Conveyor System Roller Bearings 80.0 70.0 *<63.7 F 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 93

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 94

Bearing *>88.8 C 85.0 80.0 75.0 70.0 80.5 55.1 65.0 60.0 55.0 IN-board sleave bearing should be warmer! *<51.9 C Overhead Industrial Fan Bearing 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 95

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 96

Pillow block bearing problem *>205.2 F 200.0 150.0 100.0 50.0 0.0 *<-4.0 F Courtesy Frank Vereb, ISI 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 97

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 98

Belts loose and worn 100.0 F 100 95 Courtesy, David Gleaton 90 85 2010-05-27 80.0 F Pub ITC 110 H - 2010 Infrared Training Center 99

2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 100

Overheating Air Compressor Motor 2010-05-27 Pub ITC 110 H - 2010 Infrared Training Center 101