Vibration Testing and Thermal Imaging Technology

Here's an article about vibration testing technology and thermal imaging technology. I find it really amazing hearing some companies using it and living through it, keeping it as part of their predictive maintenance technology in their manufacturing and operation.

Vibration Testing Technology

To the savvy maintenance professional, industrial machinery almost "talks" to reveal its condition. The key to success is in understanding what the machine is saying. To detect problems, the professional "listens" in many ways: With eyes and ears, to see and hear conditions that may indicate problems and...

• With thermometers and thermal imagers, to detect overheating, poor electrical connections or failing bearings
• With digital multimeters and power analyzers, to diagnose electrical problems
• Using techniques like lubricant analysis, to gauge machine condition over time

And now new vibration testing tools provide the maintenance professional with a valuable new way not just to listen, but to find mechanical problems and fixes: these new troubleshooting tools are engineered to detect and evaluate machine vibration immediately and recommend any needed repairs.

A new kind of troubleshooting tool

Many industrial maintenance teams today work under severe restrictions on money and time. They may not have the resources to train for and implement the typical long-term vibration analysis program. Further, many professionals may think there are only two options for vibration testing; high-end vibration analyzers that are expensive and difficult to use, and low-end vibration pens, which aren't particularly accurate.

Fortunately, a new breed of vibration-testing tool fills the middle of the category, combining the diagnostic capability of a trained vibration analyzer with the speed and convenience of lower-end testers, at a reasonable price. This type of tool is designed to be not merely a vibration detector, but a complete diagnostic and problem-solving solution, and targeted specifically for maintenance professionals who need to troubleshoot mechanical problems and quickly understand the root cause of equipment condition.

These tools are designed and programmed to diagnose the most common mechanical problems of unbalance, looseness, misalignment and bearing failures in a wide variety of mechanical equipment, including motors, fans, blowers, belts and chain drives, gearboxes, couplings, pumps, compressors, closed coupled machines and spindles.

Not just data, but actionable results

When these new testers detect a fault, they identify the problem, its location and severity on a multi-level scale to help the maintenance professional prioritize maintenance tasks. They may also recommend repairs.

Mechanical diagnosis can begin with the user placing the device's accelerometer on the machine under test. The accelerometer may have a magnetic mount or can be installed using adhesive. As the machine under test operates, the accelerometer detects its vibration along three planes of movement (vertical, horizontal and axial) and transmits that information to the tester. Using a set of advanced algorithms, the tester then provides a plain-text diagnosis of the machine with a recommended solution.

No training? No problem

Mechanical equipment is typically evaluated by comparing its condition over time to an established baseline condition. Vibration analyzers used in condition-based monitoring programs rely upon these baseline conditions to evaluate machine condition and estimate remaining operating life. System operators must have considerable training and experience before they can determine the meaning and significance of the vibration spectra they detect.

But what about the maintenance pro who isn't trained in vibration analysis? How do you tell the difference between acceptable vibration, and the kind of vibration that demands immediate attention to service or replace troubled equipment?

Fortunately, extensive experience with mechanical vibration, what it means and how to fix it is built into the advanced algorithms of today's testers. Now the maintenance professional can quickly and reliably determine the cause of the machine vibration, learn the severity and location of the problem and receive recommendations for repair. It's all done with the intelligence built into the tester, without the extensive training, monitoring and recording required for typical vibration monitoring programs.


Now Lets talk about things about thermal imaging technolgy.


About the Thermal Image Camera

Having a thermal image camera can be quite beneficial. There are a lot of individuals who are opting for thermal imaging nowadays. Thermal imaging is quite great for analysis and problem solving. The great thing about thermal image camera is that it is quite easy to carry with you and it gives great performance. This can be attributed to the fact that it produces great thermal pictures due to its high resolution thermal detectors. It can be like having a normal digital camera but with more benefits.

When you are planning to purchase your own camera that has thermal imaging one has to consider some pointers in finding a quality one. One has to look a camera that has a high resolution. It is also wise to note the pixels output of the camera. This feature is very important for the temperature ability of the camera.

Secondly, accuracy should be an important feature of your choice of camera. An accuracy of 3% to 5% is what you should look for. Another feature that should consider is its temperature range. You have to take into account the weather conditions in your area. Whether you a hot or cold climate, this can really create a problem with the pictures it will produce.

A camera that has thermal imaging is being widely used by law enforcers. It helps them detect things that are quite seen by the human eye and this is a valuable asset for the law enforcement departments. Even plumbing and pest control areas have a great use for this type of camera. It helps them detect problems where they can not quite see or is obstructed from view.

Of course, the price of a thermal imaging camera is an important factor in buying it. You can usually buy a camera that has thermal imaging at around $3000. This is the model that is being used by a lot of professionals. The more features it has would mean that it would be more expensive. The best thing to do is to do a little bit of research and do price comparisons. You can great deals and bargains if you know where to look.

Source: Zara Jones and Steve Glad

Predictive Maintenance: A Short Introduction to Thermography

To gain the maximum benefits from your investment in infrared systems, use it on critical systems that generate capacity in the plant

Thermography is a predictive maintenance (PdM) technique for monitoring the condition of plant machinery, structures and systems — not just electrical equipment. It uses instrumentation to read infrared energy emissions (surface temperature) to determine operating conditions. By detecting thermal anomalies (areas hotter or colder than they should be), an experienced technician can locate and define a multitude of incipient problems within the plant. Infrared technology works on the principle that objects having a temperature above absolute zero emit energy or radiation.

Infrared radiation is one form of emitted energy. Infrared emissions are invisible without special instrumentation. The intensity of infrared radiation from an object is a function of its surface temperature. However, measuring temperature with infrared methods is complicated, because three sources of thermal energy can be detected from any object: energy emitted from the object itself; energy reflected from the object; and energy transmitted by the object. Only emitted energy is important in a PdM program. Reflected and transmitted energies distort raw infrared data. Therefore, they must be filtered out of acquired data before meaningful analysis can be performed.

Variations in surface condition, such as paint or other protective coatings, can affect the actual emissivity factor for plant equipment. They may change, sometimes radically, both the surface temperatures and heat distribution recorded by the infrared scanner. If the technician fails to compensate this, it will be difficult, if not impossible to accurately diagnose the incipient problems. In too many cases, they will be missed and serious damage or catastrophic failure will occur.

In addition to reflected and transmitted energy, the user of thermographic techniques must consider the atmosphere between the object and the measurement instrument. Water vapor and other gases absorb infrared radiation. Airborne dust, some lighting and other variables can distort infrared radiation measurements. Because the atmospheric environment is constantly changing, using thermographic techniques requires extreme care each time data is acquired.

Most infrared monitoring systems or instruments use filters to eliminate the negative effects of atmospheric attenuation. However, the user must recognize the specific factors that will affect infrared data accuracy and apply the correct filters or other signal conditioning methods.

Collecting optics and radiation detectors are basic elements of an industrial infrared instrument. Optical systems collect radiant energy and focuses it upon a detector, which converts it into an electrical signal. The instrument’s electronics amplifies the output signal and process it into a form that can be displayed. Three general types of instruments are used for PdM: infrared thermometers or spot radiometers, line scanners and imaging systems.

Infrared thermometers

Infrared thermometers or spot radiometers provide the actual surface temperature at a single, relatively small point on a machine or surface. Point-of-use infrared thermometers are commercially available and relatively inexpensive. Their typical cost is less than $1,000.

Within a PdM program, the point-of-use infrared thermometer can be used in conjunction with many microprocessor-based vibration instruments to monitor the temperature at critical points on plant machinery or equipment. This technique is typically used to monitor bearing cap temperatures, motor winding temperatures, spot checks of process piping temperatures and similar applications. It is limited in that the temperature represents a single point on the machine or structure. However, when used in conjunction with vibration data, point-of-use infrared data can be a valuable tool.

Line scanners

Line scanners provide a single dimensional scan or line of comparative radiation. While this type of instrument provides a somewhat larger field of view (the area of machine surface), its use in PdM applications is limited.

Infrared imaging

Unlike other infrared techniques, thermal or infrared imaging provides the means to scan the infrared emissions of complete machines, processes or equipment in a very short time. Most imaging systems function much like a video camera. The user can view the thermal emission profile of a wide area simply by looking through the instrument’s optics.

Infrared imaging systems cost between $8,000 for a black and white scanner without storage capability to more than $60,000 for a microprocessor-based, color-imaging system. However, the lower-price units, which only operate in a scanner mode, are not very useful for a long-term PdM program.

Training and applications

Training is critical with the use an imaging system. The variables that can destroy thermal data accuracy and repeatability must be compensated for each time data is acquired. In addition, infrared data interpretation requires extensive training and experience.

Inclusion of thermography into a PdM program will enable you to monitor the thermal efficiency of critical process systems that rely on heat transfer or retention; electrical equipment; and other parameters that will improve both the reliability and efficiency of plant systems. It can also be used to detect problems in a variety of plant systems and equipment, including electrical switchgear, gearboxes, electrical substations, transmissions, circuit breaker panels, motors, building envelopes, bearings, steam lines and process systems that rely on heat retention or transfer.

Safety considerations

Equipment used in infrared thermography inspection is usually energized. For this reason, attention must be given to safety. These safety rules should be followed when performing infrared inspections.

• Plant safety rules must be followed.
• Because proper use of infrared imaging systems requires the technician to use a viewfinder similar to a video camera to view the machinery to be scanned, he or she is blind to the surrounding environment. Therefore, in addition to the technician, a second safety person is required to ensure safe completion.
• Notify area personnel before scanning.
• A qualified electrician should be assigned to open and close electrical panels.
• When safe and possible, equipment to be scanned should be on line and under normal load with a clear line of sight.
• Equipment having interlocked covers without an interlock defect mechanism should be shut down when allowable. If safe, the control covers should be opened and equipment restarted.

When used correctly, thermography is a valuable predictive maintenance and reliability tool. However, benefits derived are directly proportional to how widely it’s used. If it’s limited to annual surveys of roofs or quarterly inspections of electrical systems, the resultant benefits will be limited. When used to monitor critical processes or production systems regularly where surface temperature or temperature distribution indicates reliability or operating conditions, thermography can yield substantial benefits. To gain the maximum benefits from your investment in infrared systems, use it on critical systems that generate capacity in the plant.

Source: R. Keith Mobley, Contributing Editor | Plantservices.com

Predictive Maintenance Technology Using Fluke Ti25 IR Infrared Thermal Imaging Camera

The Fluke Ti25 is an industry leading infrared camera system. The Ti 25 is the ultimate tool for troubleshooting, preventive maintenance and predictive maintenance. This thermal Imager is the perfect tool to add to your problem solving arsenal. Built for tough work environments, this high performance, fully radiometric infrared camera is ideal for troubleshooting electrical installations, electro mechanical equipment, process equipment, HVAC/R equipment and others.

Companies use infrared for both predictive maintenance programs and diagnostics tools. Processing manufacturing has many pieces of equipment that can literally cost thousands of dollars every hour of downtime. With infrared companies can predict well in advance any problems that may be on the horizon. The return on investment for an infrared program is usually meet after only a few detections of potential problems.

The Fluke Ti25 features Fluke's patented IR fusion capabilities. IR fusion allows the user to blend both the infrared and visual light image. IR fusion ability allows the user to diagnose problems more effectively and efficiently. Other features include; a thermal sensitivity of just 100mk, 160x120 resolution, instant high low spot meters, sixty second voice annotation, seven different color palettes, a six hundred and ninety two degree temperature range, an industry leading two year warranty, and Smart View 2.1 software with all future upgrades of the software for free. This is all backed by Fluke's award winning customer service and un matched product durability.

Recently the Fluke Ti25 recently won an award from Plant Engineering magazine for product of the year. Different manufactures entered several different models, and the Ti25 took the award.