Christiaan Maras

Marketing Director EMEA & APAC

FLIR Commercial Systems

Belgium

Without predictive maintenance inspection companies are forced to use a method called preventive maintenance. This means that every piece of equipment is replaces at regular intervals to prevent breakdowns. In many cases however, equipment is replaced too early, just to be on the safe side.

Thermal imaging cameras are increasingly used in industrial environments for predictive maintenance inspections and it is the fastest growing predictive maintenance technology on the market today. Inspections using thermal imaging technology can accurately determine whether a piece of equipment needs to be replaced or not. This is important information for companies to guarantee the continuity of production without unnecessary equipment replacements, leading to cost savings of thousands of Euros.

However, for maximum effect it is important to combine several technologies: vibration analysis, ultrasonic tests, oil analysis and inspections using thermal imaging cameras. The main advantage of thermal imaging is that you can locate mechanical and electrical problems very quickly and accurately and you will be able to see immediately which component is causing the problem.

Thermal Imaging Speeds up Inspection

Thermal imaging cameras are also crucial to allow swift inspections. In some cases there are simply too many pieces of equipment or equipment components to test using vibration analysis or other methods. If a production plant features a row of conveyors, the fact that you can walk along this row of conveyors and swiftly scan them with the thermal imaging camera is a major time-saver. The same goes for electrical equipment, if you are inspecting an electrical cabinet with thirty fuses you don’t want to go and check each individual fuse using a spot pyrometer to find out which one is going to fail first. For some types of equipment thermal imaging this really is the only technology you can use. For instance, with refractory linings thermal imaging cameras are the only practical condition-monitoring tool available today.

Gunther Willems, Technology Manager of one of Europe’s largest condition monitoring consultancy agencies – Coservices, part of GP Allied’s reliability group – describes that the most important feature of thermal imaging cameras is the ergonomic design. “If you use a piece of equipment as often as we do, the ergonomics and ease of use of thermal imaging cameras are crucial.

The thermal images shows clearly that the middle roller bearing is overheated and should be replaced.

Another important factor is interchangeable optics because it is very difficult to do everything with just one lens. Sometimes there is not enough room to take a step back to capture a piece of machinery in one image, so you need to change to a 90° wide-angle lens. In other cases you cannot get close enough due to safety hazards and you need to switch to a 7° telephoto lens. Being able to make these switches in lens gives the operator much more flexibility.”

The Importance of Training and Software

The fact that thermal imaging technology is visible and intuitive makes it very easy to learn for new employees. However, the fact that thermal imaging cameras are so easy to use can also be quite deceptive. One might think that it is just a matter of pointing the camera and pressing the right button, but it is very important that you really know what you are doing.

For example you need to know how to accurately correct for emissivity and reflection, otherwise you might draw false conclusions. Another important factor in the use of thermal imaging cameras is the software. The reports produced are of vital importance and compatibility of the reporting software with Microsoft Office is an important bonus.

This electric motor is overheated and needs to be inspected and repaired before a failure occurs.

The thermal image shows faulty pipework insulation. This can disrupt the production process and cause dangerous accidents.

If you are inspecting an electrical cabinet with thirty fuses, you don’t want to go and check each individual fuse using a spot pyrometer to find out which one is going to fail first.

The refractory on this ladle shows signs of wear and if it degenerates further needs to be replaced. Thermal imaging cameras are the only practical tool available for refractory inspections.