Process Plant Reliability through Infra Red Thermography

D.Azad1*, Dr K.Ramji2
1. Associate Professor, Department of mechanical engineering, Aditya Institute of Technology and
Management, Tekkali, A.P, India
2. Professor and Tequip Nodal Officer ,Department of mechanical engineering, A.U.C.E (A), Andhra
University, Vishakapatnam, A.P, India
*Corresponding Author: Email: [email protected] : Mobile no: 919848137045

Abstract

A high level of automation characterizes modern industries deploying complex sophisticated

machines to achieve higher productivity and profits. This is possible only by maintaining the
machines remain in operation. The cost of lost production can be extremely high when
equipment breakdown lead to unplanned stoppage of the plant. A better equipment condition
monitoring system minimizes the down time, Condition based maintenance has become
widespread as a critical element in management strategies of companies operating machinery
all over the world. The prediction of imminent faults/failures is essential in fault diagnosis of
any system. The progress on reliability improvement had been significant in the last decade,
the industries have realized the benefits of using modern technologies and data bases in their
reliability improvement programme. In the quest for early detection infrared thermography
evolved and today industries placed a great emphasis on infrared thermography and its
advancements for both health monitoring and diagnostics of machines. This paper discusses a
comprehensive view of thermographic techniques and also provides thermal images of various
equipment components in process industry are analyzed to reveal the existence and locate the
position of anomalies to achieve higher reliability

Key words: Condition based maintenance, Thermal image, Infrared Thermography, Reliability

1. INTRODUCTION
The Primitive maintenance technique is breakdown maintenance, which takes place only
at break downs. Better maintenance techniques are time based regardless of the health status of
the machine. Today, an efficient maintenance approaches such as condition based maintenance
(CBM) are being implemented by many organizations.
A CBM program mainly consists of three steps [1] [2]
1. Data acquisition - step is to collect the necessary thermal scan
2. Data processing - step is to evaluate the data to identify the problem with the machine
3. Maintenance decision making - step is to recommend efficient maintenance

The output data captured by a thermal camera is in the form of temperature values. Thermal
camera manufacturers usually have their own software to read this data and display them as a
thermal image. When converting temperature values into thermal image, a pseudo-coloring or
false-coloring technique is [3] used. The difference in temperature can be imaged and
measured using an infrared camera. The recorded visual image is a thermogram or thermal
scan. Essentially this device captures electromagnetic spectrum within infrared bands (0.78 –
1000 μm), a thermal image is a function of radiated energy of an inspected object (Kaplan,
1993) [4].The energy emitted by a surface at a given temperature is the spectral radiance and is
defined by Planck’s Law [3]. Surface temperature distribution can thus be used to detect
thermal anomalies. A thermal anomaly is defined as a thermal pattern of a surface that varies
from a uniform color or tone when viewed with an infrared imaging system.
The short wave (SW) camera is best suited for warmer objects (Maldague, 2001)[5].

There are two types of themographic methods: Active and passive thermography.

Active thermography (AT) [6].an external heat source is applied when capturing thermogram.
One common heat source is a flash lamp or pulse generator. In a normal condition, the
temperature gradient between the defective and non defective (sound) area is
undistinguishable. Immediately after applying the heat flash, the infrared thermal camera can
record the difference between these two areas.

Active thermography is divided into simple and complex. In simple AT the approach is one of
applying heat and looking for a defining delta T on the surface of a target. Complex active
thermography generally employs one or more requirements for time, intensity, sequence
synching, heat generation/application and temperature data/view in correlation with observed
Delta T’s on the target’s surface. The additional features of complex AT [7] allow its use in
material irregularities that otherwise might not be visible in simple AT. The additional features
may also provide more definition, depth and site detail.

Passive thermography (PT) [5], no external heat source is applied when capturing the
Thermogram since the temperature difference between defective and sound area is so obvious
already. Passive thermography is usually employed to a hot inspected object.

Passive Infrared thermography is one of the techniques for Condition based maintenance.
Among others, advantage of this technique lies in its contact less, large area of inspection in
less time and easy to interpret thermal image and remote inspection is possible.

Infrared Thermography has been successfully applied to the areas of mechanical [8], electrical
[9],petrochemical[10][11],building and structures[12], medical diagnosis[13], material
testing[14], Industries like paper[15], Landmine Detection[16],Steel plant[17], power
plants[18], refineries[19] etc.

2. Infra Red Thermogaphic Inspection:

IR Scan and Infrared inspection process is performed as explained in flow chart Fig 2.1
Initially a qualitative analysis carried out with the recorded thermogram, if necessary
thermograms can be compared with the available thermograms of the same equipment for a
quantitative analysis. If the problem is identified prepare the report and submit it to the PM
Planner for corrective action, otherwise arrange for rescan or other condition monitoring
techniques to identify the anomaly in the machine.
Fig 2.1: Flow Chart of IR Inspection process
3.0 Applications
In a process plants thermography can be used as a condition monitoring tool to improve the
reliability of the equipments and hence the plant. It can be applied to the following equipments
and systems illustrated with thermographs [20], [21]
1. Mechanical drive and Material handling systems
2. Pipelines and Valves Investigation
3. Electrical systems
4. Refractory and Insulation management systems
5. Fuel storage systems

3.1 Mechanical drive systems

Using infrared cameras, we can see the friction that is produced in a mechanical system. In the
case of mechanical drive systems we can identify bearing problems quickly and easily as the
bearings generate more heat as they become pitted, or when they are under-lubricated and
sometimes over-lubricated. Mechanical drive systems also produce heat from the load that is
put on them this means that trending the temperatures on a system can really benefit by
studying them in order to make repairs before they break down.
We can even see the misalignment between a pump and a motor as misalignment generates
heat in both components, thermal profile not only indicates the condition of lubrication but also
the source of temperature. By monitoring the critical mechanical drives, problems can be
identified at an early stage and hence reliability of a system can be improved.
Hot material is carried through special grade conveyors which can withstand up to 2000 C
.Improper cooling of material increases the temperature of the belt and leads to failure of the
belt. Failure rates can be minimized or eliminated by properly monitoring the belt surface
through thermography and taking corrective action
The figure – 3.1 clearly shows the temperature profile of a gear coupling, Motor bearing and
Coupling, Plummer block and Material conveying system

Gear coupling Motor bearing and Plummer block Conveyor with hot
coupling metal

Fig-3.1: Thermographs of Mechanical drive systems and Material Handling systems

3.2 Pipelines and Valves investigation
The leakage from the pipe line or valves and its insulation damage lead to not only energy
losses but also effects on system performance. Deposition in pipe lines or malfunctioning of
valves can also be monitored through thermography
The Figure –3.2 shows Leaked pipe line, Choked pipe line, Oil level in tank and properly
working steam trap valve
With the early detection and corrective action energy losses can be minimized and reliability of
the process equipments and plant can be improved

Choked Gas line Oil level in Tank Properly working

leaked pipe line
Steam trap
Figure –3.2: Thermographs of Pipelines and Valves
3.3 Electrical System
A typical electrical system consists of circuit breakers, Current Transformers, Potential
Transformers, isolators, bus bars, Power circuit of electrical drives etc. Most faults are
encountered in the form of hot-spots at contact terminals which may be due to loose contact,
corrosive nuts & bolts, broken conductor strands etc. These hot spots are indicated by high
surface temperature. Higher is the current flow, more severe is the fault. Reliability can be
0
improved by attending these fault points if the hot spot temperature is above 40 C it should be
attended immediately, otherwise close monitoring is required. Other applications are discussed
below
Good power circuit is essential to ensure proper functioning of the electrical drives.
Sometimes loose contacts at Motor Control Centers (MCC) or at terminal boxes lead to
induce high resistance in the circuit and hence voltage unbalance at the motor terminal end.
This results in malfunctioning of the motor. Sludge deposition in the transformer increases the
bottom temperature due to poor cooling.
Thermograms of various Electrical systems are illustrated in Fig 3.3

Isolator MCC Panal Fuse clips Motor terminal Transformer

Fig 3.3 Thermographs of Various Electrical systems

3.4 Refractory and Insulation system: The basic purpose of the Insulation and refractory is to
with hold the process heat. Any degradation of Insulation and refractory material will allow the
heat transfer to the outer surface, thereby increasing the surface temperature Mapping of the
whole surface gives the picture of hot-zones/spots. These hot-zones/spots may be inferred as
loss of energy, damaged or improper insulation, degradation of refractory or the leakage from
the system (Furnace, pipeline, vessel, and valves)
Thermographs of Hot metal ladle, torpodoladle, and furnaces are shown in Fig3.4

Hot spots indicate

Hot metal Ladle Torpedo Ladle Leakage from the Furnace Refractory
furnace due to cracks insulation damage
Fig: 3.4: Thermograph of Refractory and insulated systems

3.5 Fuel storage system:

The IR Image of fuel storage shows the temperatures of different zones; with this we can get an
early warning of Hazardous situations. Fig 3.5 clearly shows the temperatures of different
zones in coal yard. By monitoring the temperature trends of hot zones once it reaches threshold
value an appropriate action can be taken to prevent accidents.

Fig 3.5 Thermograph of coal storage yard

 Conclusion
Infrared or thermographic analysis provides a high-resolution, non contact means of
monitoring the condition of electrical and electromechanical equipment, Refractory
management. Thermograms are used to analyze patterns of heat gain or loss. Infrared analysis
is an effective predictive maintenance tool, because mechanical or electrical breakdowns are
often preceded or accompanied by changes in operating temperatures. This information can be
particularly important in electrical machinery where circuits and connections may show no
visible signs of deterioration before a failure. Thermographic analysis can also detect cracks or
deterioration in wall insulation or refractories, which can increase heat loss or reduce
production efficiency. Infrared scanning is nondestructive and can be performed at a distance
for machinery that is difficult or awkward to reach. Since surveys are best done while the
equipment is in operation, there is no need for machine downtime and lost production. In
addition to helping avoid costly or even catastrophic equipment failures, infrared analysis can
be used to prioritize repairs prior to planned maintenance, to evaluate completed repair work.
Condition monitoring of the equipment plays a vital role in up keeping the health and
availability in delivering the quality product /process. Infrared thermography is an essential
tool to assess the healthiness of the machine from time to time in process plants and enhances
the reliability of any process plant .

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21. Thermography images are taken from the following links.

1. www.fluke.com/Thermography
2. http://www.envisionenergy.com
3 http://www.asiapacificpartnership.org
4 http://www.electriscan.com/images

Authors profile

K. Ramji is a Professor in the Department of Mechanical Engineering, College of

Engineering,Andhra University. His areas of specialisation include spatial mechanisms,
robotics, FEM, Condition monitoring and vehicle dynamics. He is an active Researcher and
doing lot of consultancy and doing services to various government and private organisations
during the last five years. He has guided 42 ME theses related to vehicle dynamics and other
fields and has published more than 130 papers in various national and International journals
and conferences and actively doing consultancy, research and project works. He also guided
six PhDs and guiding 12 PhDs. He organised 23 national and international conferences and
workshops. In his credit, he is a Rank Holder in BE and ME and Gold Medalist in ME and
awarded 14 awards in various national and international platforms.

D.Azad is an Associate professor in the Department of Mechanical Engineering,

Aditya Institute of Technology and Management, A.P. He served for Steel and power sector for
about seven years is doing research in the area of condition monitoring .He has guided several
Thesis related to Fault diagnosis of mechanical systems