1 Brendan Campbell Predictive maintenance using thermography in industrial environments and the effect on revenue protection

2 Brendan Campbell What do we know about temperature? Most frequently made measurement °C,°F and KMost frequently made measurement °C,°F and K Key condition indicatorKey condition indicator Can be used to determine state of health of equipmentCan be used to determine state of health of equipment

3 Brendan Campbell Developments in scheduled maintenance

4 Brendan Campbell Industry trends Growing concern for personal safetyGrowing concern for personal safety Increased attention for power related issuesIncreased attention for power related issues Shift from reactive maintenance to preventive maintenanceShift from reactive maintenance to preventive maintenance

5 Brendan Campbell Economics: Cost savings Half of the electrical failures could be prevented with regular maintenanceHalf of the electrical failures could be prevented with regular maintenance Unplanned downtime due to equipment failure costs manufactures up to 3% of their revenueUnplanned downtime due to equipment failure costs manufactures up to 3% of their revenue Predictive maintenance can save 6-12% over reactive maintenancePredictive maintenance can save 6-12% over reactive maintenance

6 Brendan Campbell Types of maintenance Reactive maintenance repair it when it failsReactive maintenance repair it when it fails run to failure maintenance Preventive maintenance Maintenance at regular intervalsPreventive maintenance Maintenance at regular intervals Predictive maintenance problem detected before failure, maintenance planned aheadPredictive maintenance problem detected before failure, maintenance planned ahead Break-down Time Cost Time Cost Time Cost

7 Brendan Campbell Reactive Maintenance Break-down Maintenance Reactive maintenance leads to: Secondary damageSecondary damage Safety riskSafety risk Unplanned downtimeUnplanned downtime Unplanned maintenanceUnplanned maintenance Product wasteProduct waste Spares inventorySpares inventory Time Cost Not recommended for critical equipment Break-down

8 Brendan Campbell Preventive Maintenance Time-based maintenance Time based maintenance involves: More frequent overhaulsMore frequent overhauls Risk of early failuresRisk of early failures Tampering with good equipmentTampering with good equipment Time consuming overhaulsTime consuming overhauls Experts needed for each overhaulExperts needed for each overhaul Time Cost Not recommended for critical equipment

9 Brendan Campbell Bath tub curve Detect early defectsDetect early defects Prolong life time of equipmentProlong life time of equipment Prevent costly aging failuresPrevent costly aging failures

10 Brendan Campbell Predictive Maintenance Condition based maintenance Monitor the condition of the equipment and predict when it would failMonitor the condition of the equipment and predict when it would fail Plan maintenance ahead of time and save moneyPlan maintenance ahead of time and save money Repair the equipment only when it needs to be repairedRepair the equipment only when it needs to be repaired Focus overhauls only on faulty partsFocus overhauls only on faulty parts Higher plant availability, performance and reliability Greater safety Better product quality Longer equipment life Greater cost effectiveness Time Cost Break-down Recommended for critical machines

11 Brendan Campbell Predictive maintenance procedures InspectionsInspections requires site knowledge requires site knowledge Requires inspection tools and instruments Requires inspection tools and instruments AdjustmentsAdjustments TestingTesting CalibrationsCalibrations RebuildsRebuilds ReplacementsReplacements A list of tools, parts or instruments required for predictive maintenance A form in case of taking measurements or readings On this form include a limit or range of values for indicating normal/abnormal readings Safety considerations should be listed, such as lock out or hot work procedures

12 Brendan Campbell Measurements Insulation resistance of cables and motorsInsulation resistance of cables and motors Temperature of motor housings and hot spots of electrical panelsTemperature of motor housings and hot spots of electrical panels Voltage stability of variable speed drivesVoltage stability of variable speed drives Resistance of connectionsResistance of connections Harmonics and unbalance of phases on motors, pumps, fans, coolers etc.Harmonics and unbalance of phases on motors, pumps, fans, coolers etc. And if you don’t document it you didn’t do it!And if you don’t document it you didn’t do it!

13 Brendan Campbell Thermography Thermography is a non contact technology that measures infra red wavelengths to determine an object’s thermal radiation distribution at a safe distance and in real timeThermography is a non contact technology that measures infra red wavelengths to determine an object’s thermal radiation distribution at a safe distance and in real time We are measuring the thermal representation of an object as well as 1000’s of temperature points in real timeWe are measuring the thermal representation of an object as well as 1000’s of temperature points in real time Thermal images can be taken while production is running without any contact  safe!Thermal images can be taken while production is running without any contact  safe! Analysis requires some IR knowledge about IR principlesAnalysis requires some IR knowledge about IR principles

14 Brendan Campbell It is easy to understand the IR image… ΔTΔT

15 Brendan Campbell Electromagnetic Spectrum Gamma X rays UVVisible InfraredMicrowaves Radio Short Wave IR Long Wave IR Wavelength in Microns Near IR

16 Brendan Campbell Predictive Maintenance ApplicationsPredictive Maintenance Applications Electrical applications Electrical applications Mechanical applications Mechanical applications Process Process Building Building Medical Medical Common thermography applications

17 Brendan Campbell Electrical connections The temperature readouts show that connections on both phases A and B on this main lighting disconnect are hot, suggesting an unbalanced loadThe temperature readouts show that connections on both phases A and B on this main lighting disconnect are hot, suggesting an unbalanced load

18 Brendan Campbell Predictive maintenance Electrical inspections As a rule, during an electrical inspection the load should be at least 40% of max load, for at least the last ½ hour!As a rule, during an electrical inspection the load should be at least 40% of max load, for at least the last ½ hour! Never make an electrical inspection with loads under 20%!Never make an electrical inspection with loads under 20%! If the load changes rapidly check the average load in the last 2 hours!If the load changes rapidly check the average load in the last 2 hours!

19 Brendan Campbell Maintenance routing The primary criteria that should be considered when developing routes are:The primary criteria that should be considered when developing routes are: Travel TimeTravel Time Logical sequence of inspectionLogical sequence of inspection SafetySafety Criticality of machineCriticality of machine

20 Brendan Campbell Maintenance routing

21 Brendan Campbell Location NameLocation Name CommentsComments Low and High AlarmLow and High Alarm EmissivityEmissivity RTCRTC Specify route-data

22 Brendan Campbell Take new pictures and compare to see if composition and distance etc is the same Load route into imager Upload new data to PC Inspection Routing

23 Brendan Campbell Thank you