Thermal Imaging Detects Faults Before They're a Problem
By monitoring the unique thermal signature of machines, structures and electrical panels, engineers can detect faults before they become major production issues. In addition, the cost of thermal imaging technology is coming down and it is simple and safe to use. In some cases, a company may even save money on its insurance policy, says Ian Taylor of Corus Northern Engineering Services.
Thermal imaging technology produces fast, accurate results in a real time, high resolution illustration, enabling engineers to detect problems that otherwise may be overlooked. Remedial work can therefore be carried out before costly system failures or production stoppages occur.
Ian Taylor is Business Development Engineer Plant Condition Monitoring at Corus Northern Engineering Services (CNES). He is responsible for planning all CNES’ thermal imaging services both within Corus’ own steelmaking plants in the UK and for external customers. “The great advantage with using thermal imaging technology is that it is non-invasive and can detect both hot and cold areas, enabling our technicians to evaluate the condition of structures, plant and equipment, and whether potential problems are likely to occur,” says Taylor
According to Taylor, thermography is effective across all industry sectors, helping to reduce maintenance costs and identify process improvements. “All our technicians are experienced in fault-finding techniques, so they are able to monitor a customer’s assets and machinery effectively by creating thermal patterns whilst equipment is still in operation,” he explains.
CNES has carried out thermal imaging services for a diverse range of external industry sectors, including steel, aluminium, food and beverage, aerospace, automotive, mining & quarrying, cement, pharmaceuticals, buildings, offices and airports.
Typical plant and machinery suitable for thermal imaging include electrical panels and switchgear; motor brush contact problems; high voltage distribution systems; temperature measurement of critical process components; hydraulic circuit testing; checking the mechanical condition of rotating equipment, such as pumps, motors, fans, blowers and compressors; refractory surveys; and overheated bearings.
For a typical customer, CNES will normally conduct a site survey first using handheld thermography cameras, which incorporates a built-in digital camera and customised reporting software. “We can then process trends from the information gathered, which usually illustrates the location of a fault,” says Taylor.
CNES doesn’t only monitor the condition of industrial plant and machinery. Thermal imaging techniques can also provide early warning of potential problems relating to areas such as leakages in buildings; construction faults; energy loss, room climate control; thermal insulation defects; drying of buildings; fire prevention; redevelopment; identifying mould and damp; refractory surveys; and pipe or radiator blockages.
As Taylor states: “We also carry out surveys for customers in the construction and buildings sector. Only recently, I sent some of our technicians to a local school for disabled children in the North East, whose pupils were complaining about how cold the school was.”
The buildings contractor had installed overhead/ ceiling heating systems at the school for health & safety reasons, in order that the children did not touch any hot radiators or pipes. “After conducting an initial buildings survey, our technicians discovered that the buildings contractor had not installed adequate insulation in the walls of the school. The images from the high quality thermal imaging camera that we used clearly showed us which parts of the walls had not been insulated. In addition to insulation problems at the school, we also discovered that the boiler and heating systems were inadequate. The school was then able to present our findings to the contractor and seek remedial action.”
Taylor provides one more area in which thermal imaging can help companies save money. He advises: “These days, insurance policies for business premises can be very expensive. However, often the cost of the insurance policy can be reduced if the company employs regular thermal imaging services at its premises or factory. It depends on the nature of the business, of course, but it may be worth putting the question to your insurance company to see if discounts are available for this sort of thing.”
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