Applications of thermography in predictive maintenance

The generation and distribution of heat provide crucial information about the performance or any anomaly present in the operation of various industrial equipment. For this reason, temperature is a fundamental variable for monitoring and predicting the behavior and physical condition of these assets, allowing maintenance to be planned at the most appropriate time.

To achieve this, non-destructive analysis tools and techniques are used to detect anomalies and potential defects in equipment and processes to reduce downtime and operating costs by anticipating failures before they occur. Among these tools is thermography, an efficient and non-invasive method of identifying problems by monitoring temperature distribution.

Understanding predictive maintenance

Predictive maintenance is based on continuous monitoring of equipment conditions during regular operation to detect potential failures and schedule maintenance activities accordingly. The primary goal of predictive maintenance is to improve equipment reliability and efficiency, minimize unexpected downtime, and extend equipment life. By leveraging advanced data and technologies, predictive maintenance enables organizations to make informed decisions, optimize resource allocation, and improve overall operational performance.

Implementation of infrared thermography in Non-Destructive Testing

Thermography is a non-destructive testing method that uses infrared radiation and generates representative images of the distribution of temperatures on the surface of the asset under study. Through a non-destructive analysis, these variations can indicate problems or anomalies associated with overheating, external insulation or internal refractory problems, electrical failures, and mechanical wear, among others.

This technique is significant in predictive maintenance because it provides a non-destructive, non-invasive means of analysis to assess the condition of equipment. Identifying anomalies in temperature patterns helps detect potential issues early, allowing timely intervention to prevent costly failures.

Benefits of thermography

Early detection of problems

Thermography can detect and identify abnormal heat patterns through non-destructive analysis. This can reveal problems before they cause equipment failure or breakdown. Early detection allows maintenance personnel to address problems, reducing the risk of unexpected downtime and costly repairs.

Non-destructive and non-intrusive method

It is a non-destructive testing method and simultaneously a predictive maintenance technique. This feature allows continuous monitoring and analysis without interrupting normal operations. In addition, thermographic inspections can be performed from a safe distance, reducing the need for direct contact with hazardous equipment.

Complete inspections

Thermal imaging cameras are particularly useful in complex industrial environments where it is essential to identify issues in various systems and components. Through non-destructive analysis, thermography allows maintenance teams to prioritize inspections and focus on areas requiring immediate attention.

Cost savings

Detecting and addressing problems early avoids costly unplanned downtime, reduces the frequency of major repairs, and extends the life of critical equipment. Additionally, thermographic inspections improve maintenance schedules, allocating resources efficiently and minimizing unnecessary maintenance activities.

Thermography applications in predictive maintenance

●     Electrical systems: Thermography is very effective in identifying abnormal heat patterns in electrical components, even in small deviations or changes, allowing maintenance teams to address problems before they escalate.

●     Mechanical systems: Excessive friction, misalignment, and lubrication problems can cause abnormal heat generation, leading to mechanical failures. These heat patterns can be detected by thermography, allowing maintenance teams to perform targeted interventions.

●     Combustion furnaces: The application of thermography is essential to externally monitor the firebox walls, anticipate damage to the internal refractory, and monitor the tubes inside the furnace to detect localized internal coking or poor heat distribution.

●     Building and facility maintenance: By detecting temperature variations in walls, ceilings, and HVAC systems, infrared thermography helps optimize energy efficiency, prevent structural damage, and ensure occupant comfort.

●     Process monitoring: Monitoring the temperature of different process components, such as boilers, heat exchangers, and piping, ensures their ideal operation within safe and efficient parameters. In addition, thermography can detect obstructions in pipes, valve failures, and detachment of internal refractory in pipes and pressure vessels, among others.

Considerations for Implementing Thermography in Predictive Maintenance

Selecting the Right Equipment

Selecting the right thermal imaging equipment is critical for accurate and reliable inspections. Key factors include camera resolution, temperature range, field of view, wave type, and sensitivity. High-resolution and higher-sensitivity cameras allow early detection of details and variations. The appropriate field of view varies with the working distance: wide angle for close-ups and telephoto for long distances. The type of wave varies with the application: short wave for furnaces, medium wave for flammable gases, and long wave for outdoor surfaces. Finally, sensitivity is essential to detect small temperature changes that can indicate problems in the early stages.

Training and certification

Proper training and certification are essential for personnel performing thermographic inspections, ensuring the competence and reliability of the results. Certification programs, such as those offered by the Infrared Training Center (ITC) and the American Society for Non-Destructive Testing (ASNT), ensure that technicians possess the necessary skills and knowledge to perform correct inspections.

Inspection programs

Thermographic inspections should be executed through an inspection plan with the appropriate frequency for each component. The frequency of such inspections will depend on a number of factors such as equipment criticality, operating conditions, and historical data. Regular inspections help to track temperature trends over time.

Data Analysis and Reporting

Effective thermography data analysis and reporting are essential to maximize inspection results. Advanced software tools make it easy to identify trends and generate actionable information, while detailed and clear reports, including thermograms and recommendations, are critical for decision-making. Integrating thermography with other predictive technologies, such as vibration, ultrasonic, and oil analysis, improves the accuracy and reliability of predictive maintenance, enabling more informed decisions and optimized maintenance strategies.

Thermography is an essential tool in predictive maintenance due to its ability to provide non-destructive and non-invasive analysis of the condition of industrial equipment. By generating images of the temperature distribution on the surface of equipment, it enables the detection of anomalies and potential problems at an early stage, which is crucial to avoid costly failures and unexpected downtime. Thermography facilitates complete and safe inspections from a distance, without interrupting normal operations.

Its integration with other predictive maintenance technologies, such as vibration and ultrasound analysis, significantly improves the accuracy and reliability of maintenance programs, enabling more informed decision-making and optimized maintenance strategies.