In the global competition for market shares, companies
depend on efficient manufacturing processes and machines that run reliably.
Service engineers play a key role in this: they bear the responsibility for
ensuring the permanent availability of production facilities. To them,
thermography is a valuable diagnostic tool.
Problems with electrical and mechanical installations
usually become evident at an early stage due to thermal irregularities. Thermal imagers visualize
status changes and weak spots – and they do this in a non-contact,
non-destructive manner. The next few pages outline how thermal imagers from
Testo can help you to perform typical preventive maintenance tasks more
reliably, easily and safely.
The challenge
Maintenance was previously considered to be purely a tool
for rectifying faults. These days, it is seen as a preventive maintenance
service which ensures the permanent availability of production facilities and
plays a vital role in the competitiveness of industrial companies. Every day,
specialist personnel are at the forefront of the struggle to minimize
down times, prevent damage to mechanical and electrical components, fully
exploit the level of equipment utilization, and as a result also reduce
maintenance costs. Since production usually focuses on a small number of
machines or automated systems, when these are shut down this often has
far-reaching consequences: one leaky valve can spoil the entire batch, a
machine fire could end up jeopardising your company's million euro contract, or
your company's fire insurance may threaten higher premiums as an additional
penalty. Large-scale damage may result in the plant shutting down. One out of
three fires in industrial companies can be attributed to electrical components
overheating, with minor defects such as loose terminals or damaged cables often
the cause.
Fault-free plant status also guarantees safety in the
workplace. There is additional pressure from national and international legislation,
as well as the standards of employers' liability insurance associations or
trade associations. These are all in place for your own safety, since
work-related accidents are more likely to occur in maintenance than in
production, despite the lower number of employees. Lastly, all inspections need
to be documented, and your supervisor expects a complete, technically accurate
report. Thermography is a safe, efficient and simple measuring technique for these typical
industrial tasks.
The solution
Thermal imagers convert thermal radiation in the infrared
range into electrical signals and make them visible. This extension of the
range and function of human vision by means of the thermal image is akin to a
sixth sense, which service engineers can use to detect concealed defects and
anomalies before they turn into proper malfunctions and endanger system
availability.
Versatile and
flexible
In electrical
installations, thermographic measurement methods are possible at all voltage levels. This means that
entire switch cabinets, not to mention medium, high and ultra-high voltage
installations, can be inspected efficiently and in compliance with the
necessary safety clearance. Carrying out thermographic inspection for just a second time reduces a system's rate of failure by 80
% and provides an added safeguard against fire. Even before damage occurs, the
thermal image provides information about the operating status of mechanical
assemblies. Motors, gears, couplings or bearings can be examined individually
or as a functional unit. Thermal imagers can be used for precise temperature measurements even on complex aggregates, containers for liquids and gases,
turbines or filters. You can use thermography to inspect insulation, and also
to detect internal deposits in pipelines and containers.
Safe and non-contact
A thermal imager can be used to examine live components or
moving parts from a safe distance. This means that thermography can be used to
monitor even difficult to access areas safely and accurately. This increases
occupational safety and allows inspections which were previously only possible
through investing considerable effort – by shutting down machines or
disconnecting electrical installations. The examination also reveals the
thermal behavior under full load. Problematic areas are clearly indicated on a
display. This allows the on-site service engineer to detect and eliminate
sources of error at the very moment that these crop up. Using a pyrometer could
cause the service engineer to miss these crucial details. In addition,
thermograms facilitate clear error documentation and long-term time series
comparison of system status. The software can be used to analyze the images
quickly and easily, and summaries all work in a report. This reduces tedious
paperwork.
Place your trust in
the global market leader
Testo AG is one of the world's leading manufacturers of
portable, innovative measuring instruments and thermal imagers. With an
infrared resolution of 320 × 240 pixels, thetesto 885 professional thermal imager is the flagship instrument for
universal applications. The testo 890 high end system's 640 × 480 pixel
detector will satisfy even the most demanding of requirements.
Most associations recommend detector sizes of at least 320 ×
240 pixels for applications in industrial thermography. Testo Super Resolution
improves the quality of each recorded infrared image, making it a cut above the
rest: the patent-pending technology produces four times as many readings and a
usable geometric resolution that is 1.6 times higher. testo Site Recognition
facilitates repeated thermal imaging of similar measurement objects: The
function's immediate measuring location detection and automatic thermal image
assignment enable efficient inspection route management. The ergonomic
camcorder design and extra features such as the lens protection glass ensure
safe handling in tough industrial environments.
Key advantages of
thermography
•
Safety during measurement, precision and
reliability of measurement results
•
Visualise load changes over the course of time,
preventing system breakdowns
•
Cost and time efficiency
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