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Abstract
A project on industrial applications of thermal imaging was completed to fulfill the requirements of NAIT’s IET 490 Technical report. This research-based project explains the industrial use of the thermal imaging technique to get beforehand information about the working condition of various components and equipment. The information and data can be used to develop a plan to address the problems foreseen before some breakdown occurs, and therefore, sudden damages can be avoided. This project deliberates on how thermal imaging has been put into practice in various industries. Moreover, the paper also looks into the importance of thermal to the industries that use them and to the extent to which thermal imaging has revolutionized progressed firms. Features of thermal imaging cameras from renowned manufacturers have been discussed, and a comparison has been given. It is very interesting to know that the infrared light emitted by objects conveys some meaningful messages that can be used to increase the life span of the objects and the system to which they belong. The implementation of this kind of innovative technology in the industry requires time, but it will increase productivity and enhance sustainability.
Introduction
Thermal imaging is a peculiar character of photography that encompasses many habits. The use of thermal imaging has tremendously changed the mode of operations in the various firms that use thermal imaging. However, many people are not conversant with thermal imaging and the impact that it has on companies.
Thermal imaging is the detection of surface temperatures by capturing the emitted infrared radiation. In other words, Thermal imaging is the mean by which humans enable themselves to see in the infrared portion of the spectrum of light, a type of infrared-imaging science, also known as Thermography or Infrared Thermography.
Problem
How do we identify problems within the electrical or mechanical distribution systems, and how can we detect a fault before it is too late? It is obvious that the person responsible for the general predictive maintenance of a company faces various challenges. How can you tell when equipment or a component is about to fail? Many firms face a challenge when the management cannot realize certain problems on time that eventually cause a mess in the company.
Purpose
Many companies have shifted to the use of thermal imaging to enhance their efficiency. Therefore, this paper states how various companies are using thermal imaging in solving their day-to-day challenges. Moreover, this report explains how predictive maintenance inspection has been made possible using thermal imaging.
The purpose of this technical report is to discuss thermal imaging as a solution to the problems faced by many industries. Further, the project deliberates on how the use of thermal imaging has transformed projecting preservation checkup programs in all types of firms. Thermal imaging cameras, their manufacturers, suppliers, and their use for different industries have also been discussed.
How thermal cameras work
To observe a change in temperature, thermal imaging cameras are adjusted within the required temperature ranges. When the camera is set with the automatic viewing mode, the camera will adjust to any temperature ranges depending on the object under vision. On the other hand, the camera will be under control when using manual mode.
Infrared Cameras
Thermal imaging cameras are special design cameras that capture infrared energy rather than visible light. They detect elevated temperatures and then assign colors to certain temperatures allowing users to see the variation in temperature throughout the image (Kruse, 2001). Finally, the picture is then transferred to the computer using preferred devices like flash disks or USB cables. Research has been done to determine how infrared thermometers measure the changes in temperature without coming in contact with any object. This has been easy because infrared thermometers have emissivity settings. This non-contact function makes these cameras a useful tool in a hazardous environment.
An infrared camera can also have the following functions:
- Historical records.
- Temperature trends by area.
- Events log.
Infrared Cameras (Continued)
- Sound and visual alarms.
- Malfunction reporting.
- Communication with plant DCS.
Industrial Use
In essence, all the industries have opted to use thermal imaging, as it is the best method for predicting future maintenance inspection.
The main use of thermal imaging cameras in industries is to observe the changes in temperatures on the entire surface of the machine. This is possible because thermal imaging scans and visualizes the temperature changes on the objects. Thermal measurements can be useful in predictive maintenance, where elevated temperatures can be early indicators of future problems (Williams, 2009).
Process Industry
Process industries such as oil refineries, gas processing plants, chemical and petro-chemical plants, and fertilizer plants consist of systems that have many electrical and mechanical equipment which are in continuous operation. Breakdown or failure of any of the critical components of the system may cause a big loss in production and complete or partial shutdowns, which can be avoided if these components are continuously monitored and maintained. Thermal imaging cameras are used frequently for this purpose to monitor these systems and detect any abnormalities in the system. Thermal imaging cameras are also used throughout in process industry to correct spot leaks in tanks, vessels, valves, pipe joints, pipelines, and other components of the facility. These leaks can be hazardous and may cause a fire. Once identified, these leaks are addressed before they become disastrous. Therefore, thermal imaging improves plant safety, profitability, helps reduce emissions. This way, they reduce the risk of business interruption due to actions from regulatory agencies.
Utility Industries
The use of thermal imaging in utility industries has reduced the level of errors hence minimizing the chances of failing. For this reason, infrared thermography has remained the preferred way of performing predictions on the maintenance of programs in the entire globe. In utility industries, the use of thermal imaging takes control of all operations. The industry has realized that the use of thermal imaging saves on unnecessary expenses like generating, distributing, and transferring power. Thermal imaging is able to detect errors in the system at early stages hence ensuring accuracy.
Viewing microscopic particles
Thermal imaging cameras have high-resolution power that enables them to magnify tiny particles in the system. Thermal imaging cameras view not only the smaller particles but also recognize any slight change in temperature. For instance, Thermografisch & Adviesbureau Uden BV company uses FLIRP640 thermal imaging cameras to detect small particles and changes in temperatures because it has high-resolution power. In addition, FLIR P640’s cameras enable one to share a portrait with another party. For this reason, most companies are able to maintain their customers by updating their customers. Thermal imaging is also applicable in making Videos that can be generated within a short period in a company.
Manufacturing firms
Most manufacturing firms use thermal imaging to ensure that they produce quality products to increase their profit margin. Moreover, manufacturing firms employ the use of thermal imaging to maintain their customers. Thermal imaging ensures that the machines used for production are in good conditions all the time for the efficient flow of production. When the parts of machines like bearings and switchgear become faulty, the cost of production becomes expensive for the firms. One of the advanced technologies used to check the machines while performing the production process is the use of Infrared thermography. When the surfaces release heat energy, the industries use thermal images to check on the amount of heat released on the ground and determine whether the machines are in their normal conditions. For instance, Wahl is one of the companies that employ the use of thermal imaging to inspect their machines. One advantage of these thermal images is that they are cheap and easy to use since they require no advanced knowledge. Wahl Company uses images at the cost of $2500. Therefore, thermal imaging has replaced the original traditional methods of maintaining the machines in manufacturing industries because of the advantages they have over dilapidated and dubious methods. The photograph below shows how thermal imaging detects the amount of temperature released on the ground to determine which quality of the shoes suits the ground (Stevens, & ShowMeHow Videos, 2007).
Automation
In industrial automation, thermal imaging is used for “Radiometric Assessments” to verify the temperature of electrical and mechanical components. Bad connections or components with high temperatures would show up as clear hot spots in the image. An infrared camera is used in difficult-to-reach hazardous locations, thus making the use of thermal imaging highly significant to an automation industry.
Electrical equipment
Many manufacturing industries have opted for the use of Dayton Thermal Imaging for monitoring electricity and controlling the state of the system. This is possible because thermal imaging can provide substantial details concerning the machines used for electricity (Kaplan, 2007). Further, other areas where thermal imaging can perform accurately include making fuses, wiring, and the manufacture of cables. Moreover, other heavy machines like transformers can be inspected using thermal imaging. What makes thermal imaging a preferred method for maintenance is that thermal imaging helps the directors to foresee any challenges that may affect the operations of the system. Therefore, thermal imaging ensures that there is no wastage of time and money in the production process. The assessment of aspects like power distribution, the general performance of a substation, among others, are examples of components that thermal imaging has enhanced their efficiency (Mikla, & Mikla, 2011). That is, breaker panels, location of inductive heating caused by phase separation; are some most common examples.
The above thermogram is an example of an electrical fuse that has turned faulty. The fuse block on the left shows a high temperature ranging (70 to 80 degrees C).
Mechanical equipment
In essence, most of the operations in mechanical industries produce thermal energy. It is obvious that the presence of heat in the operations is a likely indication of loss in the system that increases the cost of production. This lowers the profit margin of any company. In addition, thermal imaging can also be used in gasoline and diesel engines, heat exchangers, among others.
The producers and distributors
Fluke
Fluke Corporation is the world leader in the manufacture, distribution and inspection, and repair of electronic test instruments and software. Since the introduction of Fluke in 1948, there has been tremendous progress in technological advancement. In addition, the emergence of Fluke has helped in the correction of errors and provision of a solution to production problems hence ensuring the flow of production. This has led to massive production in most of the manufacturing firms.
FLIR Infrared Camera Systems
FLIR thermal imagers provide thermal imaging at a lower price. Moreover, they also give out well-integrated thermal and evaluation of their components in terms of efficiency and accuracy. Other services include quality assurance, safety applications, and more. The advantage of infrared cameras is that they are able to sense very low temperatures and high temperatures in all conditions. They are not affected by environmental changes like the presence of smoke, steam, or fog (Exx-Series & Exx-Series bx Infrared Cameras | FLIR Systems, 2011).
Telops
Telops Inc., located in Quebec City, operates in the optical sphere. In research and developed function, telops are major tools in developing optical systems to give a definite response as per the user’s desires. The infrared cameras from telops are considered to be of the highest quality, suitable for use in many firms.
Fluke
Performance Series
The quality pictures provided a camera fitted with infrared of the performance high and cheaper costs series. Its performance is 84%, which is more efficient than spatial resolution and has over 30% bigger screen. The numbers of images you can view at a longer distance are more. It has the capability of providing more details and options for topic suggestions to the user. The model has standardized components as a flute, a detachable SD card, a battery that has an LED charger, a rugged device robust hand strap that is modifiable, and interfaces that are flexible and simple to use.
Professional Series
The camera with infrared of professional series gives a sharp, comprehensive image that is of higher quality compared with other ordinary infrared cameras. It gives focus with high swiftness and precision on a target object despite the obstacle on your vision with laser. This device has compact parts such as a flute, improved documentation, and features. Every model arrives complete, including all connections, comprehensive documentation, quality touch screen for accuracy, and time-saving. Another strength is that it can work to give measurement at a very high temperature of about 1200o C. the device has extra capacity to give voluntary telephoto and even larger angle of lens for more detail from the wide-angle lens for extra detail from close or farther.
Series Expert
This model of the camera provides the best presentation of the focus experience. The camera has the ability to create images with more details. The Expert Series camera model has a high premium focus experience. It makes hard shots within simplicity and gives fast identification of the issues on the big screen of about 5.6 inches. The device measures a high temperature of about 1200o C, and the standard option of 2000o C. it has a flute connect as a component. The temperature option is adjustable. These additional components give improved focus that is consistent for sharp images and Laser-sharp Auto Focus. It comes with a manual, together with multifocal, that produces a sharp focus on recording.
FLIR
FLIR I-Series
This kind of device has a high-performance capacity. Its quality of performance is more than basic. The up-graded i-series The FLIR I-Series is far from basic. For contingency, FLIR’s upgraded i-Series provides an infrared camera with more working value with a line that gives options and strong alternatives. A camera of this kind gives your better-detailed option to the image on the focus of your desires. An improved FLIR i7 has a better thermal resolution higher performance. It is 36% superior and field of view of 29° wider, which is clearer and scan faster compared to the previous one. These series have advantages as they help in immediate problem detections and offer the right resolution. FLIR i-Series are more efficient in their performance. The FLIR Series have the capability to audit energy, identify damages by moisture, and look for overburdening of electricity. Various types of FLIRs are helpful in a number of ways. For instance, to perform the assessment of energy and identification of damages caused by warmth, i3, i5, and i7 are the preferred FLIRs. They find and remove any error that might be in the system to enhance production. This has assisted many industries in maintaining their systems to improve their productivity.
FLIR E-Series
Most of the companies prefer using these series because they are efficient in the correction of errors and make the distribution of images easier. These attributes are a new collection of imaging, communiqué, and efficiency tools to assist in getting additional duties done in a specific time. These models are capable of linking smartphones and tablets together using the application of Wi-Fi. E-Series are able to do live streaming of thermal video for the audience to watch over a long distance. It offers the power to import images of Joint Photographic expert groups with radiometric. It regulates contrast and color, inserts more dimension tools, and then wraps up photos in succinct reports so that you are able to send over the emails to the audience for response and get information to make valid decision email discoveries right from the ground to accelerate critical verdicts.
FLIR T-Series
With FLIR T-Series thermal imaging cameras, you are able to troubleshoot then give a report over the problem in equipment with immediate effect. These devices can allow you to detect the invisible heading through electrical resistance (Spencer, 2003). You can also detect the mechanical breakdown much faster to reduce the heavy loss that may result if the problem goes undetected for a long time. This can also help to avoid potential risks. The FLIR T-Series cameras are extremely flexible. You very easily use them to aim and focus, as they are simple to use. The models have additional features such as rotating blocks that run for 120 degrees, the screen orientation that data to picture or landscape. These give the fastest focus. It also has autofocus, manual that is controllable to give accuracy on imaging.
Compare / Contrast
As highlighted in the essay, thermal imaging has various applications because of many reasons. Despite the advantages that surpass other cameras, thermal imaging has some limitations. For instance, thermal imaging cannot be used on glass surfaces since it cannot magnify any particle across the glass. Instead, thermal imaging reflects the images on the glass surfaces. For example, a person may see a reflection of his own image while standing in front of thermal imaging glasses. Another limitation of thermal imaging is that their cameras cannot penetrate through the walls.
Therefore, thermal imaging cannot be used as the final error detector. Other methods like the use of millimeters and blueprints can be used in place of thermal imaging to confirm an error-free system.
Conclusion
In conclusion, this technology has wide coverage on different applications. The work will dwell majorly on the thermal imaging cameras, which are coming on the invention. The work will start with the analysis of the existing applications. The existing application has provided the privilege to understand emerging technology. It is notable that the existing application that has to happen over the years gave people some joy, as they could be able to get quality performance in comparison. However, this was only possible with those with huge money to spend on the technology. Modern applications and innovation are continuous processes that will influence the choice of people with time. The aim of the new technology is to increase security and superiority. The innovators should dramatically maneuver over these challenges to cope up with the demand of the users. It is notable that thermal imaging and relating innovation are there forever. However, as time goes by, the cost will continue to come down. The camera will be a more creative and standardized industry. Certainly, thermal imaging cameras will continue to emulate production in other industries. The device will be more compact, image excellence will even further advancement, and more facial appearance will be incorporated in the thermal cameras.
References
Exx-Series & Exx-Series bx Infrared Cameras | FLIR Systems. (2011). Web.
Kaplan, H. (2007). Practical applications of infrared thermal sensing and imaging equipment. Bellingham, WA: SPIE Press.
Kruse, P. W. (2001). Uncooled thermal imaging: Arrays, systems, and applications. Bellingham, Wash.: SPIE Press.
Mikla, V. I., & Mikla, V. V. (2011). Imaging applications of amorphous chalcogenides. Berlin: Springer.
Spencer, J. W. (2003). Gas discharges and thermal imaging. Bradford, England: Emerald Group Pub.
Stevens, S. T., & ShowMeHow Videos. (2007). Thermal imaging fundamentals. United States: ShowMeHow Videos.
Williams, T. L. (2009). Thermal imaging cameras: Characteristics and performance. Boca Raton: CRC Press.
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