Is your facility running too hot? Heat is often an early symptom of equipment damage or malfunction, making it a key performance parameter monitored in predictive maintenance (PdM) programs. Technicians who practice infrared predictive maintenance regularly check the temperature of critical equipment, allowing them to track operating conditions over time and quickly identify unusual readings for further inspection.

Remember:

» Infrared inspections of electrical/mechanical equipment detect hot spots well before problems occur!

» Inspections take less time than repairs, especially if done with an infrared camera!

By monitoring equipment performance and scheduling maintenance when needed, these facilities reduce the likelihood of unplanned downtime due to equipment failure, spend less on "reactive" maintenance fees and equipment repair costs, extend the lifespan of machine assets, and further maximize maintenance and production. To save money, predictive maintenance should not create excessive additional maintenance efforts.

The goal is to transition maintenance resources away from emergency repairs and into scheduled inspections of key equipment. Inspections take less time than repairs, especially if done with an infrared camera. An infrared camera takes non-contact, infrared temperature measurements that capture an object's temperature profile as a two-dimensional picture. Unlike an infrared thermometer, that only captures temperature at a single point; a thermal imager can capture temperature from both critical components and the entire integrated unit. Thermal imagers can also store previous and current images for comparison and upload images to a central database.

Studies by the Federal Energy Management Program (FEMP), estimate a properly functioning predictive maintenance program can provide a savings of 30% to 40% over reactive maintenance. Other independent surveys indicate that, on average, starting an industrial predictive maintenance program results in the following savings:

Return on investment: 10 times
Reduction in maintenance costs: 25% to 30%
Elimination of breakdowns: 70% to 75%
Reduction in downtime: 35% to 45%
Increase in production: 20% to 25%

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Reactive Maintenance:
Run-to-failure approach—letting a system run until something breaks. Maximum Cost !

Preventive Maintenance (PM):
Maintenance repairs performed on a regular schedule to minimize component degradation and extend the life of equipment. Preventive maintenance takes place after a set amount of elapsed calendar time or machine run time, regardless of whether the repair is necessary. While more cost-effective than reactive maintenance, preventive maintenance still requires substantial human resources and replacement parts inventories. Significant Savings !

Predictive Maintenance (PdM):
Tracking key indicators over time to predict when equipment needs repair. Predictive maintenance programs measure equipment on a regular basis, track the measurements over time, and take corrective action when measurements are about to go outside the equipment operating limits. Maximum Savings !

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Infrared thermography cameras are the first line of defense in a predictive maintenance program. Our technicians can quickly measure and compare heat signatures for each piece of equipment on the inspection route, without disrupting operations. If the temperature is markedly different from previous readings, facilities can then use other maintenance technologies—vibration, motor circuit analysis, airborne ultrasound, and lube analysis—to investigate the source of the problem and determine the next course of action.

A typical infrared scanning procedure begins with an Infrared Consultants technician and a list of all electrical and mechanical equipment to be inspected. After obtaining familiarity with the facility, our experienced technician is able to inspect and record the condition of these vital components in a timely fashion. A significant advantage in using thermography is that all inspections are done while the equipment is energized so that continuity of power is maintained.

1. Begin by using compiling a list of equipment to be inspected.
2. Eliminate items that are not well suited for infrared measurement.
3. Review maintenance and production records. Prioritize key equipment prone to failure or causes production bottlenecks.
4. Use thermal imager to capture baseline images of each piece of critical equipment.
5. When the next inspection is due, we then compare images from previous inspection.
6. A report is generated identifying potential system failures.

Let Infrared Consultants set up your Predictive Maintenance (PdM) program today. Our ASNT Certified Level III thermographers can develop a program that will fit your specific needs. Infrared Consultants uses only high-resolution FLIR equipment that allows us to identify even the slightest deficiencies.

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