Condition Monitoring of Exhaust System Blowers Using Infrared Thermography
Condition Monitoring of Exhaust System Blowers Using Infrared Thermography
Condition Monitoring of Exhaust System Blowers Using Infrared Thermography
512 IRT
Electrical and mechanical machines are integral parts of of all machine failures occur due to bearing failures(1). Commonly
engineering plants. Machine failures can occur due to many used bearing condition monitoring techniques are vibration,
reasons. Thermal energy produced during the operation temperature, acoustic emission, sound pressure, laser and current
of all machines can be in the form of friction losses within monitoring. Sometimes, chemical analysis is also employed by
machines, energy losses within machines, as a characteristic looking at the wear debris generated from the bearing, which is
of the process media, or any combination thereof. Infrared carried by the lubricating oil.
thermography (IRT) is an ideal Non-Destructive Testing Condition monitoring(2) is the practice of obtaining the basic
(NDT) technique to investigate abnormal temperature operating characteristics from a working plant to assess its efficiency
distribution on machine surfaces, because it provides and predict its reliability. Practically every chemical and process
thermal images of a machine or component remotely. In industry employs predictive condition management to ensure the
this paper, we discuss an important application of thermal safety, reliability and also cost effectiveness of plant operation.
imaging for condition monitoring of blower bearings, shaft A wide variety of Non-Destructive Evaluation (NDE) techniques
and the motors in ventilation systems used in nuclear plant such as acoustic emission(3), vibration analysis, ferrography and
areas. Sources of abnormal temperatures are detected at the oil analysis are used to determine mechanical problems while
bearings and shaft at the impeller end of the blower of an the equipment is in operation. Infrared Thermography (IRT) is
exhaust system. Also, abnormal temperature distribution is becoming another promising technology in verifying conditions
detected in one of the belts of the pulley drive system due found with vibration and oil analysis. With thermography, we can
to over-tightening. IRT was effectively utilised to pinpoint detect whether the bearings are hot, and using vibration analysis
the sources of excessive heat in the blower and to carry out we may determine why they are hot. Thermography allows quick
imaging of machinery to determine its thermal condition. It can
necessary corrections. We demonstrate the usefulness of IRT
be used to identify and analyse thermal anomalies for condition
to detect the sources of abnormal temperatures in various
monitoring. Thermal energy is present during the operation of all
components of the blower at an early stage of impending
machines due to friction losses, energy losses, or any combination
malfunction failure that could prevent major breakdowns.
thereof. The temperature is a key parameter for monitoring the
Keywords: IRT, passive, blower, bearings, motor, shaft, belt. performance and the condition of machines and to diagnose machine
problems. The magnitude and distribution of the temperature are
1. Introduction indicators of departure from acceptable performance.
Infrared thermal imaging or infrared thermography finds
Failures of electric or mechanical machines occur due to problems extensive applications in a variety of fields of industry(4-11). The
associated with stator, rotor misalignment, overheated bearings, versatility of IRT for condition monitoring is lucidly discussed
improper lubrication and worn out components or mechanical in some of the earlier publications(15). IRT is an ideal technology
loading anomalies. It has been observed that approximately half to investigate thermal anomalies in machines because it provides
complete thermal images of a machine, or a machine component,
with no physical attachments (ie non-intrusive), requires little set-up
Dr Baldev Raj is the Distinguished Scientist and Director of Indira Gandhi and provides the results in a short time. In this paper, we discuss
Centre for Atomic Research, Kalpakkam. He is an Hon Member of ICNDT, the applications of thermal imaging for condition management of
Hon Fellow of the Indian Society for NDT, Hon Fellow of The British blower bearings, shaft and the motors in ventilation systems in a
Institute of NDT and Founder Member of the Board of Directors, World
radioactive plant.
Federation of NDE Centres, USA.
Dr T Jayakumar is the Head, Non-Destructive Evaluation Division, Indira
2. Thermal imaging – principle
Gandhi Centre for Atomic Research, Kalpakkam, India.
Corresponding author: Dr John Philip is the Head, SMART Section, Non- Infrared thermography is a method of mapping the temperature
Destructive Evaluation Division, Metallurgy and Materials Group, Indira profile of the surface of an object. It makes use of the infrared
Gandhi Centre for Atomic Research, Kalpakkam – 603 102, Tamil Nadu, spectral band of the electromagnetic spectrum emitted by the
India. Tel: 91-044-2748 0232; Fax: 91-044-2748 0356; E-mail: philip@ object. All infrared measurements are normally made in the
igcar.gov.in wavelength band of 0.75 μm-25 μm. The fundamental equations
Shri N P George is an Engineer in Charge of Ventilation Systems, Post that link the absolute temperature of the object with the intensity
Irradiation Examination Division, Indira Gandhi Centre for Atomic and wavelength of emitted radiation are given by Planck’s, Stefan
Research, Kalpakkam. Boltzmann and the Wein’s Displacement Law(12).
Dr T Saravanan is a Scientist in the Non-Destructive Evaluation Division, The energy emitted and the temperatures are related by Stefan-
Indira Gandhi Centre for Atomic Research, Kalpakkam. Boltzmann Law:
Shri S Bagavathiappan is a Scientific Assistant in the Non-Destructive W = !" T 4 . .......................................(1)
Evaluation Division, Indira Gandhi Centre for Atomic Research, where W is the radiant flux density, ε is the emissivity, σ is the
Kalpakkam. Stefan-Boltzmann constant and T is the absolute temperature.