Mechanical Installations

In many industries, mechanical systems serve as the backbone

of operations.

Thermal data collected with a thermal imaging camera can be

an invaluable source of complimentary information to vibration

studies in mechanical equipment monitoring.

Mechanical systems will heat up if there is a misalignment at

some point in the system.

Conveyor belts are a good example. If a roller is worn out, it will

clearly show in the thermal image so that it can be replaced.

Typically, when mechanical components become worn and less

efficient, the heat dissipated will increase. Consequently, the

temperature of faulty equipment or systems will increase rapidly

before failure.

By periodically comparing readings from a thermal imaging

camera with a machine’s temperature signature under normal

operating conditions, you can detect a multitude of different

failures.

Suspected roller Overheated bearing

This thermal image shows an electric engine under normal operation.

Motors can also be inspected with a thermal imaging camera.

Motor failures like brush contact-wear and armature shorts

typically produce excess heat prior to failure but remain

undetected with vibration analysis, since it often causes little

to no extra vibration. Thermal imaging gives a full overview and

allows you to compare the temperature of different motors.

Other mechanical systems monitored with thermal imaging

cameras include couplings, gearboxes, bearings, pumps,

compressors, belts, blowers and conveyor systems.

Examples of mechanical faults that can be detected with thermal

imaging are:

• Lubrication issues

• Misalignments

• Overheated motors

• Suspect rollers

• Overloaded pumps

• Overheated motor axles

• Hot bearings

These and other issues can be spotted at an early stage with

a thermal imaging camera. This will help to prevent costly

damages and to ensure the continuity of production.

Motor: Bearing Problem.

Motor: Internal Winding Problem.

References: Flir Systems

Electrical systems

Thermal imaging cameras are commonly used for inspections of

electrical systems and components in all sizes and shapes.

The multitude of possible applications for thermal imaging cameras

within the range of electrical systems can be divided into two

categories: high voltage and low voltage installations.

High voltage installations

Heat is an important factor in high voltage installations. When electrical

current passes through a resistive element, it generates heat. An

increased resistance results in an increase in heat.

Over time the resistance of electrical connections will increase, due

to loosening and corrosion for instance. The corresponding rise in

temperature can cause components to fail, resulting in unplanned

outages and even injuries. In addition, the energy spent on generating

heat causes unnecessary energy losses. If left unchecked, the heat

can even rise to the point where connections melt and break down; as

a result, fires may break out.

Examples of failures in high-voltage installations that can be detected

with thermal imaging:

• Oxidation of high voltage switches

• Overheated connections •

Incorrectly secured connections

• Insulator defects

These and other issues can be spotted at an early stage with a thermal

imaging camera. A thermal imaging camera will help you to accurately

locate the problem, determine the severity of the problem, and

establish the time frame in which the equipment should be repaired.

A wide view of a substation can quickly show areas where unwanted high

resistance connections exist. No other predictive maintenance technology is

as effective for electrical inspections as thermal imaging.

One of the many advantages of thermal imaging is the ability to perform

inspections while electrical systems are under load. Since thermal imaging

is a non-contact diagnostic method, a thermographer can quickly scan a

particular piece of equipment from a safe distance, leave the hazardous

area, return to his office and analyze the data without ever putting himself

in harm’s way.

Thermal imaging cameras allow you to inspect high voltage installations

from a safe distance, increasing worker safety.

Continuity is very important to utilities since many people rely on their

services. Therefore thermal imaging inspections have become the core of

utility predictive maintenance programs throughout the world.

Thermal imaging cameras are used for inspections of electrical systems and

components in all sizes and shapes and their use is by no means limited to

large high voltage applications alone.

Electrical cabinets and motor control centers are regularly scanned with

a thermal imaging camera. If left unchecked, heat can rise to a point that

connections melt and break down; as a result, fires may break out.

Besides loose connections, electrical systems suffer from load imbalances,

corrosion, and increases in impedance to current. Thermal inspections can

quickly locate hot spots, determine the severity of the problem, and help

establish the time frame in which the equipment should be repaired.

Examples of failures in low voltage equipment that can be detected with

thermal imaging:

• High resistance connections

• Corroded connections

• Internal fuse damage

• Internal circuit breaker faults

• Poor connections and internal damage

These and other issues can be spotted at an early stage with a thermal

imaging camera. This will help to prevent costly damages and to avoid

dangerous situations.

Whether you intend to use thermal imaging cameras for

low voltage inspections in production plants, office facilities,

hospitals, hotels or domestic residences, FLIR Systems has

exactly the right thermal imaging camera for the job.

References: Flir Systems

Introduction

Ever since the first commercial thermal imaging camera was

sold in 1965 for high voltage power line inspections, by what

would later become FLIR Systems, the use of thermal imaging

cameras for industrial applications has been an important market

segment for FLIR.

Since then thermal imaging technology has evolved. Thermal

imaging cameras have become compact systems that look just

like a digital video camera or digital photo camera. They are easy

to use and generate crisp real-time high-resolution images.

Thermal imaging technology has become one of the most

valuable diagnostic tools for industrial applications. By detecting

anomalies that are usually invisible to the naked eye, thermal

imaging allows corrective action to be taken before costly

system failures occur.

The AMR (auto meter reading) is an I/O module that has been specifically designed for the special needs of auto meter reading applications. The AMR can be interfaced directly with the output of various types of pulse output meters (electricity, water, gas, BTU) and the data collected from the various meters sent to a central host via its RS485 interface. Some special features which distinguish it from regular I/O modules are:

– noise filtering from the pulse input to prevent miscounts

– EEPROM memory to retain count data in case of power interruption

– accommodates up to 16 channels of pulse input

– dry contact channel input that eliminates the need for additional power supply

– synchronize retain count with actual meter display

– rechargeable battery backup option to maintain at least 8 hours of continuous operation during a power outage

and many more!

Optional VAV Accessories for use with ZN Line modules

The ZASF is part of a family of control modules designed specifically for VAV terminal box applications. It is designed to be used with the ZN341v+ and ZN141v+. It mounts directly on the secondary VAV damper shaft and provides an integral actuator and a second integrated flow sensor for damper positioning and air-flow sensing in dual duct or tracking systems.

Multi-Equipment Application Controllers

M Line controllers are ideal for multi-equipment applications in commercial environments. These robust standalone controllers utilize native BACnet communications over a high-speed ARCNET 156 kbps network to ensure superior performance.

Powerful Multi-Equipment Controllers

ME 812U Line – Powerful Multi-Equipment Controllers

The ME812U controllers have the speed, power, memory, and I/O flexibility to handle the most demanding control applications in the industry. Capable of controlling multiple pieces of equipment simultaneously, this robust BACnet controller can support complex control strategies with plenty of memory for trends, and is capable of third party integration using other communication protocols.

A Tool for Sustainable Building Operations

Automated Logic’s EnergyReports™ application is an incredibly flexible, easy-to-use reporting tool that gives facility managers the power to produce a wide variety of reports showing a building’s energy consumption. Using dynamic and animated color graphs, EnergyReports allows users to compare energy consumption or demand over different periods with simple drop-down menus and calendar control options. A click of the mouse enables users to normalize consumption data, convert the data to cost or carbon dioxide emissions, and change engineering units on the fly. This gives facility managers a powerful tool to minimize energy consumption, maximize comfort, and achieve sustainable building operations

Software

WebCTRL Powerful and Intuitive Front End For Building Control

Automated Logic has long been known for its intuitive, powerful front-end building control software. In fact, ALC pioneered graphical programming in the industry. With our graphical user interface, users have such features as hierarchical scheduling, thermographic color floor plans, trending, alarm management, and reporting. And with WebCTRL®, our web-based building automation system, all of these features are available through a standard web browser – without any special software or plug-ins.

Software

Automated Logic has long been known for its intuitive, powerful front-end building control software. In fact, ALC pioneered graphical programming in the industry. With our graphical user interface, users have such features as hierarchical scheduling, thermographic color floor plans, trending, alarm management, and reporting. And withWebCTRL®, our web-based building automation system, all of these features are available through a standard web browser – without any special software or plug-ins.

Time-Lapse Graphics™ is a revolutionary new feature within WebCTRL that allows operators to roll back time, up to a 24-hour slice, and play back hours of real-time data in just minutes. This innovative feature provides a quick, visual indication of any problem areas and gives facility managers a strong diagnostic tool to quickly identify and correct issues that impact energy efficiency and comfort.

Our Environmental Index™ provides a simple and effective solution. Starting with temperature as a key component of comfort, the Environmental Index (EI), expressed as a percentage, reflects how close the zone temperature is to the effective heating and cooling setpoints. Accessed through a browser using WebCTRL, the EI is shown on an easily read analog gauge, using the red segments to indicate poor environments, and graduating to green as conditions improve and the EI begins to approach 100%.

ALC’s EnergyReports™ is a flexible, easy-to-use reporting tool that enables facility managers to produce a wide variety of reports showing a building’s energy consumption. Using color graphs, EnergyReports allows users to compare energy consumption or demand over different periods with simple drop-down menus and calendar control options. This gives facility managers a powerful tool to minimize energy consumption, maximize comfort, and achieve sustainable building operations.

EIKON® – LogicBuilder, the most advanced graphical programming tool in the industry, replaced line-by-line programming with universally understood symbols to construct both standard and custom control algorithms. All of this combines to make the most intuitive, feature-rich, easy-to-use product on the market.