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Petrochemical Applications
Refractory and Petrochemical Installations A wide variety of industries rely on furnaces and boilers for manufacturing processes, but the refractory linings for furnaces, boilers, kilns, incinerators, crackers and reactors are prone to degeneration and loss of performance. With a thermal imaging camera damaged refractory material and the corresponding heat loss can be easily located, as the heat transmission will show up clearly on a thermal image. Thermal imaging cameras are widely used in the petrochemical sector. They provide rapid, accurate diagnosis for furnace maintenance, refractory loss management and condenser fin diagnosis. Heat exchangers can be checked to detect blocked pipes. Furnace and boiler equipment is also prone to failures from a variety of other mechanisms. These include coking that plugs the inside of tubes and impedes product flow, slag build-up on the outside of tubes, under and overheating, flame impingement on tubes due to burner misalignment, and product leaks that ignite and cause serious damage to the equipment. To ensure refractory quality of boiler and furnace installations it is not enough to just perform inspections from the outside. The refractory on the inside of the boiler or furnace has to be inspected as well. With conventional methods it is necessary to shut down the installation to be able to inspect the inside. This is extremely costly due to a loss of production during downtime. These losses are not necessary, however, for FLIR Systems also has special thermal imaging cameras that can be used to inspect the inside of the installation during operation. This is possible due to the flame filter FLIR has included in the design of these thermal imaging cameras. Flames emit infrared radiation at different intensities at different wavelengths and at certain wavelengths in the infrared spectrum flames emit hardly any thermal radiation at all. A flame filter uses that fact to enable the thermal imaging camera to ‘see’ through the flames. References: Flir Systems
Related Products
Key Features
Monitor:
up to 1000 feet (305 meters) of conductive fluid sensing cable and/or spot detectors per zone; 6000 feet (1830 meters) total, or
up to 700 feet (213 meters) of chemical sensing cable per zone; 4200 feet (1280 meters) total
The LDRA6 fully integrates with RLE’s family of leak detection cables. One controller can monitor an area for both water and chemical leaks with our distinct leak detection cables.
Create a unique combination of zone leak detection and dry contact alarm annunication
Adjustable leak thresholds fine-tune the system
Supervised inputs monitor cable for breaks and contamination
Form C relay output for each input enables communication with BMS/NMS/BAS via Modbus RTU (EIA-485)
One tri-color notification LED per input, and one audible alarm
Included Equipment: LDRA6 alarm panel
Additional Requirements: Isolated RLE power supply, leader cable, end-of-line (EOL) terminator, sensing cable (as needed for application)
Power: Requires an isolated power supply.
24VDC Isolated @ 600mA max.; requires RLE power supply PSWA-DC-24 (not included)
Inputs
Leak Detection Cable: Compatible with SeaHawk sensing cable and SD-Z and SD-Z1 spot detectors (not included)
Cable Input: Requires 15ft (4.6m) leader cable and EOL terminator for each zone (not included)
Maximum Length: 1000 feet (305m) of conductive fluid sensing cable and/or spot detectors per zone; 6000 feet (1830m) total, or 700 feet (213m) of chemical sensing cable per zone; 4200 feet (1280m) total
Detection Response Time Digital: When used with conductive fluid sensing cable or chemical sensing cable, 20-3600sec, software adjustable in 10 second increments; ±2sec Dry Contact NO/NC.
Outputs
Relay: 1 Form C Summary Alarm Relay, 6 Form C alarms, one per input/zone 1A @ 24VDC, 0.5A resistive @ 120VAC; Configurable for supervised or non-supervised, latched or non-latched
Communication Ports
EIA-232: 9600 baud; Parity none; 8 data bits, 1 stop bit
EIA-485: 1200, 2400, 9600 or 19,200 baud; Parity none, odd, even (programmable); 8 data bits, 1 stop bit
Protocols
Terminal Emulation (EIA-232): VT100 compatible
Modbus (EIA-485): Slave; RTU Mode; Supports function codes 03, 04, 06, and 16
Alarm Notification
Audible Alarm: 85DBA @ 2ft (0.6m); re-sound (disabled, 8,16 or 24 hours)
Visible Alarm: LED: Alarm: red; Cable Fault: yellow
Front Panel Interface
LED Indicators: Power: 1 green (on/off); 1 tri-color Status LED per zone (6 total) (Power On: green; Alarm: red; Cable Fault: yellow)
Push Buttons: Quiet/Test/Reset: 1
Operating Environment
Temperature: 32° to 122°F (0° to 50°C)
Humidity: 5% to 95% RH, non-condensing
Altitude: 15,000ft (4572m) max.
Storage Environment: -4° to 158°F (-20° to 70°C)
Dimensions: 10.5″W x 8.0″H x 2.0″D (267mmW x 203mmH x 51mmD)
Weight: 4 lbs. (1.82kg)
Mounting: Wall mount enclosure
Certifications: CE; ETL listed: conforms to UL 61010-1, EN 61010, CSA C22.2 No. 61010-1, IEC 61326:1997; RoHS compliant
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!
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