Thermography for Energy Saving

REVOLUTIONARY NEW CONCEPT IN ENERGY CONSERVATION & MACHINE MAINTENANCE

- Thermal Scanners can convert infrared radiation into electric signals, and thus present them visually.
- Thermal Scanners are of great significance in preventive service and maintenance, but also in building and production monitoring, as well as in technical diagnostics.
- A thermal Scanners makes differences visible, thus making an exact search for errors possible.
- It checks materials and components completely without any damage and exposes problems before a malfunction can occur.

THERMOGRAPHY FINDS APPLICATION IN

1. Manufacturing

2. Quality Control

3. Troubleshooting

4. Process Control

5. Predictive Maintenance/Monitoring equipment for thermal indicators of potential failures.

6. Machinery- bearings, wiring, etc.

7. Electrical Distribution Panel

THERMOGRAPHY APPLICATION IN ELECTRONICS

Thermal measurements can be useful in predictive maintenance where elevated temperatures can be early indicators of future problems.

Application areas include:

1. Thermal management in electronic product design.

2. Reliability Engineering

3. Component thermal performance

4. Passive components- Resistors, Capacitors, Relays, etc.

5. IC Packaging Hybrid circuits

6. Enclosure cooling effectiveness

The Thermal images and Thermography report gives the exact status of the quality of their Electrical installation right from the Transformer end and right up to the “Printed Circuit Boards” (PCB’s) of their Hi-tech process machines.

Hence the THERMOGRAPHY study will results in following advantages:

1) Power saving of around upto 3% by arresting the power leakage & improving the efficiency of all electrical installations.

2) Helping in the Preventive & Predictive maintenance of all spinning machines.

3) Avoiding Breakdown Maintenance to a great extent.

4) Improving the quality of Electrical & Mechanical installations as a whole.

IMPLEMENTATION OF THERMAL IMAGING STUDY MEASURES

The Practical corrective actions taken on the Electrical side is to do:-

Check 3 Phases RYB in the terminals of busbar, contactor, ACB, isolator, Fuse links, Fuse, Cable lugs, motor terminals, undersized, single phasing, etc.

If the readings between the two phases are as like below,

20 degrees C: - Corrective measure required as scheduled maintenance permits.

40 degrees C: - Corrective measure required As soon As possible.

40 degrees C and above; - Corrective measure required immediately.

In general, any hot spot is above the following temperatures then,

Any joint is above 60 degrees C – then correction is required immediately.

Any joint is 80 degrees C – the correction is required today.

The Practical corrective action to be taken on Mechanical side:-

LOADS & MOTOR – problems of Alignment, Poor ventilation by back fan, Poor greasing, Friction due to yarn, bearing overload, skid vibration etc.

♦Any Load with 40*C above ambient – correction required immediate.

♦Any Load with 20*C above ambient – correction As soon As Possible.

TEMPERATURE NORMS

1. BEARINGS : 30⁰C (Ambient) +/- 20⁰C = 50⁰C

2. GEARS : 300C (Ambient) +/-27⁰C=57⁰C

3. WORM GEAR : 30⁰C (Ambient)+/-50⁰C=80⁰C

THERMOGRAPHY AUDIT SCOPE OF WORK

ELECTRICAL INSTALLATIONS:

1. TRANSFORMER Yard including transformer. Covering both EB & Customer Side.

2. Main MV Panel – Both EB & Genset supply side covered along with ACB’s & Stabilizers.

3. All SSB’s inside the department fully covered.

4. Air Conditioning installations including False Ceiling and Ducting.

PRACTICAL ADVANTAGES OF THERMOGRAPHY STUDY:

• The abnormalities / anomalies existing in your present Electrical Systems & Installations are checked in a very short time.

• Corrective Action can be Planned & Implemented immediately.

• Even PCB / High Cost Electronic Systems can be checked & corrected.

• As the machine is Thermographed as a whole, the correction or effect of Mechanical Friction on the Motor is clearly found & can be corrected, leading to Best Possible Machine Operation condition. This results in Power Optimization also.

• In addition to the present system of PREVENTIVE / PREDICTIVE maintenance program, the possibility of “SELECTIVE MAINTENANCE” can be introduced.

• As you are able to visually see the performance or status of each and every area the correction of “HOT SPOTS” alone is a practical possibility after the advent of “Thermography”.

• Thermography study results will reveal new ideas w.r.t. your maintenance / lubrication

schedules, cleaning schedules, life of bearings etc.

• Thermography reports are considered authentic by several OEM’s throughout the World in all sectors.

“PAY BACK” through Thermography:

• Direct pay back of 3 to 4% energy savings after implementing corrective action on “HOT

SPOTS” in electrical installation & Transmissions.

• Direct savings on Lesser Machine Breakdowns & Down Times.

• In case of Controlled Atmospheric Condition like Humidification / Air Conditioning,

Identification & Correction of Hot Spots & Insulation defects will give opportunity for more power conservation.

• Thermography Study for “Risk Management Services” ( Insurance Sector) give an authentic & scientific proof for better “Premium Rates”.This has already come into existence in

INDIA.

• “Thermography” in being recommended by several International Accredition

Agencies as a scientific way of Annual Factory Audit.

• THERMOGRAPHY’s Biggest Advantage is its non-contact IR sensing which is very fast & accurate & easy to master.

• The Patented “SOFTWARE” enables you to analyze and find problem Areas with ease.

TOWARDS “ 0 ” AIR LEAK

• COMPRESSED AIR LEAK DETECTOR / FLOW METER will be able to assure you the following solutions:

• The Air Leak Detector will be able to Accurately Pin Point all the Leak Points so that it can be corrected by you.

• The Flow Meter will help you to fix up the actual Air Consumption of Each and Every machine and hence find out the Air Capacity required against your Actual, Present Air Consumption.

• The Flow Meter readings will help you to Analyze & Assess the Air Loss in Machine side & Line side separately.

• With these Instruments & Concept the possibility of “ZERO AIR LEAK” will be a reality.

- Save Energy

 ◄◄ LIKE This Page and get free tips for reduce energy bill ►►

https://www.facebook.com/save.energy.104