Infrared Thermography: A Key Tool in Predictive Maintenance

Infrared Thermography: A Key Tool in Predictive Maintenance

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Predictive maintenance has revolutionized the manufacturing industry by allowing plant maintenance and reliability teams to anticipate and address potential equipment failures before they occur. This proactive approach reduces downtime, enhances safety and improves overall operational efficiency. Infrared thermography is one of the most valuable tools a Cornerstone Mechanical reliability technician uses in predictive maintenance.
 

What is Infrared Thermography?

Infrared thermography is a diagnostic technique that uses thermal cameras to detect and visualize heat emitted by equipment. All objects emit infrared radiation as heat. While it may be invisible to the naked eye, heat can be captured and translated into detailed thermal images. These images reveal temperature variations that may indicate normal operation or potential issues.
 

Infrared Thermography Inspection as Predictive Maintenance

Heat anomalies in rotating equipment often signal underlying problems such as misaligned components, excessive friction or electrical faults. For example, overheated bearings could point to inadequate lubrication, while uneven heat distribution in motors might indicate an internal failure. By analyzing these heat patterns, maintenance teams can pinpoint problems before they become costly breakdowns.
 

Common Infrared Thermography Testing Applications

Monitoring Bearings

  • Bearings are essential for the smooth operation of rotating equipment, but they are also prone to:
    • Wear and tear
    • Overheating
  • Infrared thermography detects abnormal heat patterns caused by misalignment, overloading or insufficient lubrication, enabling teams to perform targeted maintenance

Monitoring Gearboxes

  • Gearboxes are prone to:
    • Excessive friction
    • Misalignment
    • Inadequate lubrication
  • Infrared thermography identifies heat irregularities that signal early signs of wear and tear

Inspecting Motors and Pumps

  • Uneven heat distribution in motors and pumps often indicates issues like:
    • Electrical imbalances
    • Internal defects
    • Mechanical strain
  • Infrared imaging provides early warnings, allowing for timely repairs or replacements

Assessing Hydraulics Systems

  • Overheating in pumps, valves or other components can indicate:
    • Inefficiencies
    • Hidden leaks
  • Infrared thermography allows for noninvasive monitoring of heat distribution within hydraulic systems, ensuring they function efficiently to avoid costly repairs

Electrical System Analysis

  • Hotspots in electrical components such as circuit breakers, connectors and panels may signal:
    • Loose connections
    • Overloaded circuits
    • Failing components
  • Infrared thermography for electrical inspection identifies these hotspots to help prevent fires and equipment malfunctions

Ensuring HVAC Efficiency

In manufacturing environments, infrared thermography can:

  • Monitor HVAC systems
  • Determine whether heating and cooling units are operating efficiently
  • Support the health of a facility’s operations

Inspecting Conveyor Belts

  • Conveyor belts are essential for transporting materials, but they can overheat and develop system inefficiencies due to:
    • Misaligned rollers
    • Excessive tension
  • Infrared thermography detects abnormal heat patterns along the belt and its components, helping to pinpoint problem areas

 

Benefits of Infrared Thermography for Rotating Equipment Maintenance

Enhanced Safety

  • Infrared thermography improves workplace safety by detecting potential equipment failures before they become dangerous
  • Identifying overheating bearings, electrical hotspots or misaligned components reduces the risk of fires, machinery breakdowns and accidents that could harm workers or disrupt operations
  • By addressing these issues proactively, businesses create a safer environment for employees while avoiding unexpected emergencies

Energy Efficiency

  • Abnormal heat patterns often indicate inefficient energy use, such as overworked motors or improperly functioning components
  • Addressing these inefficiencies through timely maintenance keeps machinery operating at peak efficiency, reducing energy consumption and operational costs
  • Enhanced energy efficiency also minimizes the environmental impact of industrial processes, helping businesses meet sustainability goals and comply with regulatory standards

Minimal Disruption to Operations

  • Infrared thermography’s noninvasive nature allows facilities to conduct inspections while equipment is running
  • This minimizes production delays, allowing maintenance teams to gather essential data without interrupting operations
  • Businesses can maintain productivity and optimize maintenance schedules with help from infrared thermography

Data-Driven Decision Making

  • Thermal imaging provides precise, actionable insights into equipment performance, allowing maintenance teams to prioritize repairs based on urgency and potential impact
  • With detailed data, businesses can allocate resources effectively, plan maintenance schedules efficiently and give attention to critical equipment before minor issues escalate into costly problems

Extended Equipment Lifespan

  • Regular monitoring with infrared thermography allows for the early detection of wear and tear so teams can resolve minor issues before they develop into major failures
  • This proactive approach reduces stress on equipment components, optimizing their performance and longevity
  • Over time, this results in fewer replacements, lower maintenance costs and increased return on investment for industrial equipment

 
Whether you’re maintaining rotating equipment, like motors and bearings, or critical electrical systems, our expert team leverages infrared thermography inspections to help businesses identify and address potential issues before they cause costly shutdowns.

Minimize downtime, reduce maintenance costs and extend the lifespan of your equipment with help from Cornerstone Mechanical’s infrared thermography testing services. Schedule a site walk at 214-570-9498 to learn how we can support your maintenance goals with infrared thermography services.

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