Hi all,

Does anybody here have sample procedures for mechanical IR inspections on motors, pumps and fans?
I need to prepare internal (for our mechanical PDM group) detailed step-by-step procedures for Level 1 thermographers.
Any help with documents or links to websites would be greatly appreciated.

Thank you in anticipation,
Alex

There are several good starting places, even if, perhaps, not EXACTLY what you are asking for:

• ASTM E-1934, Standard Guide for ExaminingElectrical and Mechanical Equipment with Infrared Thermography: this is a useful standard, even if not perfect, and can provide you with some good language and concepts as well as a foundation on which to build your own procedure. You can download for a fee at www.astm.org.

• Canadian National MasterSpecifications,Section 02 27 19 - Thermographic Inspection Services:Mechanical Equipment: an excellent new document (not sure yet where it can be procured!) that will also provide a strong foundation for any inspection work

• ISO 19434, Condition Monitoring and diagnostics of Machines (to be published in 2009): this is a very good set of standards (IR, vibration, oil and ultrasound) that all work together. Publication is expected in 2009 for the IR portions. 

 

One of the problems with "mechanical inspections" is finding the common elements among so many different types of equipment. I just delivered a webinar on mechanical inspections (soon to be available recorded as well) so I'm fresh into the topic AND the problems we routinely encounter. Limiting the procedure to certain equipment should help!

 

 

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Thermally Yours,

John
ASNT NDT Level III #48166
The Snell Group
www.thesnellgroup.com
www.thermalsolutions.org
800-636-9820

First a Pdm route MUST be developed. At first our bean counter wanted just the critical equipment done. We decided that "critical" is a piece of equipment that will shut the machine down. The other equipment will become RTF (run to fail). I still have ALL equipment looked at but it's cool when I see an RTF getting close to fail and have the spare ready and changed. It cuts down on stock, downtime, and pulling Mtechs off of jobs that are important. Once the route is developed, you can look at some Pm's and see that they are close to being the same. When my guys do a Pdm route say on a gearbox, part of it is checking oil levels. Since this is done we are finding that time is opening up for the Mtech to do other jobs that are lagging. I developed a form for the thermographer that has a space for the image number w/ description, route number, air and humidity. Just for myself, I want ALL motors and pumps shot for history. Since we have equipment inside and outside, the history has to be broken down into seasons. It's taken about two years for the process to flow,but we are seeing results! My L1's are being trained by Snell so I am sure the images that I study are gonna be good ones. 

Good luck Alex.

  

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Cary Weaver
cary.weaver@owenscorning.com
DoUSeeGreen.com
Maintenance Specialist
Thermology L3

Thanks for the first-hand examples, Cary, and for the plug for good training! All three of the standards I reference speak about the equipment list and frequency of the inspection of that equipment. We often find customer already have an equipment list of some sort. In many cases an "in-house" thermographer has input into developing, refining or updating the list. Typically it will be the thermographer who groups equipment into routes, often based on machine inspection needs, access and availability, time of year (as Cary suggests), and any other relevant factors.

 

I've attached a great graphic, from the proposed ISO18434-1, which shows one good example, and of course there are many others, of how one might portray measurement targets on a complex machine. Please note that ISO standards are copyrighted.

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Thermally Yours,

John
ASNT NDT Level III #48166
The Snell Group
www.thesnellgroup.com
www.thermalsolutions.org
800-636-9820

John and Cary,

 

Thanks for your comments.

 

About five years ago, before I started working here, engineering decided to use vibration analysis as main technology at our plant. Maintenance Optimization Plan program was implemented before that. All our equipment was divided into categories, so we know what's critical and we have developed routes.

 

Because IR is not a preferred technology (!?) here, our L1 guys do not spend much time with IR camera on the floor. Considering they did not have any thermography experience prior to working here (all are new hires), even though they got their L1 certificates a year ago, they have not gained any satisfactory experience, adequate for their job. It is a sad situation as I and other fanatical L2’s realize that this program is driven by us instead of being managed from the top.

 

I still find inspection reports with a single IR image of motor casing and rectangular area showing the temperature of motor casing. This made me think about need for detailed internal procedures for inspections on particular types of equipment. So maximum information can be obtained during the inspection and when need comes we have the info. I prepared Field Data Sheets, IR inspection Checklist that can be used during pre-job briefs. However their use is not enforced and I feel that it will be beneficial to have approved internal procedures for our group. Then all L1 thermographers MUST follow procedures and hopefully acceptable quality reports can be produced. So what I need is to create detailed step-by-step instructions for mechanical IR inspections. I know it will take time to implement this project. Therefore I was looking for any similar documents that someone has already worked on. Naturally full credit would be given to those who contribute with any info, with references provided.

 

Thanks again for your feedback on this subject.

Cheers,

Alex

When my routes were developed, I knew each peice of equipment and what information was needed for data collection. It is my assumption that you know the same. My question is, do your routes pop up the same as a Pm in your dept. as mine do? Monthly, quarterly, annually? If so I hope that you wrote the Pdm route. In my routes the Mtech can look on the Pdm route ( on the computer) and see what exactly must be looked at. I spelled out piece by piece what I need.

Second, we are Thermologist, not expensive photographers. The form I developed MUST be filled out DURING the inspection.  It has a space for equipment number, image number, humidity,(temperature that I fill in),and time of day. If I could get an e-mail address, I will gladly pass it to ya.  You have a great start! I have a plant leader that gives me the right to make sure that the Pdm route is followed to the letter. I think that you can achieve the same when you start to save him or her a million or two in downtime!!

One last question. Are you in a plant that you stay at or do you have multiple customers and travel?

P.S.  Get the L1 guys to Snell's Electrical and Mechanical classes or yourself. It's a HUGE benifit!

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Cary Weaver
cary.weaver@owenscorning.com
DoUSeeGreen.com
Maintenance Specialist
Thermology L3

"• Canadian National MasterSpecifications,Section 02 27 19 - Thermographic Inspection Services:Mechanical Equipment: an excellent new document (not sure yet where it can be procured!) that will also provide a strong foundation for any inspection work"

 

Greg McIntosh, Managing Director of Snell Infrared Canada, let me know these can be purchased at <http://www.innovative.ca/nms_library_pricing.html> (among several places). "Division 2" contains all four infrared standards (mechanical, electrical and large and small buildings) and costs $100, a bargain in my way of thinking!

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Thermally Yours,

John
ASNT NDT Level III #48166
The Snell Group
www.thesnellgroup.com
www.thermalsolutions.org
800-636-9820

Keen to hear from anyone who  has established check lists for mechanical thermography

Ken,

I've written routes for 4 of our plants and more in the near future. How can I help? Do you have a copy of what John spoke about? Are you looking to write routes or make sure that you are following guidlines?

Drop me a line!

 

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Cary Weaver
cary.weaver@owenscorning.com
DoUSeeGreen.com
Maintenance Specialist
Thermology L3