Infrared Digital
Periodic inspection infrared Best Practices – Road-based surveys
Introduction
From the late 1960s, thermal imaging has been limited to the power line and inspection station overheated electrical connections. These systems were bulky systems mounted on vehicles that cost may be less than $ 500,000 in today's dollars. Although these systems proposed for the first time a simple and intuitive identification of connection problems, these systems could not measure the temperature or digitally record images for later analysis and reporting. The global market in 1970 for infrared cameras was less 50 units. Today, the market for infrared cameras used for maintenance inspections should exceed 18,000 cameras. Thermography with vibration monitoring, oil analysis, laser observation based on the rotating shaft alignment machines and ultrasonic testing have become tools used by maintenance facilities departments in a growing number of capital-intensive.
In adopting an approach based thermography road with a database in camera and intuitive user PdM data recorder can win time, get more consistent results and significantly improve their return on investment thermography program (ROI).
Today operations manager is under tremendous pressure to increase asset availability, reduce costs, cope with levels of skills employees and return, safety rules, respect for the ISO quality and ever more competitive environment. A new class of data collectors thermography is now available designed to create and follow routes created by the user, capturing details of the incident Field and automate report generation and run the synchronization database. By adopting an approach based on the road with thermography a database at the camera and data recorder intuitive, users can save time MDP, consistent results and improve significant return on investment thermography program (ROI).
CMMS is not based on itineraries maintenance
The dilemma is that the provider of CMMS do not think in terms of activities based on all routes. Their systems are driven by work orders. If each inspection is given a work order number, you can perform inspections in a journey documented with over 250 orders work. Firstly, it is impossible for the person who conducts inspections, and secondly, it will take much time for someone to close all the work orders. Another approach based on shared activities are carried out in a book edited by orders of CMMS is to give each line a work order number and describe each inspection in order to work. This always creates complications and administrative delays. Third example of how some plants to try to document and manage the activities based on the routes is to give each line a serial work and the route documented in a spreadsheet. Again, the dilemma is that this method will not support effective and roads, it will be heavier necessary to change the content of inspections, the transfer tasks to operators, the frequency change, merger mechanical inspections and electrical and so on. All these activities are often carried out if you have a good system implementation. The solution is to have an autonomous system of activities based on the routes. Even in an era where it seems that all activities must be integrated into a single system across the enterprise which covers all the best solutions can still be autonomous systems. There is very little, or nothing in place a system based on routes to be tied with other activities. Therefore, you might as well buy a standalone system for this activity. A single-user system that can do this well is not expensive.
Pen-based computers simplify field data collection
Pen tablet computers allow the technician to gather infrared data inspection, test temperature, diagnose the problem, assess their degree of urgency, to propose corrective measures and to capture a visible image of reference. Powerful handheld Pen computers are now integrated into the infrared cameras that provide a technician to conduct spot checks and maintenance all the computing power necessary to do the job quickly and efficiently, whether the integration of their operations with the management system computer aided maintenance or testing, diagnosis and repair on site.
The pen tablet is the most widely used device to be deployed in field applications because of the versatility of its interface, its screen Touch for data entry and large memory.
Handheld Computer Pen
For industry and the military problems in the use of laptops in the factory or the field are determined by handheld Computer pen tablet or a personal digital assistant (PDA). To date, the pen, almost as powerful as a laptop, but smaller lighter and has become the most widely used device for deployment in field applications because of the versatility of its interface, its screen Touch for data entry and large memory. HotShot HD camera incorporates an infrared electro Tablet PC processor running on the operating system Microsoft Windows CE. The touch screen features icons directly related enough to be operated finger other features such as data naming files using a stylus. More reliable data are obtained. On errors, handwritten cards are replaced by reliable data, automatically collected, stored and always available throughout the enterprise. Record keeping costs are reduced. Less paperwork reduces administrative costs, because the data are processed more effectively and widely disseminated, without generating redundant copies, or even any document printed at all. Decision making is faster and more profitably. By integrating field reports in real time with the maintenance management system Computer Aided (CMMS), managers at all levels of sharing complete information to the minute, and can react quickly to changing field conditions or emergencies. Condition monitoring tests involving a number of parameters of vibration, heat, oil quality, pressure can be compared quickly to confirm the impending problems before they become catastrophic.
Collection data
Interview first know what is going on how the equipment is in operation, which increases constraints are applied, how conditions have changed. Data should be collected either by a system of remote monitoring or by workers on site. In the latter case, the handheld data collection allows faster, more accurate and more flexible.
Route-based Infrared Inspection
Many PdM technicians know, or are users of Route data based on the vibrations of collectors. Many of today's vibration instrument vendors to provide software tools to both a PC platform phones and vibration data collectors to organize and create route instructions that are downloaded into the system phones that help the user through a series of inspection points. For example, electro, HotShot HD is the first infrared camera of its kind to integrate the logic of road and all the interfaces needed to create roads and capture all the details in his computer inspection pen recorder with data in camera. The device has two modes of programming road.
Mode 1: Learning a road
In most installations, it is advantageous to create a file by simple and walk along the entrance each item according to the natural flow of how the equipment is constructed and optimize the work of support or the need to comply with safety regulations as personal protective equipment (PPE) policies. At each point the operator captures a reference image and enters the location and details of equipment. At the end of the walk / see the creation of roads in the route log file transferred to the application of PC database for editing and add any additional information you want.
Method 2: Create a Route on PC and load Camera
In this mode, the user fills in the database Active thermography with data exported from a CMMS system or data records and creates a new route by selecting files in the order of sequence of the inspection. A log file route will be created and once transferred to the camera will shoot all relevant data sets in the unit. On the screen will direct the user to point to point. Functionality further allows the user to add an item not on the current route, then synchronize the log file path update if the point re-inspection is intended to be included on a recurring basis.
Prompts Route Guide Data Collection
Once a route is created and uploaded to the camera, the camera presents prompts to help guide the user from point to point. You can add descriptive information which gives a certain level inspection instruction on this point.
ROI
In order to fully appreciate the impact of a comprehensive software suite (Database of assets, route management and report generation), we have built a cost analysis of a program of thermography and potential improvements that can be achieved with highly integrated into the camera and the PC host. For this analysis, we will make assumptions following:
- The cost of the camera and the software is $ 20.0001
- Salary hectic schedule of a technician from the infrared is $ 60 an hour, or about $ 125,000 per year.
- Technician uses the infrared camera 50% of hours worked.
- The program documents thermography 20 incidents per week or about 1000 per year.
- The camera is an asset is capitalized and amortized over 5 years
annual savings nearly $ 14,000 can be achieved
Return on investment productivity tools is very high because they are integrated in the systems available for less than $ 20,000.
1 – The monthly cost of the camera, based on a five-year plan or amortization 60 months are approximately $ 350 per month. The costs for the infrared camera operator will be $ 1,200 per week or $ 62,400 per year.
Conclusions
The largest cost in a thermography inspection program is the camera operator / Technician. By focusing on the integration of advanced features, including the management of roads and the data of the camera operators forest can significantly improve their energy efficiency programs and costs while improving the quality of work and ease of training requirements for operators. developments underway to integrate the infrared inspection data CMMS and Asset Performance software systems will lead to the next step in the convergence on the factory floor and continue to develop new and innovative solutions to to improve the overall operation and installation of equipment availability.
Please visit us to www.electrophysics.com / rirab
For more comprehensive white papers online Visit our Knowledge Center www.electrophysics.com / thermal imaging
Electrophysics – infrared cameras for thermography professionals
373 Route 46, Fairfield, NJ 07004? Phone: 973-882-0211? Fax: 973-882-0997
About the Author
Life Pixel Digital Infrared Conversion Video
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