[webinar] Embracing Digital Transformation in Maintenance & Plant Operations | March 13 at 10AM EST – Register Now
Inspecting Seals with IR Thermography
Inspecting Seals with IR Thermography
James Gambrell Predictive Maintenance Technician Hercules Inc. Pinova div.
In today’s industry, practices that were once acceptable are no longer even tolerated. Environmental concerns and EPA mandates are applying more and more pressure on businesses like the chemical industry to improve the manufacturing processes being used, to the point that not only is a slight drip from a pump seal not acceptable, but in 2004 the MACT will be enacted and only 500 – 1,000 parts per million vapor will be allowed and, eventually, no vapor at all.
Thus mechanical seals and packing for pumps that were once acceptable at a cost of $50.00 to $1,500.00 will have to be replaced with seals costing $3,500.00 to $7,000.00. For a plant with at least 100 or more pumps with seals, that’s a cost difference of up to $700,000 a year IF you can get your MTBF on seals to go a year.
Hence the condition monitoring technologies in use today include infrared, vibration analysis, ultrasound, and vapor detecting equipment. My particular expertise is in the thermography and vibration analysis condition monitoring techniques. My company has already started implementation of advanced mechanical sealing, where a great deal of the seals being used are the double mechanical kind with some type of barrier fluid being used between them, i.e. (water, process fluid, or synthetic oil).
Thermograms before and after seal correction and a visible photo, note the dramatic temperature drop.
The infrared technology can be a great tool if used in a route circuit, check your seals for temperature increases and you will be surprised to find out just how many seals either do not have proper flow of barrier fluid or none at all! Not only will you save and/or increase the life of the seal, but the savings in maintenance and seal replacement can be tracked and documented. The possible bonus at the end of the year isn’t bad either.
In closing; check, track, and document your seals with your infrared equipment, if you do not have thermal equipment it’s time to invest; it’ll be worth the cost. For some strange reason, for the officials in charge, a picture is worth a thousand words, and the IR camera is the only device that can provide it.
Any time you use dual seals (two seals) in an application, you should have a fluid circulating between them to prevent the generation of unwanted heat.
Maximum achievable control technology (MACT) standards are technology-based air emission standards authorized by the Clean Air Act of 1990 and monitored by the Environmental Protection Agency (EPA). The nearly 100 MACT standards are found in 40 CFR Part 63. Each standard regulates a specific source category such as dry cleaners, petroleum refineries, or vegetable oil production.
Mean Time Between Failure (MTBF), a measure of reliability. The longer the time span between failures, the more reliable the device.
Before bearings, valves and other mechanical parts fail, they usually scream for help. But their piercing wails usually fall on deaf ears because the sound frequencies are far too high for humans to hear. No wonder deteriorating components may go undetected until they break down completely. Now, however, a variety of tools using ultrasonic technology—ultrasound, as it is commonly known—are helping companies in a wide range of industries avoid wasteful replacements or costly breakdowns.
Before bearings, valves and other mechanical parts fail, they usually scream for help. But their piercing wails usually fall on deaf ears because the sound frequencies are far too high for humans to hear. No wonder deteriorating components may go undetected until they break down completely. Now, however, a variety of tools using ultrasonic technology—ultrasound, as it is commonly known—are helping companies in a wide range of industries avoid wasteful replacements or costly breakdowns.
As with many condition monitoring techniques, infrared thermography is a skilled art form that requires technician and engineeers to be educated in infrared physics, have a thorough understanding of applications and be able to develop their knowledge with continual field experience.
As with many condition monitoring techniques, infrared thermography is a skilled art form that requires technician and engineeers to be educated in infrared physics, have a thorough understanding of applications and be able to develop their knowledge with continual field experience.
The Interplay of Smart Manufacturing Technologies: IIoT, Industry 4.0, and AI. Let's explore this fascinating evolution chronologically. These concepts are deeply intertwined, but they emerged at different times and gradually converged.
The Interplay of Smart Manufacturing Technologies: IIoT, Industry 4.0, and AI. Let's explore this fascinating evolution chronologically. These concepts are deeply intertwined, but they emerged at different times and gradually converged.
The purpose of this paper is to introduce condition monitoring and reliability engineers to the principles of using ultrasound for the assessment of machine condition. Ultrasound can be a complimentary technology to vibration, thermography and lubrication monitoring. It must be emphasized that it is rarely successful as a stand alone technology for effective machine condition assessment and subsequent required maintenance planning. This paper concentrates on the use of airborne ultrasound as a complementary technique particularly for machinery that may be inaccessible due to guards or hazardous locations.
The purpose of this paper is to introduce condition monitoring and reliability engineers to the principles of using ultrasound for the assessment of machine condition. Ultrasound can be a complimentary technology to vibration, thermography and lubrication monitoring. It must be emphasized that it is rarely successful as a stand alone technology for effective machine condition assessment and subsequent required maintenance planning. This paper concentrates on the use of airborne ultrasound as a complementary technique particularly for machinery that may be inaccessible due to guards or hazardous locations.
The paper deals with the method of gearbox diagnostics fault detection, and shows that using: design, production technology, operational, change of condition (DPTOCC) factors analysis leads to the inference of gearbox diagnostic information. In the paper is a review of the current possibilities for using mathematical modeling and computer simulation for investigating the dynamic properties of gearbox systems. Computer simulation of dynamic behavior of gearboxes is a powerful tool for supporting gearbox diagnostic inference.
The paper deals with the method of gearbox diagnostics fault detection, and shows that using: design, production technology, operational, change of condition (DPTOCC) factors analysis leads to the inference of gearbox diagnostic information. In the paper is a review of the current possibilities for using mathematical modeling and computer simulation for investigating the dynamic properties of gearbox systems. Computer simulation of dynamic behavior of gearboxes is a powerful tool for supporting gearbox diagnostic inference.
Misalignment is probably the most common cause of machinery malfunction. Considering the importance of alignment, the vibration spectra of alignment is not well documented. Various authors have reported different spectra. The goal of this research was to determine the unique vibration signature for misalignment at varying operating and design conditions such as speed, type and level of misalignment, coupling types and machinery dynamic stiffness.
Misalignment is probably the most common cause of machinery malfunction. Considering the importance of alignment, the vibration spectra of alignment is not well documented. Various authors have reported different spectra. The goal of this research was to determine the unique vibration signature for misalignment at varying operating and design conditions such as speed, type and level of misalignment, coupling types and machinery dynamic stiffness.
Integrity Testing is a proactive approach to preventive maintenance for Plate and Tubular Heat Exchangers in sanitary processing environments. This process allows for the early identification of potential leaks and failures, serving as a cost-effective and environmentally friendly form of preventive maintenance.  
Integrity Testing is a proactive approach to preventive maintenance for Plate and Tubular Heat Exchangers in sanitary processing environments. This process allows for the early identification of potential leaks and failures, serving as a cost-effective and environmentally friendly form of preventive maintenance.  
