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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.
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.
To be able to truly evaluate the effectiveness of an infrared predictive maintenance program there must be an understanding of the relationship between the equipment that is to be inspected and the problems that are found and repaired. Too often the focus is on only the infrared images that the camera produces while the solutions that the data produced from the program can provide get lost. It all boils down to a simple but fundamental law that is expressed by the equation E = IR8 which focuses on measuring the effectiveness of the overall infrared program as well as on each of the individual components that contribute to its success.
To be able to truly evaluate the effectiveness of an infrared predictive maintenance program there must be an understanding of the relationship between the equipment that is to be inspected and the problems that are found and repaired. Too often the focus is on only the infrared images that the camera produces while the solutions that the data produced from the program can provide get lost. It all boils down to a simple but fundamental law that is expressed by the equation E = IR8 which focuses on measuring the effectiveness of the overall infrared program as well as on each of the individual components that contribute to its success.
Why Balance? All rotating components experience significant quality and performance improvements if balanced. Balancing is the process of minimizing vibration, noise and bearing wear of rotating bodies. It is accomplished by reducing the centrifugal forces by aligning the principal inertia axis with the geometric axis of rotation through the adding or removing of material. In order to understand the basics of balancing it is necessary to define the following fundamental terms.
Why Balance? All rotating components experience significant quality and performance improvements if balanced. Balancing is the process of minimizing vibration, noise and bearing wear of rotating bodies. It is accomplished by reducing the centrifugal forces by aligning the principal inertia axis with the geometric axis of rotation through the adding or removing of material. In order to understand the basics of balancing it is necessary to define the following fundamental terms.
The present study is aimed at establishing the vibration standards for precision machine tools. The machine tools are first segregated and then their vibration data are analyzed for determining the normal vibration level and damage factors (DF). After refining and fixing the vibration standards obtained, they can be used to assess the machinery health.
The present study is aimed at establishing the vibration standards for precision machine tools. The machine tools are first segregated and then their vibration data are analyzed for determining the normal vibration level and damage factors (DF). After refining and fixing the vibration standards obtained, they can be used to assess the machinery health.
From stringent hygienic requirements to ensure food safety, to tight production schedules and constantly changing consumer tastes, food and beverage processors face a number of unique challenges. It’s imperative that processors’ equipment operates at peak performance, minimizing downtime while ensuring high quality end products for consumption. Pump performance is a critical factor in overall operational efficiency. Properly functioning pumps ensure product flows effectively through the line to final packaging and distribution, and they play a crucial role in efficient cleaning-in-place processes. Condition monitoring of pumps in the food and beverage industry.
From stringent hygienic requirements to ensure food safety, to tight production schedules and constantly changing consumer tastes, food and beverage processors face a number of unique challenges. It’s imperative that processors’ equipment operates at peak performance, minimizing downtime while ensuring high quality end products for consumption. Pump performance is a critical factor in overall operational efficiency. Properly functioning pumps ensure product flows effectively through the line to final packaging and distribution, and they play a crucial role in efficient cleaning-in-place processes. Condition monitoring of pumps in the food and beverage industry.
Costly oversights occur repeatedly despite thoughtful planning dedicated to maximizing the operation and lifespan of the motor. One unsettling realization is that testing, considered part and parcel of preventive maintenance, is not preventing anything because there is nothing to indicate that analyzing the data was even considered. This is a major pitfall and a classic example of a gap in a company’s motor management program.
Costly oversights occur repeatedly despite thoughtful planning dedicated to maximizing the operation and lifespan of the motor. One unsettling realization is that testing, considered part and parcel of preventive maintenance, is not preventing anything because there is nothing to indicate that analyzing the data was even considered. This is a major pitfall and a classic example of a gap in a company’s motor management program.
Condition monitoring (CM) is not a life-extending activity. Life-extending activities are things such as lubrication, alignment, balancing and operating procedures. It’s very important to keep this very basic fact clear in all communications within your plant; otherwise, too little importance may be placed on the planning and scheduling of corrective work orders originated in CM.
Condition monitoring (CM) is not a life-extending activity. Life-extending activities are things such as lubrication, alignment, balancing and operating procedures. It’s very important to keep this very basic fact clear in all communications within your plant; otherwise, too little importance may be placed on the planning and scheduling of corrective work orders originated in CM.
