Infrared thermal imaging camera as a high-tech test and measurement instruments, the price has not been low generally in the tens of thousands of dollars, the cheaper 2-3 million also have. Although with the rapid development of infrared thermal imaging technology, there has been a thousand-dollar thermal imaging camera, but compared to other daily use of testing instruments, still belongs to the relatively high-end tools.
While thermal imaging cameras are worth a lot of money, using them for preventive and predictive maintenance tasks greatly reduces maintenance costs and unplanned downtime of equipment operation.
Infrared thermography plays an important role in troubleshooting problems in commercial and industrial operations. Problems with equipment operating conditions are usually caused by some anomaly or indication. On the surface, the problem may be an obvious vibration, sound or temperature reading. On a deeper level, it may be difficult or impossible to discover the source of the problem.
Thermal patterns are pseudo-colored images of infrared energy or heat emitted by an object. Comparing the heat pattern of a normal device with that of a device that is operating in an abnormal condition can provide excellent troubleshooting.
The main benefit of infrared thermography is that tests can be performed quickly and without damage to the equipment. In addition, because thermal imaging cameras do not require contact, they can be used during operation of equipment or components.
The economic benefits of thermal imaging:
Effective use of infrared cameras and the application of preventive maintenance, including predictive maintenance techniques, will eliminate 33% to 50% of maintenance expenditures, which are wasted by many manufacturing and production vendors. Based on historical U.S. data, the initial savings resulting from an effective preventive/predictive maintenance program involve the following:
1. Reducing unplanned downtime caused by equipment or system failures: Typically, cost reductions of 40 to 60 percent can be achieved within the first two years, with 90 percent reductions being achieved and sustained over a five-year period.
2. Improve employee productivity: Statistically, a maintenance person actually works 24.5% or about 2 hours per shift.
Preventive/predictive maintenance can dramatically increase effective work time by identifying the exact repair tasks needed to correct defects within the plant's resources, as well as the parts, tools, and support needed to correct the problem. Most plants have been able to achieve and maintain an effective utilization rate of 75% to 85%.
3. Reducing maintenance costs: In some cases, actual maintenance expenditures will increase within the first year of implementing an effective preventive/predictive maintenance program. This increase in spending, which is typically 10 to 15 percent, is caused by inherent reliability problems identified through the use of predictive techniques. After these problems are eliminated, a 35% to 60% reduction in labor and material costs is typically achieved.
4. Extend equipment asset life: Typically, the useful life of plant resources can be extended by 33% to 60%. The extension of service life is due to the detection of incipient problems or deviations from optimal working conditions before damage to the equipment occurs. Minor adjustments or repairs can extend the useful life of equipment almost indefinitely without allowing minor defects to become serious problems.