“Infrared Imaging as

Diagnostic Tool”
Authorised By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
Engineeringpapers.blogspot.com
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Abstract:

Temperature is a key variable in virtually any situation and for all

processes. For example power generation in electrical plant is based on different boiling and

condensation temperatures of the different components. By using that, the different fractions can

be separate. Infrared thermography is simply a picture of infrared radiation. When you consider

our natural environment, everything is radiating a particular intensity of infrared. Infrared

thermography is the science of the acquisition and analysis of thermal information from non-

contact thermal imaging devices. Thermography allows the engineers to evaluate the thermal

condition of a wide variety of equipments.Another area where thermography can provide

significant benefits is in the optimization of preventive maintenance(PM). Preventive

maintenance (PM) tasks are designed to avoid unplanned failures by periodically inspecting,

testing and replacing parts. In many Cases, these time-based tasks result in unnecessary work

and wasted parts or materials, satisfactory preventive maintenance inspection can justify deferral

or elimination of some tasks, reducing plant manpower requirements and part expenditure

Introduction:

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 All electrical components have a tendency to heat up as their physical

condition worsens or their electrical properties deteriorate. In 1965 the Swedish Power Board

began inspecting approximately 1,50,000 components a year. In 1986 the UK Electrical

Generation Board began utilizing infrared thermography for predictive maintenance on

transmission lines. However, thermography was revolutionized with the introduction of image

type thermovision cameras in the Nineties.

As this is a non –contact technique, it is safe and shutdown is not required. It

helps to record and documents the thermal characteristics of almost any object that emits infrared

radiation. Thermal images can quickly and easily locate abnormal sources of heat, which in

electrical systems often indicate potential problems. Portable infrared cameras are used to convert

this infrared radiation energy into high resolution thermal images that are displayed on

conventional video screens for quantitative and qualitative analysis. Temperature is the single

most measured parameter for a condition monitoring exercise. Temperature is simply crucial and

having control over it will mean higher quality, better safety and money saved.

Thermography spans many subject areas like electrical power generation, transmission, and

distribution systems. An Infrared Camera is designed to detect this overheating and interpret it as

early warning signs of imminent failure.

Infrared energy:

Our environment contains many different forms of energy that are propagated
through space at the speed of light. These forms of energy are differentiated as a function of their
wavelength. Infrared radiation begins just above the visible light spectrum and continues up to
wave lengths of one thousand of a meter. Above infrared are radio waves.

All objects above absolute zero in temperature emit infrared radiation .This
natural occurrence is caused by thermal agitation of the object’s molecules .Because molecules
are composed of electrical charges, the oscillations of the molecules created radiation emitted by
an object is directly related to its temperature. The Infrared spectrum is divided In to four
common regions. These are 0.75 to 2 micron referred to as near infrared, 2 to 5 microns referred

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to as short wave Infrared, 8 to 14 microns referred to as long wave Infrared. Radiation in the 5 to
8 micron range is almost completely absorbed by the atmosphere.
Infrared Thermography spans many subject areas like electrical power
generation, transmission, and distribution systems and various fields like mechanical and
medicine fields as follows:

the short wave region has areas of signal attenuation caused by the absorption
of the signal by CO2 H20 and 03. The long wave system is not sensitive to reflections, which are
normally a problem for a short wave system. The choice of using a short wave system over a
long wave system, or a long wave system over a short wave system, should not be based on
theoretical detection but on actual detectability of the particular system.
Radiation:
Exitant radiation is all the radiated energy that leaves the surface of an object regardless of its
original sources:
1. Emitted, from the object itself
2. Reflected from a source in front of the object
3. Transmitted, from a source behind the object
The target fig -2 has a temperature and an emissivity, which the power of the
radiation coming from the target depends upon the radiation power of the other two radiation
component does not depend on the target temperature, but on the temperature and emissivity of
the reflection and the transmission heat sources, respectively. The sizes of the reflected and
transmitted proportions however, do depend on the reflectivity and transmissivity of the target
itself. In real life most targets are not transmissive, but opaque. Hence total exitant radiation
depends upon emissivity and reflectivity of the target.

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Applications of Infrared Thermography:
The various fields of applications are:-
1. Electrical
2. Mechanical, friction
3. Furnaces and boilers
4. Civil-such as buildings
5. Non-destructive testing
6. Military
7. Medical and veterinary
8. Quality control and process monitoring
9. Fluid flow problems
10. Tanks and vessels
How is A Visual Light is Image Created From Infrared energy?

An infrared imaging device contains one or more detectors that convert energy in the
infrared spectrum into an electrical signal. The more energy detected the greater the electrical
signal output. The electrical signals are typically formatted into a video signal and displayed on a
CRT/LCD. The amplitudes of the electrical signals are then displayed as varying intensities on
the CRT/LCD thus creating a contrast in the image in different pallets such as Grey, Iron and
Rainbow etc. depending upon the applications,

In thermography, there are many factors apart from the surface temperature of the
object s that affect and disturb the temperature measurements for accurate temperature
measurements it is crucial to know which those factors are, and how the equipment compensates

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for them. Before the measured radiation can be transformed into temperature all other radiation
sources have to be compensated for by the equipment so that the measured temperature is a
function of the object temperature and not of the distance, emissivity or the internal equipment
temperature.
If any Electrical components deteriorate there is an increase in resistance to the flow
of electrical current. With increase in resistance comes the increase in radiant energy output as
the component gets heated a thermal imaging system detects this radiant energy. In case of an
overloading conductor or imbalance in a three phase system the more current flowing through the
line the greater the temperature of that line and the brighter the thermal pattern appears.
Quantitative v/s Qualitative Analysis:

In planning for an infrared inspection is normally looking to obtain the best service
for the amount of money spend. Unfortunately, due to many mis-representations by infrared
service companies the customers are confused about the “facts of infrared operations” and often
pay for meaningless date. This problem is especially prevalent in conducting infrared inspections
for the electrical utility industries.
Quality infrared systems have been in service for over 30 years and continue to
evolve. The old story that al chain is as strong as its weakest link certainly applies to obtaining
infrared services. While the technology is “solid” we have two weak links that constantly
plague our business of providing “quality” inspection. One of the most misunderstood and
misleading facts of preparing for infrared inspections is this question. Just how important is
temperature measurement to what I am trying to accomplish,..? Many companies are selling
temperature measurements (Quantitative) as an advantage over delta measurements (qualitative).

Factor Affecting the Measurement:

• Atmosphere:- Though it is a transmissive object between camera and the target the
following factors affect the measurement:-
o Distance
o Ambient temperature
o Relative humidity

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 • Reflected radiation: - Reflection from nearby objects apparent temperature of
these objects that result in radiation that is reflected by the target into the camera is known as
reflected apparent temperature.
• Emissivity: - A low emissivity target will always try to look like the surroundings
if the target is hotter than the surroundings it will look colder than it.It can be said that a low
emissivity target tries to camouflage its real temperature to the thermal imager for high
emissivity targets apparent t temperature is very close to real temperature.

• Calibration: - The calibration of the camera is performed in a lab under controlled

environmental conditions with a large number of black body reference sources within emissivity
approaching 1.0.
• Spatial resolution and target size:- Ideal equipment would of course measure the
same object temperature even when looking at an object that is very small compared to the whole
field of view. The object does not fill the detector area then the detector will measure an average
of the object and the background temperatures hence it is very important to know the field of
view {FOV} of the equipment.
Relation between Field Of View and Distance (240 Lens)

Infrared Applications:
Infrared inspections may be performed for electrical systems, mechanical systems,
structural or petrochemical systems. Infrared inspections may be performed for the purpose of

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Preventive/Predictive Maintenance, Condition Assessment, Quality Assurance, Condition
Monitoring, and Forensics. Listed below are several common infrared applications along with
representative thermal images for each application. Also listed are the benefits of each
application and the theory on which the subject applications are based.

Electrical Distribution Systems

Theory: As electrical current flows through a conductor, heat is generated. Many
electrical defects are accompanied by a rise in temperature for up to several
weeks prior to failure. Some defects may be represented as cool
components.
What Can Be Detected:

• Loose/deteriorated connections
• Overloads
• Imbalanced Loads
• Open Circuits
Improperly Closed • Inductive Heating
Air Switch • Harmonics
• Defective Equipment

Benefits:

• locate problems quickly, without interrupting

Load Imbalance
service
on Bus Duct
• drastically reduce costly, unscheduled power
outages
• minimize preventive maintenance time and
maximize troubleshooting effectiveness
• prevent premature failure and extend
equipment life
• identify potentially dangerous and hazardous
equipment
Loose/Deteriorated
Fuse Clips • reduce insurance premiums and deductible

Mechanical Systems

Theory: As mechanical devices operate, heat is generated. Forces such as friction, misalignment
and improper belt tension cause excessive heating.

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 What Can Be Detected:

• Misalignment of coupled equipment

• Over/under lubrication of bearings
• Over/under tension of belted systems
• Excessive friction
Uneven Heating Caused • Defective Equipment
by Misalignment

Benefits:

• quickly locate misaligned coupled equipment

• increase equipment reliability and life
• increase production and efficiency while
Defective Pillow saving energy
Block Bearing • increase quality of product
• minimize downtime by planning the required
manpower and materials before shutdown

• improve worker productivity and morale by

correcting potential problems proactively

Overheated
Shaft Bearing

Conventional Maintenance Procedures:

Generally a fairly uniform set of maintenance procedures are adopted in many

organizations. These include:-
• Visual inspections
• Cleaning equipment
• Tightening connections
• Over current device testing
• Insulation quality testing
Cost Benefits Of Using INFRARED THERMOGRAPHY:
Justifying the cost of starting and maintaining an in house infrared thermography
programme is essential in enquiring continued funding and sponsorship cost benefit studies,
whether brief and general or strictly formalized, tend to focus on costs associated with projected
equipment failure and production downtime. While these numbers can be quite dramatic their

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validity rests on acceptance of the predicted failure, which is often the subject of some
conjecture.
Sometimes overlooked in this cost- benefit analysis are the savings from avoided
work, the optimization of routine time- directed tasks and identification of non-problems using
thermography inspection results in direct maintenance to the root cause of a performance
problem and can shorten downtime and eliminate unnecessary work and material expenses.
Advantages of Thermographic Approach:
• Infrared inspection is non-contact. It uses remote sensing. Firstly, it keeps the
user out of danger i.e. away from live electrical components. Secondly, it
does not intrude upon or affect the target as well
• Infrared thermography is two dimensional. We can measure temperature of many points
in the same image and compare them. Thus analysis of image is very effective and
simple.
• Infrared thermography is real time. It allows us to do over fast scanning
• Electrical equipment is inspected during operation, so the power doesn’t have to be
interrupted.
• Reduced inspection costs as large quantities of equipment can be scanned in a short period
of times finding the trouble spot quickly, saving labour time and money over regular
trouble shooting.
• Faults can be pinpointed before maintenance is carried out, so maintenance resources are
directed where they are most needed and prioritized, resulting in significant labour and
cost savings.
Facts:
• A properly conducted infrared inspection can save precious maintenance expenditure.
• Companies are misleading customers by over-stating the importance of obtaining component
temperature measurements
• A qualitative inspection which detects the temperature rise (delta measurement) of a
component is the most significant aspect of any line inspection. A component will never fix
itself and can either be flagged for monitoring (trending) or repaired as soon as possible.
• A detected anomaly discovered on a line inspection is considered to be a single point in time
discovery. The fact that it was discovered is what should be most
• Important.
• Criticality of the discovered find can’t be determined by the temperature rise.

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• Anomalies with the highest estimated and/or measured temperature could be the least
significant discovery.
• A component with the lowest temperature could be the most serious with failure eminent.
• Component’s temperature varies with the components shape and orientation to the sensor.
• Surface temperature is dependent on heat transfer within each component. A poor correlation
exists between the actual point of high resistance and the surface temperature of the
component.
• Wind has a big affect on temperature. A 5 mps wind can decrease the temperature at the
surface of an object by 50%.
• The type of material that a component is made of significantly affects both its heat emitting
properties (emissivity) as well as its internal damage due to heat
• Thermal anomalies typically have a failure cycle once the high resistance connection begins
to produces heat.
Conclusion:
Hence conventional cleaning and tightening procedures can overlook many
problems these overlooked problems as well as those that may have been remedied by the
preventive maintenance program will be identified by a competent infrared survey. It is capable
to instantly identify all resistive type problem, that are the object of the conventional cleaning
and tightening procedures poor connections that are not readily accessible during conventional
maintenance can be checked connection contact and calibration problems in thermal overload
devices and fuses can be instantly spotted.
The most costly component of many preventive maintenance program is
equipment cleaning and connection tightening are directed towards correcting deficiencies in
terminations, joints and contact points the location of most electrical failures also these
procedures are highly labour intensive since substantial component disassembly and reassembly
is required to access all the major contact points and terminations.
Thermo-graphic imaging and infrared temperature measurements have been
used extensively by POWERGRID for maintenance related activities. Improvements in the
sensitivity and selectivity of infrared imaginary now allow more meaningful observational
comparisons of sub station equipments the team of thermographers with skills and capabilities
have allowed to uncover a number of impending problems that could have led to catastrophic
failure and unscheduled outages. The increased sensitivity of newer designs rejection of
unwanted reflections .improvements of specific point resolution and in depth training have
contributed to our availability to “Infrared Imaging as an effective Diagnostic Tool”.

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