Fluke Thermal ImagingCompany Confidential 1 Fluke Thermal Imaging.

Fluke Thermal Imaging Company Confidential 1

Fluke Thermal Imaging


Agenda

•Thermography Definition and Benefits

•How a Thermal Imager Works– Thermography Physics

– How Does an Imager Measure Temperature

– Imager Optics

• IR-Fusion Technology

• Imager Features– Ti10/25/32, & Ti5X

•Thermography Examples

•PC Software


What is Thermography?

Measurement of temperature remotely and assignment of colors based on temperature.

Very effective to inspect: Electrical equipment Electrical circuits Mechanical equipment Heating/cooling equipment Building envelope Electronic Other


Is the science of seeing heat patterns using special electronic camerasRather than seeing light, these remarkable instruments create pictures of heat. They measure infrared (IR) radiation and convert the data to images corresponding to the source temperatures.

Thermal imaging


Can be obtained from objects even if they are:

– moving or very hot

– difficult to reach

– expensive to shut-down

– dangerous to contact

– contaminated or altered if contacted

Fast, safe and accurate non-contact measurements


1. Safety - Avoid catastrophic failure or injury

2. Greater asset reliability - Reduces unscheduled outages

3. Increased revenue - More uptime, revenue is maximized

4. Reduced outage costs Planned maintenance saves

5. More efficient inspections Just looking for heat

6. Improved and less expensive maintenance7. Reduced spare parts inventory - Fewer spares

8. Reduced operational costs

Advantages of infrared inspection programs


Downtime is expensive

Industry Sector Revenue/Hour– Chemicals $704,101

– Construction and Engineering $389,601

– Electronics $477,366

– Energy $2,817,846

– Food/beverage processing $804,192

– Manufacturing $1,610,654

– Metals/natural resources $580,588

– Pharmaceuticals $1,082,252

– Utilities $643,250

Source: Jacksonville Power Authority


• Applies to most types of equipment and conditions

• Is obtained without disturbing production

• Quickly identifies location of problems

• Allows for detection of problems before failure

• Can scan large areas quickly to identify areas of concern, a picture is worth 1000 words

Thermal imaging


Proactive or reactive?

• Thermal Imaging can be used to both prevent problems from occurring and to troubleshoot them when they do.

• Thermal Imaging can make visible “the invisible” and help pinpoint potential problem areas faster than any other measurement tool.


Exam. Of an invisible problem


Thermal Imaging helps find/solve problems in electrical circuits

• Overloaded systems or excessive current

• Loose or corroded connections• Component failures• Wiring mistakes• Under-specified components• Power quality problems like

phase unbalance, overload or harmonic distortion

• Insulation failures• The use of one technology does not

exclude the use of another.

Image shown here is Picture-In-Picture (PIP) mode where center ¼ of image is IR surrounded by ¾ visible


Thermal Imaging helps find/solve problems in electric motors

• Over-heating due to:

- reduced cooling airflow

- under sized

- electrical insulation degradation in windings

• Bearing ware due to:

- poor lubrication

- miss alignment

- excess belt tension


Thermal Imaging helps find/solve problems of moisture in buildings

• Water entering building structure through:

– leaks in building envelop

– failed and poorly installed plumbing

• Condensation caused by:– improper construction

– poor building management

– air leakage

All of which can cause health, comfort, safety and financial issues


Thermal Imaging helps find/solve problems of air leakage

• Poor construction– Leaks around envelop penetrations like:

* Chimneys

* Plumbing vents

* HVAC lines

* Utility lines

– Leaks around window and doors

– Poorly installed siding and wraps

• Damaged and misfit heat ducts


Infrared radiation is electromagnetic radiation with wavelengths longer than visible light but shorter than microwaves

• Infrared radiation is radiated heat that cannot be seen by our eyes but can be sensed by our skin

• All objects, whatever their temperature, emit infrared radiation

• The intensity of infrared radiation depends on the temperature and a surface property termed “emissivity”

Infrared Radiation Is Not Dangerous


Temperature

• Temperature is a measure of hotness and/or coldness

– It is a measure of the molecular vibration in an object relative to the molecular vibration in other objects

– Molecules vibrate faster in warmer objects and slower in cooler objects

• Fahrenheit and Celsius are the most commonly used temperature scales

– They use the freezing and boiling points of water as reference points


Temperature Scales

100 212 672

32 4920

373

273

0 -273 -460 0

Water Boiling Point

Water Freezing Point

Absolute Zero

Kelvin Celsius Fahrenheit Rankin

Thermal radiation from objects depends on the 4th power of the absolute temperature, thus boiling water radiates 3.5 times as much as ice


Heat Transfer

•Heat always transfers from hotter to colder

•Steady state heat transfer is when the heat flow is constant with time

– Example: A electric motor that has been operating continuously for a period of time

•Transient heat transfer is when the temperature is constantly and significantly changing

– Example: An engine starting up or cooling down

– Heat capacity of material must be considered in transient heat transfer


Three Modes of Heat Transfer

Solids

Conduction

Fluids & Gasses

Convection

Electromagnetic Waves

Radiation

Ts

Temperature

of heated

surface

SUR

FAC

E


Conduction Heat Transfer

• Conduction is the transfer of heat from one molecule to another in a solid, sometimes in a fluid

– Higher temperature molecules vibrate faster and transfer their energy to adjacent cooler molecules that are vibrating slower

– If an object is totally isolated all the molecules will eventually come to thermal equilibrium and vibrate at the same rate

• Metals are good conductors of heat; they conduct heat by electron flow as well as molecule to molecule

• Nonmetals are generally poor conductors of heat– Materials that entrap small pockets of dead air are

very poor conductors and are called insulators


Conduction examples

Heat is conducted away from a corroded and high resistance connection showing a temperature gradient along the fuse

Extruded rebar shows a lower temperature exiting the die because heat is conducted from the surface of the bar to the die

And the bar surface temperature reheats down stream from internal heat conducted from the center of the bar to the surface


Conduction examples

Heat conducted through the ceiling shows missing insulation and joist pattern

Heat is conducted along copper bus bar away from resistive connection


Combined Conduction and Convection Examples

Heat from outside is conducted through siding, convected inside empty wall cavity, conducted through inside wall board and convected into air conditioned room

Heat is convected onto inside wall and ceiling, conducted through insulation and stud structure and convected to the outside air

Convection air currents don’t flow in corners very well causing cold spot at ceiling


Convection mixing

Warm water discharge from Power Plant is mixed with cooler river water


Radiation Heat Transfer

• Radiation is different from convection and conduction– Radiation does not require a medium

– Conduction and Convection are linearly proportional to temperature difference

– Radiation from a surface is proportional to the four power of absolute temperature

– Heat exchange between two objects involves complex relationships of geometry, emissivity and surrounding objects


Be aware wind can effect temperature

85F 76F 72F

15 mph wind

117F 95F 81F

No windT = 13F T = 36F


Thermal Capacitance

• Heat capacitance can both confuse or aid an inspection because it affects the rate of temperature change

– Water heats and cools slowly because of its high heat capacity

– Air heats and cools rapidly because of its low heat capacity

• Which has the highest thermal capacitance?- Copper- Steel- Brick- Wood- Water


Heat Capacity

Thermal capacitance can help find the liquid level in a tank

Also leaks in a flat roof, Sun heats roof and after Sun goes down dry insulation cools faster than higher heat capacity wet insulation


Phase Change

• Material can exist in three states -- Solid, Liquid and Gas

• To change state, energy must be added or removed

• Energy required to heat one pound of water at different states is shown below

32F

Ice (0.465 BTU/F)

Liquid Water (1BTU/F)

Steam (0.489 BTU/F)

143 BTU

970 BTU212F

Thermography takes advantage of water to vapor phase change


Phase Change Provides Moisture Detection

• Evaporation of the water into vapor draws heat from wall

Fluke Thermal Imaging Company Confidential 31 XXX Elements

XX

X E

lements

Each of the thousands of elements, or pixels, contain an accurate temperature value. The Imager, through the use of a complex set of algorithms, assign specific colors that correspond exactly with the temperature value found at the specific X Y coordinate.

How do we get the picture?

Some cameras save a simplepicture which does not actually contain any measurements.

Fully radiometric cameras store the actual temperature measurements which can be brought into a PC later for analysis.


Radiometric Imagers

It’s like having Thousands of infrared thermometers in one instrument

When a Fluke thermal imager captures an image, all the background data is also saved along with the picture allowing in-depth post processing analysis.


InsideIR PC Software

Image Analysis and Sharing

Input location name from your keyboardChange emissivity in post processingAdjust for background temperature

Turn on a temperature grid

Insert accurate point measurements or Min/Max/Average area measurements


Array Sizes

• Most Imager manufacturers provide imagers with either 320 by 240 or 160 by 120 arrays

• Advantages– 320 by 240 arrays have four times as many pixels and if they

have the same overall array dimensions and all other things being equal the imager will have four times finer detail

– Imagers made with 160 by 120 arrays are less expensive but adequate for the majority of users/applications


How does it work?

• Every object emits infrared energy / heat

• 12,280 / 19,200 / 76,800 sensors measure the energy emitted by the object and produce a digital thermal image

• Sensors can detect temperature changes as slight as 1/7th degree Fahrenheit

– The minimum temperature difference that a Thermal Imager can measure is called Thermal Sensitivity or Noise Equivalent Temperature Difference (NETD)


Comparison of Detector Type

160 x 120 320 x 240


Important temperature measurement variables

•Surface Emissivity•Surface thermal reflectivity•Background temperature•Thermal capacitance•Angle of view•System load•Target distance•Camera settings•Heat transfer•Solar and wind conditions


Reflection, Absorption and Transmission

• When IR radiation strikes an object surfaceonly three things can happen

– Some can be reflected ()

– Some can be absorbed as heat ()

– Some can pass through the object ()

• From 1st Law of Themodynamics

+ + = 1

• From Kirchhoff’s Law: emissivity () = absorptivity () Therefore + + = 1

ρ


Transmission

• Most materials are opaque (not transparent)

• Some materials are partially transparent:– Atmosphere

– IR Lens materials

– Thin film plastics

• For opaque materials = 0, = 1 - – This relationship is fundamental to the

operation of a thermal imager

ρ

= 0


Imager Temperature Measurement

W

W

W

TT

TB

Only emitted radiation tells us surface temperature and the imager must eliminate reflected and transmitted radiation to measure it

Single detector element is focused on target spot receiving radiation emitted from target W, background radiation reflected off target W and transmitted radiation from behind target W


Selecting the Correct Emissivity Value

• Only emitted radiation tells us surface temperature and the imager must eliminate reflected and transmitted radiation to measure it

• Rules of thumb

– Use 0.95 for all painted target surface independent of color

– If unpainted or un-corroded metal use 0.2 or lower

• Values for common materials are found in the imager owners manual, in the PC software, internet sources and on some Imagers

• If the target emissivity is unknown use the Imager to measure it – Use the tape method


Background Temperature

Ways of estimating the background temperature– Use room temperature

– Take images of the background

– Use an aluminum foil curtain

– Crumpled kitchen foil smoothed to act like a diffuse reflector

TargetCrumpled Aluminum Foil Curtain

Camera


Selecting Background Temperature• Background temperature is the temperature of the surround behind and to the sides of the camera where reflected radiation emanates from

• Often the background temperature has little effect on the target temperature measurement

– Target emissivity is high

– Target temperature is higher than the background

WTotal = T TT4 + (1 - T) TB

4

>


Selecting Background Temperature (cont’d)

• For Example: TT = 70F, TB = 65F, and T = 0.95

WTotal = T TT4 + (1 - T) TB

4

• But if the target temperature and emissivity are low, background temperature is very important

• For Example: TT = 20F, TB = 70F, and T = 0.10

• What to do? Use tape making the emissivity 0.95

>100 5

<2.1 32.4


Diffuse versus Specular Targets

• If the target reflects diffusely the background radiation measured by the camera comes from all around

• If the target is specular (mirror-like) the background radiation comes from specific point


Example of a Specular Target

Two hot spots are not in the window pane, they are reflections from hanging light fixtures

Image of window shows high specular reflection

To identify reflections from real hot or cold spots move camera; if spots move they are refections


Measuring Emissivity Example

Label E Ave T

A1 0.95 90.24

A2 0.95 90.39

A3 1.00 90.23

A4 0.28 90.41

•Place electricians tape (any color) on surface and take image •Record tape temperature using 0.95 emissivity •In same image place cursor on targetsurface next to tape•Adjust camera emissivity until the temperature reading equals that of the tape

White tape

Black tape

Hole with emissivity of 1.00


Controlling “Level & Span”

Span = 20.1F

Level = 80.55F


Level and Span •Level and Span can be adjusted

– to fixed span temperatures or– to automatically rescale based on the maximum

and minimum temperature in image•Narrow span produces more thermal detail•Wider span produces less thermal detail•Saturation colors will appear when the image temperatures are above or below the manually set span

For example: When viewing a face, the image will show much more detail if the span is held to 10°F with the level at 92°F to 94°F


Building - “Level & Span”

Auto Scaled including hot spot

Manually scaled with hottest spot saturated


Level and Span (cont’d)

Auto Scaled

Manual scaling shows more IR colors on transformer and small saturated point


FOV, IFOV & IFOVm

• Field of View (FOV) is total target area seen by

imager, usually expressed in degrees

Detector Array

Lens

FocalLength

Target

Distance to target

d


FOV, IFOV & IFOVm (cont’d)

• Instantaneous Field of Viewmeasured (IFOVm) is

the target area required by a single detector to

accurately measure the temperature of a

target area, usually expressed in milli-radians

• IFOVm is usually 2 to 5 times larger than IFOV


Interchangeable lenses

• Standard (20mm)– Suited for most applications

– Ideal for general purposes

• Wide angle (10.5mm)– Sees a larger surface at shorter distances

– Ideal for cramped spaces

• Long distance (54mm)– Sees more detail at longer distances

– Ideal for power line insulators/transformers


Wide Angle Standard Telephoto

Lens Options


FOV, IFOV for 160 by 120 Imagers

Distance to Target (feet)

30

25

20

15

10

5

0

0 10 20 30 40 50 60 70 80 90 100

Tar

get S

ize

(fee

t) -

- FO

V

3.0

2.5

2.0

1.5

1.0

0.5

0

Pixe

l Siz

e (i

nche

s)--

IFO

Vm

40

33.3

26.7

20

13.3

6.7

0

Horz Vert

For example, an imager with 20mm lens at 20 ft has a FOV of 8 ft horizontally and 6 ft vertically and an IFOV of 0.06 inches square


320 by 240 versus 160 by 120

320 by 240 160 by 120

19,200 pixels76,800 pixels shows additional small feature

details


Spot Size• Spot Size is the area on target seen by single detector similar to IFOV

– Usually used to spec point radiometers

– Expressed as a ratio, like 60:1 which means at 60 ft the measurement spot on the target is 1ft square or at 30 inches the spot is ½ inch square

Spot Size

Target

Spot Size > Target Area Spot Size < Target Area


IFOVm example

Hot spot is seen but temperature may not be best accuracy because spot size includes surrounding area

Move closer to measure it!


Focus is CRITICAL

• Focusing an IR imager is less sharp than a visible camera– far more elements in a visible detector array

– Infrared images are naturally less sharp

* IR wave lengths are more than an order of magnitude longer

* visible light cameras generally measure reflected radiation not emitted; IR imagers must measure emitted radiation to determine temperature

* sharp edges can exist between a black line and a white line but sharp edges can not exist between a hot line and a cold line

• Best focus is critical for accurate temperature measurements

• Anything but focus can be modified/optimized later with PC software


Best Focus Practices

Look for edges Use IR-Fusion Hold imager still Some people find best results with gray scale --

human eye most often can focus best in black and white


Checking your imager calibration

• As with any sophisticated piece of equipment, having the

calibration check is a good habit.

• Routinely check basic calibration before each scan. Here are a few

simple test you can perform

– Check the tear duct of a work partner (recommend the same person)

– Check an ice bath to verify camera performance at 0º C

– Check boiling water to verify camera performance at 100º C

– Acquire a blackbody reference in one of your common temp ranges


IR Fusion®IR Only Visible Only

50/50 Blend


What is IR-Fusion® ?• IR-Fusion only is available on Fluke Thermal Imagers

– Be aware of imitations !

• IR-Fusion links the Thermal Image with the Visual Image

– Easier to understand what you are looking at

* See the context

* Read any markers/labels/text

* No laser pointer needed

– Easier to report findings to others

* No need to also take a picture with a normal camera

– Helps you focus the Thermal Imager better

* The Thermal Imager is focused correctly when the Thermal and Visual images are completely aligned


IR Fusion® view modes

• Traditional full IR -full display is 100% infrared

• Blended full -full display is IR blended with visible

• Full Visible -full display is 100% visible


Fluke Ti series

For everyday troubleshooting and maintenance


Ti features

• IR-Fusion® Technology

•Large crisp images

•Made for rough environments

•Easy-to-use

•Flexible data storage

•Voice annotation

•Free of charge, unlicensed PC software

•2 year warranty

•The complete package


IR-Fusion Imager viewing modes

Max IR (traditional Thermal Imaging) Mid IR Min IR

PIP Max IR PIP Mid IR PIP Min IR

Ti25 OnlyTi25 and Ti10


IR-Fusion Software Viewing Modes

Traditional Full IR

Blended IR/Visual

PIP Full IR

PIP Blended IR/Visual

Color Alarms

Full Visual

Infinite blend from 100% IR to 100% visible


For rough environments

• Engineered and tested to withstand a 6.5 ft drop

• Withstands dust and water: IP 54 rating

• Integrated protective lens cover– No string to get in the way or cause

dangerous situations close to rotating equipment

• Works in ambient temperatures from 14ºF to 122ºF and measures up to 662ºF


Easy to use

• Intuitive, three button menu – Easy to use with gloved hand

• Single handed operation– Important when standing on heights

– Improved safety

• Adjustable (left or right) hand-strap makes imager convenient to hold

• Supports 16 different languages


Voice annotation (Ti25/TiR1 only)

• Record and save commentary with stored images

– Up to 1 minute with every image

– No need to write down comments

• Playback (review) on Imager or with the software


• Fluke Software is included at no additional charge, with no license agreement and no costly upgrades

• The Fluke Thermal Imager stores all radiometric data to allow full analysis capability– All parameters can be adjusted except focus if image is

saved as an is2 file

• The report wizard makes it easy to create professional reports quickly

Powerful software


Color Palettes

• Choose from 6 different palettes


Extra large display

• >40% larger than other Imagers

• 320x240 pixel resolution

• Crystal clear images

• Sunlight readable


180º articulating lens

• For areas with poor accessibility

• Easy to scan floors and ceilings without looking down or up

• Select any angle that works for you


Easy to use

• Single hand focus and image capture

• Windows CE based interface

• Mouse “on screen” operation

• Programmable function buttons


Thermal sensitivity and range

•Flexcam can be used in most applications:

– Measure temperature differences as low as 0.05ºC (depending on the model)

– Measure temperatures as low as -4ºF and high as 1200ºF (depending on the model)


Example Thermograms


Thermography found loose connections

Connections hotter than normal


Thermography found hidden overheated part

Heat from hidden part produces elevated temperature on outer surface via heat conduction


Thermography works especially well with multiple units

Far-right compressor is obviously off


Thermography helped make house greener

Large air leak causes cold spot on ceiling


Thermography helped plumbers find water leak in church heating system

Plumbing leak in cement floor caused hot spot


Thermography helps inspect power plant equipment

Baseline for feed water pump


Thermography helped distinguish between loose connection and overloaded circuit

Overloaded circuit fuse hot on both ends

Loose connection, fuse hot on one end only


Thermography helped identify overheated pole transformer

Transformer problem easily identified from a distance


66.9°F

202.3°F

80

100

120

140

160

180

200

Thermography helped identify a worn belt

Hot v-belt stressed due to wear and/or misalignment


Thermography helped identify tank fill levels

Subject to warming from the Sun the high heat capacity of oil keeps tank wall lower temperature than the lower heat capacity of air above the oil


Poor Electrical Contact


Three Phase Fuse

Phase imbalance


Loose Fuse Socket

Extra resistance at one end of fuse socket


Transformer Cooling

Some cooling tubes appear to be plugged


Overheated transformer, P1 was 350F due to cooling oil leak had exposed top of coil

Near catastrophic failure! Found and managed until normal factory shut down


Most likely caused by high resistance or corrosion on the connector


Motor control centers

Inspect lug connections and also look for subtle patterns that may be caused by internal contacts or connections to the bus


Wrong washer used in 3 phase connection on 150 HP motor

3-Phase connection with galvanized steel washer

3-Phase connection with copper washer

3-phase connection box


Motors

Uneven heating in an electrical motor will reduce the life and efficiency of the motor if not properly addressed

For each 10ºC (18ºF) rise over maximum rated temperature, approximately ½ the life of a motor is lost due to insulation failure!


Uneven temperatures on cover of lower left cylinder alerted maintenance to investigate and find faulty valve in natural gas compressor

Natural Gas Compressor


Small bearings

• No other method is as effective or fast for small bearings

• Small bearing failures can result in fire, mechanical stress, belt wear, and increased electrical loads

93.7°F

117.8°F

95

100

105

110

115


Bearings/couplings

• May be difficult to see if guard is in place

• Temperature varies depending on type


119.7°C

302.2°C

150

200

250

300

Rotating cement kilns


Determine valve on/off and leakage

Steam Traps


Process monitoring

Example of

spray cooling


Liquid Tank Levels

-18.8°C

48.2°C

0

20

40

LI01

Sludge buildup found at bottom of tank

Fill level clearly identified


Dry grain fill levels can be seen in elevator storage

Location of wet and possibly spoiled grain can also be seen

Solid Tank Levels


Roof inspection

Wet spots under roof membrane


Typical patterns

• Patterns vary with:– Roof type

– Insulation type

– Deck

– Conditions

• Non-absorbent insulation types are more difficult to inspect


Air infiltrationAir Infiltration

Clearly shows air infiltration through poor door seal


Bridge Deck / In-Floor Heating


Subsurface Anomalies

• Locate lines and utilities in walls, floors or underground


Building Envelope

Moisture remaining in wall after 2 days of extensive drying

Missing insulation


Located missing cement fill in block wall


Fluke Smartview Software

•Free of charge

•Unlicensed

•Free upgrades

•Easy to use

•Extends the Thermal Imager’s functionality

•Makes reporting easy


• Fluke Software is included at no additional charge, with no license agreement and no costly upgrades

• The Fluke Thermal Imager stores all radiometric data to allow full analysis capability– All parameters can be adjusted except focus if image is

saved as an is2 file

• The report wizard makes it easy to create professional reports quickly

Powerful software

Fluke Thermal ImagingCompany Confidential 1 Fluke Thermal Imaging.

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