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Chapter - 3 (Reflection Problem)
Chapter - 3 (Reflection Problem)
Chapter - 3 (Reflection Problem)
REFLECTION PROBLEM
Temperature Level
To assist the thermographer with the ‘out of range’ problems, modern day
cameras have a built-in function which saturates all temperature zones outside the
measuring range with an ‘overflow’ or an ‘underflow’ colour. Unfortunately, under
certain operating conditions this can present a problem, e.g., when inspecting
electrical panels. During a general survey of an electrical plant the thermographer
may have to carry out an internal inspection of a large number of panels. Often
these panels contain a considerable number of components varying in
temperature from near-ambient up to a few hundred degree, e.g., resistors can
often reach 300ºC. Temperatures of typical faults can be more like 100ºC or less.
During the survey, while viewing the image, the thermographer must be able to
immediately recognize what is being viewed in order to distinguish between faults
and normal operating temperatures. Under these conditions, when the ‘saturation’
mode is engaged, large areas of the thermogram may be blanked out by the
saturation colors, making it very difficult to recognize what the image represents.
The lesson that a thermographer should learn from this is: do not be overly
impressed by the seemingly high quality of the picture, always watch the image
and the temperature and other parameters displayed to make certain the
instrument is operating within its correct settings.
Although the modern software for processing images allows for a number of
features to be modified later, the features mentioned above must be set correctly
at the time of recording, since once saved, they can not be altered.
Most modern infrared cameras have a zoom function, but zooming is acquired
electronically rather than by optical means. Zooming, therefore, reduces the pixel
resolution of the thermogram. It is always advisable to set the camera so that the
object under investigation fills the field of view to the maximum.
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The above description is base on one make of infrared camera, and cameras
produced by different manufactures may incorporate different temperature ranges
and images displays. Nevertheless, the above principles should apply to any
modern infrared camera.
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The example below shows the tubes inside an oil heater in a refinery
demonstrating a case where it is not wise to assume what the ambient
temperature might be. In this instance a camera fitted with a high temperature filter
was used, which allows measurement of temperatures of the tube with minimal
interference from the flame. Thermogram 8 shows the temperatures of the tube
and the support, with both atmospheric and ambient temperature compensation
set to 15ºC, i.e., with no ambient temperature correction. On the other hand,
Thermogram 9 takes the ambient temperature into consideration and, in this
instance, the temperature of the support bracket was used.
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Figure 2 shows the thermal pattern of a layshaft bearing assembly in a hot air fan
unit. The front bearing is very close to the fan casing which operates at an
elevated temperature. There will, therefore, be some interaction between the hot
casing and the nearby objects.
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Thermogram 10 Figure 3
Figure 2 shows the effect on ‘object temperature indication’ when varying the
ambient temperature compensation. It can be seen that ignoring the ambient
temperature in the calculations has a marginal effect at low ambient
temperatures. However, the measuring error can be significant if very high
ambient temperatures are present and these are not taken into consideration.
Thermal reflection is also discussed in section 3.3.
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3.3 REFLECTIONS
3.3.1 ELECTRICAL
Figure 4
Thermogram 11 Thermogram 12
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Figure 5
Thermogram 13 Thermogram 14
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Figure 6
Thermogram 15 Thermogram 16
Often control panels may incorporate a reflective back plat and, as can be seen in
Figure 7 and Thermogram 17, the reflection of the thermographer is clearly
detected by the camera.
In such situations do not stand directly in front of the panel.
Figure 7 Thermogram 17
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The connectors can be viewed from above the panel (Figure 9). It is seen that all
the surfaces in this area are very reflective and Thermogram 18 shows the switch
to busbar connectors, which are in good condition. It also shows the reflection of
the thermographer and the camera on the bright surfaces either side of the mesh
above the connectors.
Also note how the metal mesh provides a viewing window for the infrared camera
without adversely affecting temperature measurement.
Thermogram 18
Figure 8 Figure 9
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Figure 10
Another survey of a main panel fused
isolator shows how the position of an
apparent ‘hot spot’ changes with viewing
angle, clearly identifying it as a reflection,
as shown in Figure 10 and
Thermograms 19 and 20.
Thermogram 19 Thermogram 20
Thermogram 21 Figure 11
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Yet another example thermal reflection can be seen on capacitor terminal links,
shown in Figure 12 and Thermogram 22.
These capacitors form part of a power factor correction unit. In front of the
capacitors are hot windings and the heat generated is reflected on the copper links
between terminals.
Thermogram 22 Figure 12
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Thermogram 23 Thermogram 24
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Figure 14
It is critical to the accuracy of results
and competence of thermographers that
they are aware of thermal reflections
and, wherever possible, produce
thermograms free of them.
Thermogram 25 Thermogram 26
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3.3.2 MECHANICAL
Thermogram 27 Figure 15
Thermogram 28 Figure 16
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Thermogram 29 Figure 17
Most of the surface of the tank dome is painted but there are new sections of
bright stainless steel cladding fitted in some areas, as indicated by the arrow in
Figure 18.
The dome was surveyed during the night. Note the reflection of cold sky on the
bright sections of the cladding. On the right side of Thermogram 30 a warmer
area can be seen which is a result of heat generated by the flare located on the hill
behind the tank, seen as background on the photograph.
This illustrated the point that the thermographer collecting the data must be aware
of the total environment around the target object and apply deductive reasoning to
identify, or if possible eliminate, reflections from data submitting for interpretation.
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Figure 18
Thermogram 30
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Thermogram 31 Figure 19
Thermogram 32 Figure 20
3.3.3 SW vs LW
When dealing with reflective surfaces, thermal patterns can be greatly affected by
external heat sources such as solar radiation or nearby hot objects. However, with
experience it is relatively easy to distinguish between a genuine hot spot and a
reflected hot spot.
As shown in previous examples, the basic rules for identifying a reflection are:
1. Genuine hot spots do not alter their position on the viewed surface with the
change of viewing angle;
2. Reflected hot spots move across the viewed surface with the change of
viewing angle and often have sharp edges to the anomaly.
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There is one distinct difference between the two types of reflection mentioned. The
intensity of the solar reflection, as seen by the infrared camera, is greatly influenced by the
type of detector used. Reflected radiation anomalies appear to be much more noticeable
when viewed with a Short Wave system (SW). When using Long Wave systems (LW) the
effect of reflected solar radiation is greatly reduced, or even eliminated. This is
demonstrated in Figure 21 and Thermograms 33 and 34 of metal clad pipes. However,
influence from nearby hot or cold objects is very similar, irrespective of the type of
instrument used, as can be seen in Thermogram 35 and 36 showing reflection of the
operator on a gloss-painted surface.
As noted, reflected hot or cold spots move across the viewed surface with the change in the
viewing angle. This is very noticeable when viewing objects at a relatively close range,
where a slight change in the viewing position produces a relatively large change in the
viewing angle. When surveying objects at long distance, shifting position may only produce
a small change in the viewing angle. In such situation it is difficult to see if the hot or cold
spot has shifted from its original position. This can be particularly troublesome when
surveying insulated objects that are clad in bright metal, as illustrated in some of the
examples below. In such situations there are other indicators that can be used by the
thermographer to determine what type of ‘anomaly’ is being viewed.
Solar reflection
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Reflections of the sun, or the cold sky, usually produce thermograms with a very
sharp change in temperature between the reflection and the normal surface.
Missing insulation under cladding can also produce a very similar thermal pattern
to solar reflection, but often the shape of the thermal pattern on top of the cladding
is different, and this can be used to distinguish between a genuine defect and a
reflection. For example, areas of insulation damage due to water ingress tend to
produce much more diffused thermal patterns.
Figure 21
Thermogram 33 Thermogram 34
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Thermogram 35 Thermogram 36
Reflection on gloss painted surface - SW Reflection on gloss painted surface - LW
Figure 21 and Thermograms 33 and 34 show some metal clad pipes and solar
reflections. Although the cladding ties are still bright, the remainder of the
insulated pipes are well oxidized. Thermogram 33 was recorded with a short
wave (SW) system, whereas Thermogram 34 was recorded with a long wave
(LW) system. Note the difference in temperature readings.
As can be seen from the recorded temperatures, the LW systems is affected much
less by solar radiation. Still, this does not solve the problem. Al though the solar
‘glare’ is reduced, the pipes have absorbed energy from the sun and this is
detected by both infrared cameras. Thermograms 35 and 36 indicate reflections
on a gloss painted surface, using a SW and LW system, respectively.
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Figure 22
As can be seen in the example in Figure
22 and Thermogram 37 and 38, in
cases where there is no solar reflection
to consider, the SW and LW systems
behave similarly. Note the improved
quality of the picture of the LW system
when operating at low temperature
differences and near ambient
temperature.
Thermogram 37 Thermogram 38
3.4 SOFTWARE
Modern day infrared scanners are fully computerized and the software provided for
analysis of thermal images can range from very basic to highly advanced systems.
These software packagers are developed by manufacturers to suit their particular
equipment; it is not the intention of this book to discuss every system in detail, but
to highlight the more important features. However, most advanced software
systems will have a number of common features, such as those mentioned below.
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Modern day scanners usually store data on memory cards, such as ‘Flash’ or
‘Compact Flash’ the information from which can then be downloaded into the
computer for processing.
Most modern software packages have built-in templates for writing reports and
also have provisions for creating individual report templates for the user. These
templates allow for import of thermograms, data relating to the thermograms, as
well as digital photographs. Thermograms may also be altered by allowing
changes to settings such as thermal span and level, changes to parameters
related to the imported thermogram (such as the analysis tools), changing
paletters, etc. The software also allows for creation of text boxes, data tables and
temperature profile graphs to be included in the report as necessary.
More advanced software packages may also have facilities for trending events
over time, storage and management of data, etc.
Analysis tools
Areas These can be box-shaped, circles or polygons and each can be set
to display maximum, average or minimum temperature within the
area
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Thermogram 39
The analysis tools mentioned above are
illustrated in Thermogram 39 and Figure
23.
For convenience, the temperatures are
superimposed onto the thermogram.
However, it is also possible to create a
table where the fields can be linked to
the data stored with the thermogram,
such as emissivity, ambient
temperature, atmospheric temperature,
object distance, relative humidity, data
and time of creation.
Figure 23
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