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Final Report of "Infrared Thermography To Failure Detection in Induction Motors
Final Report of "Infrared Thermography To Failure Detection in Induction Motors
Final Report of "Infrared Thermography To Failure Detection in Induction Motors
On
Submitted by
BONAFIDE CERTIFICATE
This is to certify that this project report titled “Infrared Thermography to Failure
Detection in Industrial Motors” that is being submitted by
Declaration
PLACE:PIUTTUR
DATE: V.SASIDHAR REDDY
17F61A0243
II
ACKNOWLEDGEMENTS
Finally, I would like to express my sincere thanks to our parents, friends, one and
all those who guided, inspired and helped me in completion of my Seminar course
work
V.SASIDHAR REDDY
III
Abstract
Infrared thermography which has been extensively applied over decades to areas
such as maintenance of electrical installations. Its use in electrical machinery has
been mainly circumscribed to the detection of faults in static machines, such as
power transformers. However, with regard to the predictive maintenance of
rotating electrical machines, its use has been much more limited. Inspite of this
fact, the potential of this tool, together with the progressive decrease in the price
of infrared cameras, make this technique a very interesting option to, at least,
complement, the diagnosis provided by other well-known techniques, such as
current or vibration data analysis. In this topic, infrared thermography has recently
shown potential for the detection of motor failures including misalignments,
cooling problems, bearing damages or connection defects. This topic presents
several industrial cases that help to illustrate the effectiveness of this technique for
the detection of a wide range of faults in the field induction motors. The data
obtained with this technique made it possible to detect the presence of faults of
diverse nature (electrical, mechanical, thermal and environmental); these data were
very useful to either diagnose or to complement the diagnosis provided by other
tools.
Signature of the guide
IV
CONTENTS
1. INTRODUCTION. 1
2. THERMOGRAPHIC CAMERA. 5
3. THERMOGRAPHIC TECHNIQUE. 10
4. PROCESS OF THERMOGRAPHY. 12
5. APPLICATIONS OF THERMOGRAPHY. 14
6. Conclusion 23
7. Reference 24
V
1.Introduction
1.1.1. Thermography
Infrared Thermography is the technique that uses an infrared imaging and
measurement camera to "see" and "measure" invisible infrared energy being
emitted from an object.
1
Thermography is a non-contact, non-destructive test method that utilizes a thermal
imager to detect, display and record thermal patterns and temperatures across
the surface of an object. Infrared thermography may be applied to any situation
where knowledge of thermal profiles and temperatures will provide meaningful
data about a system, object or process.
2
A special camera can detect this radiation in a way similar to an ordinary camera
does visible light. It works even in total darkness because ambient light level does
not matter. This makes it useful for rescue operations in smoke-filled buildings
and underground.
It is two dimensional.
3
It is real time
4
1.4. Advantages of thermography
• It shows a visual picture so that can help compare temperatures over a large
area.
5
2. THERMOGRAPHIC CAMERA
Every object whose surface temperature is above absolute zero (-273 °C) radiates
energy at a wavelength corresponding to its surface temperature. Utilizing our
highly sensitive infrared cameras, it is possible to convert this radiated energy into
a thermal image of the object being surveyed.
Infrared energy is just one part of the electromagnetic spectrum that encompasses
radiation from gamma rays, x-rays, ultra violet, a thin region of visible light,
infrared, microwaves, and radio waves. These are all related and differentiated
in the length of their wave (wavelength). All objects emit a certain amount of
black body radiation as a function of their temperatures. The higher an object's
temperature is, the more infrared radiation as black-body radiation it emits. A
special camera can detect this radiation in a way similar to an ordinary camera
does visible light. It works even in total darkness because ambient light level
does not matter. This makes it useful for rescue operations in smoke-filled
buildings and underground.
6
Fig 2.1.Cameras - FLIR T250
8
This chart illustrates the hierarchy of colors used to represent the relative
temperature differences of the problems found during the inspection.
Black and white, and color, are properties of visible light that do not exist in the
infrared world. Because we need to convert these images into visible light, the IR
camera assigns black to the coolest temperatures in an image, white to the hottest
temperatures in an image, and graduating shades of gray in between. Similarly,
different colors can be used to portray different temperatures.
The higher the temperature, the more energy emitted. The typical infrared
thermography camera resembles a standard camcorder and produces a live TV
image of heat radiation. The camera provides a basic grey scale image which is
converted to false color images to make interpretation of thermal patterns easier.
The thermal image produced by an infrared camera is called a thermogram.
9
3.THERMOGRAPHIC TECHNIQUE
The basic principle of thermography is that all types of surfaces will emit some
degree of heat. The thermographic equipment will detect heat which differs from
the temperatures in the surrounding area of a surface. These higher temperatures
might be an indication of a potential malfunction of the scanned object
i.e. faults in electrical circuitry or overheating of bearings in mechanical equipment,
i.e. pumps, motors, compressors, etc. Thermographic imaging can detect
insufficiently insulated hot spots in engine rooms, which create a large fire risk.
If material under inspection is heated with radiators (active thermography), the
temperature of the surface will rise suddenly. The speed at which the heat front
dissipates into the material depends on the thermal properties like density, heat
capacity, thermal conductivity and the bonding quality between top surface layer
and the base material. A defect in the sub-surface creates a barrier for the heat
diffusion process and, therefore, the surface temperature above the defect will
decrease more slowly than the temperature in other regions. The surface above such
a defect will show a hot spot for a longer time as its vicinity covering good bonded
material. The principle of this effect is shown schematically in Fig 3.1.
In contrast to the fast dissipation of heat in metallic materials, the dissipation of heat
in wood-based-materials is comparable slow. The detection of defects can take a few
seconds or even some minutes after the heat impact depending on the material and
depth of the defect.
10
3.1. Active and Passive Thermography
If the inspected material is heated during the production process (passive
thermography), the surface temperature will decrease after leaving the production
line. Invisible defects within the material will appear as cold spots on the surface,
because of the good insulation between the hot core material and the colder surface.
In both cases, active or passive thermography, the defects can be either detected as
hot (active) or cold spots (passive) on the surface.
11
4. Process of Thermography
Fig 4.1.This image shows the radiant heat rather than light.The light
areas are warmer than the dark areas
12
The ability to measure temperature from an IR image is called radiometry. This
requires sophisticated and expensive electronics. The ability to measure a
temperature anywhere on the image is available only on the high-end cameras.
Fig 4.2. This image of shows a hot coffee mug and a plate of cookies. The
colors bear no correlation with visible light, rather the colors correspond to
the radiant heat.
13
5.Applicatins Of Thermography
This motor was a L.V. machine that was driving a pump for bearing lubrication. The
infrared inspection revealed a motor overheating, since the frame temperatures were
reaching values above 70ºC in some points (Fig. 5.2). After a more detailed analysis of
the motor, it was observed that the cooling air flow was insufficient; the cause was an
obstruction of the cooling channels that was produced by product wastes.
14
The cooling channels and fins were properly cleaned and the subsequent infrared
inspection revealed an abrupt decrease in motor frame temperatures up to values around
30-40ºC with the motor operating under similar conditions as in the first inspection (see
Fig. 5.3). Hence, in this case, infrared thermography enabled to detect the source of the
problem.
15
5.3. Blower motor (deficient bearing lubrication)
In this case, the inspected element was a bearing of a motor that was driving a blower. An
initial infrared inspection revealed an excessive heating of the bearing. This can be noted in
(Fig. 5.4) which shows superficial temperatures above 90ºC (and even 100ºC) in the bearing
region. We can also observe the deposit of product waste over the bearing cage. The bearing
was properly cleaned and a new inspection was carried out. However, no significant
temperature drop was detected.
Therefore, it was finally decided to re-lubricate the bearing. This measure was much more
effective, as a new infrared inspection revealed: the temperatures were not higher than 60ºC
in the bearing region for the motor operating under similar conditions (Fig. 5.5).
It is important to emphasize that, in the past, this motor had an episode of catastrophic failure
caused by problems in the bearings: in 2010, the lack of proper bearing lubrication was not
properly detected via vibration analysis; finally, this fact led to the collapse of the bearings
and to the damage of the stator insulation (see Fig 5.6). This is an illustrative case that shows
how the infrared thermography may provide very interesting information for the diagnosis
in situations where other techniques may fail.
In order to prevent the occurrence of this type of bearing lubrication problems, the plant
engineers proposed not only the use of the infrared technique to detect such anomalies in
advance, but they also suggested the lubrication of the bearings by means of ultrasounds; this
lubrication method may bring interesting benefits, such as the reduction of the possibility of
an inexact lubrication, amongst others. Moreover, the accurate study of this failure enabled
to plot a P-F curve associated with bearing faults; this curve shows, for the corresponding
fault, the minimum detectable alarm level for each considered technique. This curve is
plotted in (Fig.5.7) and shows how primary bearing defects (wear, indentations, smearing,
corrosion…) are best detected via infrared thermography and ultrasounds while vibrations
and oil analysis are best suited for the detection of secondary defects
16
Fig. 5.4. Infrared inspection of bearing of Motor2:defiecient bearing
17
Fig. 5.6 Insulation damage occurred in 2010 in the same motor due to catastrophic failure
of the bearings
Fig. 5.7. Developed P-F curve for bearing faults as a function of alarm levels
Anyway, this field case has shown the usefulness of the infrared technique to detect bearing
problems that lead to abnormal levels of heat transmission. This was also proven by another
of the field inspections carried out in the survey which nabled to detect similar faults in
other bearings.
18
5.4. Deodorization fan motor (insufficient belt tightening)
The inspected motor in this case was an L.V. machine driving a fan for deodorization
purposes. Oddly enough, the infrared inspection revealed a very high heat dissipation in the
belt transmission system (see Fig. 5.8), with a maximum temperature of 129.8 ºC that was
read on the pulley. The deficient tension leads to belt slip on the pulley and increases the
heat dissipation due to the friction, which results in decreased efficiency and a reduction of
the belt service life.
To solve the problem, the belts were properly tightened and, afterwards, a new inspection
was carried out. (Fig. 5.9) shows the new thermal map after the belt tightening that reveals
much lower temperatures in the transmission system (30ºC in average lower than in the
previous case).
19
Fig. 5.9. Infrared inspection of Motor 3 after belt tightening.
In this case, the considered motor was driving a fan of a cooling tower. The infrared
inspection of that motor (Fig. 5.10) showed a significant heating in the motor frame (85.2 ºC
in the surface and, probably, above 100 ºC inside the motor). No cooling anomalies were
found during the inspection. As a first measure, the bearings were re-lubricated and repaired
in a workshop but no temperature drop was observed.
Then, the motor terminal box was inspected and only a little temperature difference between
connections was found. The winding resistance of each phase was measured with an
ohmmeter and the results were very interesting (see Table IV, which compiles the results of
the measurements): a significant winding asymmetry was detected between phases, leading
to a Max Delta R value of near 9%. This could indicate internal high resistance connections,
broken turns or internal shorts. This may be the potential cause of the abnormal heat
dissipation. A motor re-winding was finally suggested.
Hence, the advantage of the technique in this case is that it informed about the existence of
an anomaly in the stator winding, suggesting the adoption of further maintenance actions.
Note that these anomalies are not always easily detectable with other techniques (e.g. current
analysis), therefore, the information provided by infrared thermography may be very
interesting to prevent eventual catastrophic consequences.
20
Table1. Measured Value of Resistance in each Phase
accurately plays a crucial role; in order to avoid this dependence on the user, expert systems
based on artificial intelligence techniques are being developed to enable an automatic
interpretation of infrared images and reach a diagnosis of the condition discriminating
between faults and other effects .
21
5.6. Non Destructive Testing
Nondestructive Testing (NDT), also called nondestructive examination (NDE) and
nondestructive inspection (NDI), is testing that does not destroy the test object. To
detect different defects such as cracking and corrosion, there are different methods
of testing available, such as X-ray and ultrasound.
While destructive testing usually provides a more reliable assessment of the state
of the test object, destruction of the test object usually makes this type of test more
costly to the test object's owner than nondestructive testing. That there is a tradeoff
between the cost of the test and its reliability favors a strategy in which most test
objects are inspected nondestructively; destructive testing is performed on a sampling
of test objects that is drawn randomly for the purpose of characterizing the testing
reliability of the nondestructive test.
During their service lives, many industrial components need regular non-
destructive tests to detect damage that may be difficult or expensive to find by
everyday methods.
22
6.Conclusion
By comparing the results with other classical non-destructive testing techniques such
as ultrasonic testing or radiographic testing, thermographic inspection is safe,non-
intrusive and noncontact, allowing the detection of relatively shallow subsurface
defects under large surfaces and in a fast manner. Thermography enables us to see
and measure heat. Thermography is a method that utilizes a thermal image to
detect, display and record thermal patterns and temperatures across the surface of
an object. Thermography is the future in water damage and mold claims
adjudication for the insurance industry.
Thus from the analysis done on IR Thermography probably the IR Thermography is
going to allow the industry to be more exact in the data that it obtains, and to
be able to resolve any claims that may be occurring now, as well as in the future,
more quickly and cost-effectively, saving time and money.
23
7. REFERENCES
[2] R. Gade, T.B. Moeslund, “Thermal cameras and applications: a survey,” Machine Vision
and Applications, vol. 25, no. 1, pp. 245-262, Nov. 2013.
[3] M. S. Jadin, S. Taib, “Recent progress in diagnosing the reliability of electrical equipment
by using infrared thermography,” Infrared Physics & Technology, vol. 55, no. 4, pp. 236-
245, July 2012
[4] J. Bryan, “Keeping it cool: A look at causes of motor overheating,” Electrical Apparatus
Service Association, Inc, www.easa.com, March 2015, pp. 1-5.
[5] A.R. Mohanty, S. Fatima, “Shaft misalignment detection by thermal imaging of support
bearings,” IFAC-Papers On Line, vol. 48, no. 21, pp. 554-559, 2015.
[6] Armando Guadalupe Garcia-Ramirez, Luis Alberto Morales- Hernandez, Roque Alfredo
Osornio-Rios, Juan Primo Benitez-Rangel, Arturo Garcia-Perez, Rene de Jesus Romero-
Troncoso, “Fault detection in induction motors and the impact on the kinematic chain
through thermographic analysis”, Electric Power Systems Research, Vol. 114, Sep. 2014,
pp. 1-9.
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