Indeed, according to a study conducted by the American Council for an Energy-Efficient Economy, predictive maintenance based on infrared thermography can reduce operating costs for businesses by 8 to 12% annually.
These savings primarily come from reductions in unplanned downtime, extended equipment lifespan, and increased worker safety.
An Effective Real-Time Anomaly Detection Method
Infrared thermography is a non-destructive thermal imaging technique that measures the thermal radiations emitted by objects when the installation is in operation, ensuring safety at a distance.
The thermal images are then analyzed to detect thermal anomalies that may indicate issues in the machinery.
A Variety of Industrial Applications
- Overheating detection in electrical equipment
- Lubrication problem detection
- Mechanical equipment inspection
- Pipe erosion detection
For Tangible Benefits in Maintenance
Example 1: Averted $200,000 Production Shutdown for Potential Lubrication Issues
At a site we worked on, a gearbox was operating at an excessive temperature. This temperature increase could have caused a failure in the lubrication properties of the oil. The lack of lubrication could have led to gearbox failure, resulting in production shutdowns and significant repair costs.
Example 2: Averted $1,000,000 Shutdown for Potential Leaks
At one of our clients’ factories, a thermal camera was used to detect internal insulation wear in the cyclone basin. The thermal images revealed areas where the temperature was higher than the surrounding parts. The slurry at the cyclone outlet was eroding the internal wall of the basin, which could have resulted in perforation and substantial costs.
Example 3: $5.2 Million Savings Achieved After 1 Year in a Thermographic Program
This program, implemented for our client, covered electrical, mechanical and process applications. Our efforts resulted in significant savings, with the respective percentages for each application being 10%, 30%, and 60% of the total savings achieved. The gains were multiplied when IR thermography was applied to our maintenance.
In conclusion, infrared thermography is a valuable method for predictive maintenance in mechanical equipment and industrial processes.
By quickly detecting thermal anomalies, companies can avoid costly downtime, high repair expenses, improve employee safety, and enhance energy efficiency in their facilities, leading to significant annual savings.
Take your maintenance inspections to the next level by using our application along with the powerful capabilities of the associated thermal camera.