Using Thermography in Predictive Maintenance
Thermal imaging cameras are indispensable in the predictive routine for the detection of hot spots in electrical, mechanical and thermal equipment.
Predictive maintenance differs from traditional preventive maintenance by focusing on failure prognosis through the analysis of real-time data from the equipment. Instead of performing interventions based on pre-established time intervals, predictive maintenance uses advanced technologies to detect trends that suggest an imminent failure. For this strategy to be effective, it is essential to continuously monitor the operating conditions of assets, such as temperature or vibrations. Fixed thermography is a key technology in predictive maintenance, as it allows infrared radiation to be captured and converted into thermal images in real time, facilitating the early identification of anomalies and the scheduling of maintenance before failures occur.
Infrared thermography transforms predictive maintenance, allowing early detection of failures through
continuous temperature monitoring in critical equipment such as motors, electrical panels and transformers. For example, a system like bcbCondition, which uses FLIR cameras, can identify overheating points in motors on production lines. These points often indicate friction problems in bearings or faulty connections in electrical circuits, allowing predictive maintenance to be carried out before production is stopped. The key benefit is that, with continuous monitoring, equipment can continue to operate without unnecessary interruptions while potential problems are identified before they become costly failures.
In the energy sector, thermography is widely used to monitor substations and their critical equipment such as CTs, TPs, disconnecting switches and others, in high and medium voltage systems. A slight increase in temperature in a transformer can warn of a possible overload or malfunction, allowing adjustments to be made without interrupting the power supply. The integration of bcbCondition as an automation system with connectivity to PLCs ensures that any variation outside the programmed parameters triggers alarms sent via SMS, e-mail or activating digital outputs, thus protecting operations and avoiding productivity losses.
In addition to operational advantages, fixed thermography offers key benefits in the areas of Safety, Health and Environment (EHS). Continuous monitoring with infrared thermography not only protects the integrity of equipment, but also ensures the safety of workers and facilities. Critical equipment such as MCCs (Motor Control Centers), compact substations, cycle converters and PSRs (Protective Overcurrent Relays) are subject to dangerous phenomena such as arc flash. These incidents can cause significant damage, both at the operational and personal safety level, due to the high temperatures and energy released in the electrical arcs.
Fixed thermography allows for the constant inspection of this equipment, detecting any thermal anomalies that may precede such a failure. For example, a localized increase in temperature in an electrical panel can be an early indicator of a faulty connection or wear in components. This not only improves safety, but also minimises workers’ exposure to high-risk environments as they do not need to physically approach the equipment to perform manual inspections.
With the integration of bcbCondition , the frequency of maintenance and the planning of scheduled downtime can be optimised, extending the useful life of assets, as well as significantly reducing unplanned downtime. This translates into increased productivity and lower operating costs.
