Maintenance & Reliability Seminar in Kansas City / St. Louis, MO

1. September 2015
The Benefits of a
Thermography Program
Bill Nolan
District Sales Manager
FLIR Systems

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Who is

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About FLIR
• FLIR is a vertically integrated manufacturer
with 50 years experience in military and
commercial markets.
• FLIR cameras set the standard for detection
and temperature measurement.
• FLIR is the industry leader with over 67% +
market share –
• Selling more cameras than all other
competitors combined - by offering the
best infrared technology at every price
point. .

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• Government System – Thermal Imaging for Military , Coast Guard and Law
Enforcement Applications
• CVS – Commercial/Consumer Night Vision (Cars, Boats, Airplanes, Security
Systems, Hunting)
• Instruments – IR Cameras for Industrial Thermography Applications

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It is the process of turning Infrared Radiation into a
usable “picture”.
Allows you to see things in a different light.
What is Thermal Imaging?

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How does it work?
 IR waves are emitted by all objects
 IR radiation increases with temperature

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Photons Impact and
HEAT the Detector Element.
E = T4
Stefan - Boltzmann Law
Advanced Calculations
22 39 44 86 35 25
23 56 48 53 46 58
25 45 84 35 45 55
22 39 44 86 35 25
23 56 95 53 46 58
25 28 81 35 45 55
48
83
22
How do thermal cameras work?
83
83

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Why do we want to see heat?
Heat anomalies tend to indicate problems

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Why do we want to see heat?
Heat anomalies tend to indicate problems

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Thermography Applications
Electrical Inspections
Mechanical Inspections Commercial /Residential
Energy Audits
Industrial Energy Audits
Manufacturing/Process
2 7 . 2
8 7 . 9
4 0
6 0
8 0
Roofing R&D
Wildlife Studies

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Electrical Inspection
• Industrial
• Residential
• Commercial
• Utilities

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•motor control centers
•breakers and fuses
•relays
•switch gear
•bus ducts
Electrical Inspection

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•Pumps
•Motors
•Conveyors
•Gear boxes
•drive shafts
•belts and pulleys
•bearings
*>70.5°C
*<34.7°C
35.0
40.0
45.0
50.0
55.0
60.0
65.0
70.0
Mechanical Inspection:

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•Electrical
•Mechanical
•Energy Efficiency
•Moisture Detection
•Steam and Plumbing
•Radiant Heat Systems
•Insect Infestation
•HVAC Problems (motors/electrical)
Property Inspection

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•Roofing Systems
•Walls Systems
•EFIS Systems
•Fire/Flood
•Water Migration
Building DiagnosticsMoisture Detection

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Energy Efficiency
•Energy Assessments
•Radiant heat systems
•Missing/Poor Insulation
•Air Infiltration
Building Diagnostics
8,6°C
16,0°C
10
15

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Veterinary Sciences/Wildlife Research
•Equine performance
•Marine mammal health
•Wildlife management
•Hunting?

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Why the conversion from old spot gun
technology to IR Cameras?
Spot Radiometer/Temp Gun
$79 to $459
Infrared Camera
Now as affordable as $699
Speed - Accuracy - Documentation - Safety
Imaging Thermometer
Now as affordable as $499

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A spot gun has one detector
no image
and a single temp reading
Spot Temp Gun = Limited Technology
Speed

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FLIR E4 - $995
C2 - $699
TG165 - $499
80 horizontal
X 60 vertical
4800 infrared pixels
Advanced Technology
= 4800 Spot Temp Guns

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FLIR E6 - $2495
160 horizontal
X 120 vertical
19200 infrared pixels
Advanced Technology
= 19200 Spot Temp Guns

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FLIR E6 - $2495
Advanced Technology
= 19200 Spot Temp Guns

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90.0
How is a spot temp gun used?

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90.0
How is a spot temp gun used?

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90.0
How is a spot temp gun used?

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90.0
How is a spot temp gun used?

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90.0
How is a spot temp gun used?

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90.0
How is a spot temp gun used?

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Look Familiar?

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Where is the
“hot” wire?

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Would a Substation in the US be easier?

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We could find an overheated situation with a FLIR Camera.

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Accuracy

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6” distance to target
6:1 Spot Size
Accuracy
At 6” the IR Gun averages the temperatures within a 1” area
And, no the laser beam is not measuring the temperature

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36” distance to target
At 36” the area averaged balloons to 6”
6:1 Spot Size
Accuracy

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6:1 Spot Size
Accuracy
To accurately measure a
¼” target
You must be within 1.5”
UNSAFE

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Documentation
Documentation

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IR Camera Documentation

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Speed, Accuracy, and better
Spot Size
Safety
Lead to finding
problems faster from
a safer distance

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Allowing you to find Hot Spots
before they become a bigger….
Safety

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Allowing you to find Hot Spots
before they become a bigger….
Safety
More dangerous problems.

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Infrared obviously:
1) saves time
2) is more accurate
3) allows for better documentation
4) and offers greater safety
…but how can we justify the price?
Simple:
IT SAVES MONEY!

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10/20/2015
48
Industrial Savings

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BUT!
That’s only the 1st cost
associated with an equipment
failure or lost.
A fire in a Motor Control
Center will cost thousands
of dollars and can cost
hundreds of thousands of
Dollars in lost equipment.

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“PRODUCTION DOWN TIME can far outweigh the cost of
replacing the equipment or component”1
1) Sandy Sanor, HSB Thermography Services, Cost/Benefit Analysis of
Infrared Programs, Maintenance Technology, June 2001
Based on Sample Data from Hartford Steam Boiler:
Industry Total Claim Equip. Claim Production Loss Failure
In this case, production loss accounted for 71% of the claim.

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Sample Totals:
27% of total claims are for things other than the
equipment, but not all coverage included production
loss and therefore were not recorded.

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Failure Statistics
Of the failures cited, nearly 85% involve problems that are typically
found with established IR Programs.

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One of HSB customers documented 41
problems in a calendar year.
Total savings (not including production
losses) totaled: $32,560 - that’s a 4x
ROI on an E60.
Over an 8 year period, this same facility
has saved $389,000 and corp. wide,
they saved $2,300,000
Total Program Savings

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Bad bus-breaker connection
VERIFY CONTRACTOR REPAIRS
& IMPROVE PLANT SAFETY
Location: U.S. Manufacturer
Electrical Problem = $100,000 Fire
Quick IR Scan before start up found a similar
problem in the new equipment, averting
another shutdown and potentially another
fire.

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Overheating bushing connection
166˚F
LOCATE POOR ELECTRICAL CONNECTIONS
Location: Substation outside Paper Mill
Problem – A Quick Scan from outside the
substation found a connection
issue
Savings: Estimated Outage =
$200,000 - $300,000

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Location: US packaging and distribution
company
Problem: Numerous Motor, Drive and
Bearing Problems.
Savings: After initiating a IR Survey
program, they are reporting
savings from this program
estimated at over $1,000,000.Internal winding problem on motor
INSPECT WORN MOTORS,
PUMPS AND CONVEYORS

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High resistance connection
EVALUATE NEW EQUIPMENT
AND INSTALLATIONS
Location: US Tool Manufacturer
Equipment: New piece of capital equipment
Problem: A startup scan found a faulty
bypass switch
Estimated Savings: +$100,000

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Overheated conveyor belt
81.1˚F
INSPECT CONVEYOR
SYSTEMS WHILE RUNNING
Location: US Shipping/Distribution
Company
Problem: 79 miles of conveyors
Bears every 8-10 feet
40,000 bearing sets
Solution: IR allows these to be quickly
scanned from a distance.

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IN-HOUSE PROGRAMS ALLOW FREQUENT
INSPECTION OF CRITICAL COMPONENTS
Location: US Automobile Mfg
Problem: MMC Drive Failure shutdown
entire manufacturing line.
Cost: 1.5 hours production = $225,000
(nearly 25 years ago..circa 1992)
Solution: IR Camera allowed them to
check drive weekly (5 min work)

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Additional Benefits of an IR Program
1) Plant and worker Safety.

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Additional Benefits of an IR Program
3) Reduced Insurance Premiums
Most Insurance Companies offer
reduced insurance for companies with
established IR Programs:
Many now require a minimum of an
annual survey, but some offer costs
reduction for more established
programs.

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Additional Benefits of an IR Program
4) Increase Production Efficiency by:
Preventing unscheduled shut downs
Allowing repairs to be made at convenient time
Allows equipment to run a peak efficiency
Assures smooth workflow and consistent product delivery

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The Equipment

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The NEW Generation
Imaging Thermometer and IR Cameras

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 Easy to Use
 Easy to Interpret & Share
 Accurate
 Innovative

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2 Years Parts and Labor
5 Year Battery
10 Year Detector
WARRANTY
2 Years Parts and Labor
10 Year Detector

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Easy to Interpret

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Picture in Picture
&
Blended Fusion
Image
Dilution=

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MSX the new standard

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MSX vs. Blending

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Easy to Share

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JPEG Image Storage
• Patented Radiometric Image Storage
• Portable - ONE FILE - USE ANYWHERE
• Easy to find
• Easy Email (and use in Presentation and Word Documents)
• Easy to Analyze
81

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Wi-Fi

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Tools Software Ecosystem
Bluetooth/Meterlink
CM83/85Exx Series

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• 1000V AC/DC True RMS Digital DMM
• VFD Mode (w/ simultaneous Voltage/Freq display)
• LoZ Filter
• Meterlink/Bluetooth - Camera and Smart Phones (DM93)
• Large Easy to Read Backlit LCD
• Work lights
• .05% accuracy
• 2M Drop Rated/IP54
• Type K temperature (2192oF)
• Silicon Test Leads Included
• Limited Lifetime Warranty
FLIR DM92/DM93
DM92 $299.99
DM93 $349.99

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• 600A/1000A AC/DC True RMS Digital Clamp Meter
• VFD Filter
• Easy to Read Backlit LCD
• Work lights
• Bluetooth – Camera and Smartphones (CM83/CM85)
• Power Factor, THD, and Harmonics 1-25
• Total Watts
• Inrush Current
• 2M Drop Rated/IP54
• Type K Temperature (1400oF)
• Silicon Test Leads
• Limited Lifetime Warranty
FLIR CM82/CM83/CM85
CM82 $299.99
CM83 $349.99
CM85 $399.99

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• 1000V AC/DC Insulation Tester w/ DMM Combo
• 1000 V True RMS DMM
• VFD Mode (w/ simultaneous Voltage/Freq display)
• Meterlink/Bluetooth - Camera and Smart Phones (DM93)
• Adv Insulation Mode – 20GΏ, Polarization Index, Dielectric
Absorption Resistance, Earth Bond Resistance
• Resitance Range: 50V, 100V, 250V, 500V, 1000V
• Large Easy to Read Backlit LCD
• Work lights
• Silicon Test Leads Included
• Limited Lifetime Warranty
FLIR IM75
IM75 $599.99

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• CAT IV-1000V Non-Contact Voltage Detector/Flashlight
• Tactical Feedback - Works in Noise Plant Environment
• High Sensitivity Mode for 24V Range
• 60 lumen Flashlight
• On/Off - Auto OFF
• 2 AA Batteries
• Limited Lifetime Warranty
FLIR VP50
VP $34.99

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Also Available:
DM92 - no Bluetooth version of the DM93
CM82 – no Bluetooth version of the CM83
CM78 – 1000V/1000A AC/DC Clamp w/ IR Temp
IM75 - Insulation Tester - DMM Combination
MR77 - Moisture Meter/Hygrometer
VS70 - Video Borescope
VP50 - Tactile feed back Voltage Detector/Flashlight
FLIR Test and Measurement

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Choosing the right camera
Some many features
So many options

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Choosing the Right Camera
TG165/C2
Lower Resolution
Simple to use
Point-n-Shoot
C2 and above with
MSX
Ex-Series
Troubleshooters
$399/$699
$1K - $4K

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Choosing the Right Camera
TG165/C2
Lower Resolution
Simple to use
Point-n-Shoot
Mid-Range
Resolution
Addition Function
Manual Focus
Connectivity
Optional Lenses
Ex-Series
Exx-Series
Troubleshooters Basic PM
$499/$699
$5K -$8K$1K - $4K

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Choosing the Right Camera
TG165/C2
Lower Resolution
Simple to use
Point-n-Shoot
High Resolution
Advanced Features
Autofocus
Real-Time Recording
Many Lenses
Mid-Range Resolution
Addition Function
Manual Focus
Connectivity
Optional Lenses
T6xx Series
Ex-Series
Exx-Series
T4xx Series
Troubleshooters Pro-SeriesBasic PM Advanced PM
$499/$699
$9K - $15K - $29K$5K - $8K$1K - $4K

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Choosing the Right Camera
TG165/C2
Lower Resolution
Simple to use
Point-n-Shoot
High Resolution
Advanced Features
Autofocus
Real-Time Recording
Mid-Range Resolution
Addition Function
Manual Focus
Connectivity
T6xx Series
Ex-Series
Exx-Series
T4xx Series
Troubleshooters Pro-SeriesBasic PM Advanced PM
$499/$699
$5K - $8K
Hi-Def
$40K
T1K Series
Highest Resolution
Most Advanced
Continuous Autofocus
Radiometric Video
Unmatched Accuracy
$1K - $4K $9K - $15K - $29K

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FLIR’s Infrared Training Center
• Global Leader in IR Thermography Training.
• ISO-9001 Registered and NETA accredited in IR Thermography Training.
• Level I, II and III Condition Monitoring IR Certification, R&D Courses, and
Application Courses.
• Course Website with many FREE courses

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Free On-Line Training Courses:
Camera and Software Operation Courses
Infrared Basics
Thermography Basics
Emissivity Explained in Plain English
Plus – numerous application specific courses ($35)
Numerous FREE Webinar (live and Replay)
Variety of Topics (16 Webinars)
www.infraredtraining.com
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