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Leak Detection & Predictive/Preventative Maintenance Solutions Presented by FLIR
- 1. TRANSCAT & FLIR SYSTEMS WEBINAR LEAK DETECTION & PREDICTIVE / PREVENTATIVE MAINTENANCE SOLUTIONS
- 2. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. AGENDA LeakDetection Overview Gas Detection(GF77) Air Leaks& PartialDischarge(Si124) Q&A FLIR Si124 FLIR GF77
- 3. LEAK DETECTION OVERVIEW LEAK DETECTION & PREDICTIVE / PREVENTATIVE M AINTENANCE SOLUTIONS
- 4. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. TARGET USERS & APPLICATIONS • One of 3,300 utilities that provide power transmission and distribution of electricity through out the US • IOU, Co-op’s, Municipalities • Electric Generation using Nuclear, Natural Gas, Coal, Renewable energy
- 5. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. TARGET USERS & APPLICATIONS • Do you have gas or air leaks that are hard to find? • Do you have gas or air leaks that you think you have but aren’t sure (because if you can’t see it, it must not be there? • Do these potential leaks create a safety/environmental hazard at your plant? • Do these leaks cost you money if left unattended? • Do you want to find partial discharge failures? • Do you want to improve the reliability of your operation? • Do you wish every employee had access to a thermal camera for quick checks and safe working environments? • Do you think thermal imaging cameras are expensive?
- 6. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. HOW DO YOU FIND A GAS LEAK? Gas is invisible to the naked eye
- 7. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. COMMON CHALLENGES? • Time Consuming • Hard to pinpoint where the leak is coming from • Especially around energized equipment • Easy to miss leaks (leaks could happen right under your nose) • Expensive – You paid for the gas why waste it • Environmental Damage especially SF6 and Methane • Safety – Can cause explosions and loss of life
- 8. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. DO YOU/EMPLOYEES WEAR PPE/FR CLOTHING? • PPE = seat belts, it’s the last line of defense. • Seat belts don’t prevent the car crash and PPE doesn’t prevent the Arc Flash. • Do you drive at night without head lights? • Answer = No • So why do we do electrical work in the dark?
- 9. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. THERE HAS TO BE A BETTER WAY • What if you could scan large areas quickly and safely at a distance like an RMLD? • What if you can pinpoint exactly where it was coming from like Snoop or a TVA(sniffer)? • What if you could document in a picture or a video the exact location of the leak to make repairing faster?
- 10. FLIR GF77 – GAS DETECTION LEAK DETECTION & PREDICTIVE / PREVENTATIVE M AINTENANCE SOLUTIONS
- 11. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. FLIR GF77 METHANEDETECTION SF6 DETECTION AMMONIA DETECTION HOTSPOTS THE FIRST OPTCAL GAS IMAGING CAMERA VERSATILE ENOUGH TO ALSO SEE THERMAL (HOT SPOTS)
- 12. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. HOW DOES OPTICAL GAS IMAGING WORK?
- 13. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. HOW DOES OPTICAL GAS IMAGING WORK?
- 14. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. HOW DOES OPTICAL GAS IMAGING WORK?
- 15. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. ELECTROMAGNETIC SPECTRUM Visible: 0.4-0.7 m Midwave Infrared: 3-5 m Longwave Infrared: 7-14 m MW LW 1 µm 3 µm 5 µm 7 µm 14 µm .4 µm .7 µm
- 16. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. 0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0.800 0.900 1.000 3.000 3.200 3.400 3.600 3.800 4.000 4.200 4.400 4.600 4.800 5.000 Transmission Wavelength (microns) Propane, Benzene, Methane, Ethylene Ethylene Methane Benzene Propane THE SCIENCE BEHIND OGI We “match” the spectral response of the camera to the “peak” spectral absorption of the gas! * Data intentionally skewed to protect Cooled Midwave OGI Camera
- 17. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. 0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0.800 0.900 1.000 3.000 4.000 5.000 6.000 7.000 8.000 9.000 10.000 11.000 12.000 0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0.800 0.900 1.000 3.000 4.000 5.000 6.000 7.000 8.000 9.000 10.000 11.000 12.000 0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0.800 0.900 1.000 3.000 4.000 5.000 6.000 7.000 8.000 9.000 10.000 11.000 12.000 0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0.800 0.900 1.000 3.000 4.000 5.000 6.000 7.000 8.000 9.000 10.000 11.000 12.000 0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0.800 0.900 1.000 3.000 4.000 5.000 6.000 7.000 8.000 9.000 10.000 11.000 12.000 INFRARED GAS SPECTRA OF COMMON GASES Transmission Wavelength (microns) Methane CO2 CO R-22 SF6 * Data intentionally skewed to protect
- 18. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. FUEL GAS SKID (METHANE) – GF77
- 19. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. FLANGE (METHANE) – GF77
- 20. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. CIRCUIT BREAKER SF6 GF77
- 21. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. GF77 PREDICTIVE MAINTENANCE
- 22. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. GF77 CAMERAFEATURES GF77-HRLENS NEWGF77-LRLENS FLIR GF77 PORTFOLIO • Temperature ranges: • -20 – 80 °C • 0 – 250 °C • 0 – 500 °C • On-board routing available • Temperature accuracy of ± 3°C • Spectral range: 9.5-12 µm • Primary Gas: SF6 (Sulfur Hexafluoride) • Secondary Gases: NH3 (Ammonia), C2H4 (Ethylene) • Lenses • FOV 25 • FOV 6 • Spectral range: 7- 8.5 µm • Primary Gas: CH4 (Methane) • New Secondary Gases: SO2, (Sulfur Dioxide), N2O (Nitrous Oxide) R-134a, R-152a • Lenses • FOV 25 • FOV 6
- 23. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. • Camera bundles • Base model: GF77 25° LR OR 25° HR MSRP: $29,950 • Base model + extra 25° MSRP: $34,900 • Base model + extra 6° MSRP: $39,900 • Base model + extra 25° + 1 extra 6° MSRP: $44,850 • Base model + extra 25° + 2 extra 6° MSRP: $54,800 • Aftermarket lens purchase • Extra 25° MSRP: $6,950 • Extra 6° MSRP: $12,950 GF77 PRICING
- 24. FLIR SI124 – ACOUSTIC IMAGING CAMERA LEAK DETECTION & PREDICTIVE / PREVENTATIVE M AINTENANCE SOLUTIONS
- 25. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. 25 COMMON CONDITION MONITORING TOOLS EARLY DETECTION OF POTENTIAL FAILURES
- 26. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. WHAT IS ULTRASOUND? High frequency sound waves Beyond the range of human hearing Produced by operating equipment, electrical emissions and by leaks Highly Directional Highly localized sources Provides early warning of impending failure Part of a comprehensive asset management system DISTINCT60 OR 50 HzHARMONICS
- 27. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. WHY ULTRASOUND? • A pressurized leak will cause turbulence, which can be located using ultrasound. • When air leaks into air, finding it using any other method than ultrasound can be difficult. With an advanced ultrasonic system it can be easy. • Background noise can very effectively be filtered out, which means that a good ultrasonic solution like the FLIR Si124 Camera also works in noisy conditions.
- 28. Proprietary - Company Confidential ©2019 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. 28 WHY ULTRASONIC IMAGING? Multiple microphones allow the camera to triangulate the source of the high frequency sound because the sound is directional
- 29. Proprietary - Company Confidential ©2019 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. WHY ULTRASONIC IMAGING? Combine an array of microphones with a camera and you can pinpoint the sound location on a picture Imaging technologies typically provide a 90% reduction in inspection time Imaging technologies are relatively easy to learn
- 30. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. WHY SO MANY MICROPHONES? • More microphones improve the ability of the camera to precisely locate the source of the sound • Similar to pixels on your TV, the more pixels you have, the greater clarity and detail you’ll receive
- 31. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. ULTRASOUND APPLICATIONS • Electrical Partial Discharge • Compressed Air System Leak detection • Vacuum system leak detection • Compressed Gas leaks (any gas) • Product Design • Sound Localization and Analysis • Mechanical troubleshooting • Upset condition identification and alarming • Scientific research • Building acoustics planning • Sound abatement
- 32. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. 32 AIR LEAKS
- 33. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. 33 COMPRESSED AIR SYSTEMS 33 US DOE Estimates up to 30% of a Manufacturing facility’s electricity is consumed for compressed air. On average 1/3 of compressed air is wasted due to leaks, misuse, pressure drops and over pressurization. Usage for Compressed Air 30% Of total Compressed Air 33.3% Typical losses avg. Manufacturing Facility $38,532 Potential annual savings Based on a typical manufacturing facility running a 200 Hp compressor, 6,800 hrs./yr and $0.11/kw Industrial Electricity
- 34. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. COMPRESSED AIR LEAK
- 35. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. COMPRESSED AIR LEAK
- 36. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. PARTIAL DISCHARGE
- 37. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. CORONA TRACKING ARCING CLASSIFICATION OF PARTIAL DISCHARGE Ionization of fluid or air surrounding a conductor Surface tracking over contaminated insulation Electrical breakdown of a gas producing a plasma discharge
- 38. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. PD DETECTION PROCESS / WORKFLOW We combine advanced signal processing with AI to automatically detect and recognize PD’s
- 39. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. PARTIAL DISCHARGE Faulty Insulator
- 40. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. PARTIAL DISCHARGE Surface Discharge on Insulator
- 41. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. FLOATING DISCHARGE
- 42. Proprietary - Company Confidential ©2020 FLIR Systems Inc. Information and equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. FEATURES – SI124 • Can do both air leaks and partial discharge • Lightweight and portable (2.2 lbs / 980 g) - can be operated with one hand • Operating range from close to mid distance 1.6’ to 49’ (0.5 to 15 M) all the way up to 328’ (100 M) • Both built-in + external replaceable battery allowing up to 8hrs of operating time • Built in Wi-fi for connecting to cloud for further AI powered analysis • Bright 5-inch color display • Operation temperature +14 to +122°F (–10 to +50°C) • Pricing - $19,999
- 43. QUESTIONS? LEAK DETECTION & PREDICTIVE / PREVENTATIVE M AINTENANCE SOLUTIONS Email Christina Spearman cspearman@transcat.com Transcat: 800-828-1470 www.transcat.com For related product information, go to: www.transcat.com/brand/flir-store
Editor's Notes
- If you answer “yes” to any of these questions, then your time will be well spent and there is a potential for you to improve your facility
- Since the early 80s, the “gold standard” for leak detection has been Method 21 (or TVA; Toxic Vapor Analyzer), which is slow and labor intensive – taking several days to complete a thorough survey. In addition, the TVA must be in contact with the leaking component in order to detect gas, so if the operator misses the leak point, it may go unnoticed. This also requires the operator to be put in harm’s way during the inspection. Another method is Snoop (soap & water test looking for “bubbles”) – again, labor intensive having to hit all various components that could be leaking Laser assisted – RMLD – can scan larger areas but may be limited to the gases it can detect. The development of Optical Gas Imaging revolutionized gas detection allowing the visualization of VOCs and other gases.
- The map above is a plot of all of the Natural Gas Electric Generation plant in the United States. This camera solves all of their problems: Methane Gas Detection Circuit breakers near the generation plant Combined cycle that use ammonia As well as predictive maintenance for any electrical hot spots throughout the plant It solves at least 3 problems that every plant will have
- The camera sees more than gas ONLY. It sees the things in the background (pipes, people, the ground, plants, etc.) but the gas blocks the energy from those things from reaching the detector.and shows up as “smoke”.
- The camera sees more than gas ONLY. It sees the things in the background (pipes, people, the ground, plants, etc.) but the gas blocks the energy from those things from reaching the detector.and shows up as “smoke”.
- Infrared is just beyond the Visible wavelengths (the rainbow). We have both MidWave and LongWave Cooled (GF3xx) and now have LongWave uncooled.
- By focusing on wavelengths that a gas does not absorb, we reduce the energy that reaches the detector to “match” that of the gas.
- FLIR has an OGI camera for many solutions to meet the demands of many industries. This helps show the “main” gases our GF77 portfolio will detect.
- Here is an image of a fuel gas skid with a methane leak at a power plant. The question is – don’t we already solve for methane leaks with Mercaptan? The short answer is yes – but in most plants that have natural gas, you can start to smell this right when you walk onto the grounds. This environment is different than your home; however. So in a natural gas plant, it will seem like everyday. But in your house, if your oven started leaking, you would notice right away. In a lot of cases, the camera will find the leak before you smell it and/or you’ll smell it and not know where it is coming from.
- Here is another example of a flange that is leaking natural gas– this video will go through 3 different modes: Thermal image Visual image Enhanced high sensitivity mode Remember that image that said “NO SMOKING” – this is why. These environments can be very dangerous not knowing what is happening in them.
- Now, switching gears, but using the same camera, we switch to SF6 (Sulfur Hexafluoride) detection. In order to do this, all we have to do is change the lens. In the other videos, we were using our LR (Low Range) Lens to detect methane. By simply switching this out to our HR (High Range) Lens, now we can see different gases and the primary gas for this lens of SF6. On this breaker at the top of the bushing, you can see the leak.
- Basic image of a connection at a substation. There isn’t a hotspot on this image, but you can clearly see the versatility of this camera with a clear, crisp thermal image. Making this GF77 the most versatile camera on the market.
- The GF77-LR Lens is what has always been known as the “GF77”. Some may have heard of the “GF77-HR” as the “GF76”. No longer use this terminology.
- For some kinds of equipment issues, ultrasound can detect the defect earlier in the component degradation process. Let’s talk about why that is…
- First let’s describe some of the key characteristics of ultrasound itself. Ultrasound technology involves using high frequency sound waves which are beyond the range of human hearing that are produced by equipment. The sound waves themselves are highly directional in nature and tend to be produced by discreet, localized sources. Ultrasonic waves tend to be indicative of equipment degradation, so when we find them, we can use them as early warning signals of future equipment failure. Ultrasonic inspection tools are a valuable part of a comprehensive asset management solution which is important for helping companies save money, increase product quality and worker safety, while reducing unplanned equipment outages.
- What do air leaks and partial discharge have in common? ULTRASOUND We filter the background sound out by tuning the camera to the right side of this acoustic wavelength essentially muting everything else. Similar to a dog whistle – they can hear it but we can’t.
- So given that standard ultrasound technology is effective, why would you look at ultrasonic imaging? First let’s discuss how it works. Ultrasonic imaging takes advantage of the principle that ultrasonic waves are highly directional by triangulating the source of the sound emission.
- By having many microphones in an array, we can do an accurate two-dimensional location of the sound source and superimpose that location and intensity the information on an image from a camera that has been calibrated to the ultrasonic microphone array. Ultrasonic imaging has only been practical recently due to the combination of very powerful, yet low-cost computer processing power and the recent advent of small, low power, digital microphones. The net result of performing ultrasound inspections this way is an approximately 90% reduction in the time needed to inspect. Many users indicate this kind of technology is easy to learn and more effective than scanning system to find issues.
- Another reason why more microphones is better is for locating the exact source of the issue. Just like with a common digital camera or thermal camera, more microphones is like more pixels, the more you have, the better detail you can generally achieve. Here we are illustrating the concept.
- There are many applications for ultrasound technology – electrical partial discharge, compressed air leaks, vacuum system leaks, refrigerant gas leaks and many more, but the ones that tend to have the biggest return on investment for most users are the three highlighted at the top.
- https://iac.tamu.edu/files/doe/1_-_Determine_the_Cost.pdf https://www.pneumatictips.com/four-ways-compressed-air-systems-waste-energy-and-what-to-do-about-it/ Air is expensive and we can’t see it
- So using this camera, all you have to do is trace your facility from your compressor all throughout where your air could be going, and if you see something like this rainbow spot, you’ve found a leak or a problem. Simply take a picture for record and then after service has been done, you can go back and check that it has been fixed.
- All of these issues create significant problems. Imagine in a substation and you’re looking for partial discharge on the insulators that are made of porcelain. If they get water inside, or start to degrade – what could possibly happen? They could explode. And if these porcelain shardes go flying out, it becomes very dangerous for both the people and the equipment in the area.
- PD or Corona is identified by the Si124 Image is stored on camera Once connected to the internet, the image is sent to the cloud for PROCESSING Our sophisticated AI engineer processed the data Discharge to air Discharge to component Discharge internally (this one indicates the biggest problem) A determination is made, based on the data to the potential problem A recommended solution is provided in the cloud-based application
- As you’re walking, you want to take images of anything like this like we see on this insulator. We see this rainbow image on the body of the insulator indicating some acoustic activity: Take an image Save it to the cloud Perform a visual inspection (take out binoculars if necessary) to ensure the insulator is clean of any potential dirt, debris, bird poo that could cause discharge on the surface of the device If it is clean, then something could be happening internally (which you would want to fix) Schedule the repair on your time
- This is an example of a discharge between components (we don’t know until we put it through the software/AI). This is actually ok, but we don’t want to waste time fixing something that doesn’t need to be fixed.