How do you measure and improve the accuracy and reliability of thermography and vibration analysis results?

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Thermography and vibration analysis are two common techniques for condition monitoring of rotating machinery. They can help detect faults, assess performance, and prevent failures. But how do you ensure that the results you get from these methods are accurate and reliable? In this article, we will compare thermography and vibration analysis, explain how to measure and improve their accuracy and reliability, and provide some tips and best practices for using them effectively.

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Ahmed Mosbah

I help professionals to sharpen turbomachinery experience | through coaching, training, maintenance consulting, and…

1 Thermography basics

Thermography is the use of infrared cameras to measure the surface temperature of an object. By comparing the temperature patterns of a normal and a faulty machine, you can identify hot spots, cold spots, or uneven heat distribution that indicate problems such as misalignment, friction, wear, or electrical faults. Thermography is a non-contact, non-invasive, and fast method that can be performed while the machine is running.

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Ahmed Mosbah

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Essential concept of thermal imaging that thermography cameras are not providing a heat distribution or temperature measurements. It provides a pattern for Infrared Emmission from bodies that can be interpreted to identify heat-related or temperature increase-related failures. This is crucial as sometimes sensetivity and surface types can vary during analysis giving misleading data. It is well-known monitoring tool for electric assets undergoes a current failure or for mechanical assets having frictional or rubbing failures.

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2 Vibration analysis basics

Vibration analysis is the use of sensors and analyzers to measure the vibration signals of a machine. By analyzing the frequency, amplitude, and phase of the vibration, you can diagnose the type, location, and severity of faults such as imbalance, looseness, resonance, or bearing defects. Vibration analysis is also a non-contact, non-invasive, and fast method that can be performed while the machine is running.

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Ahmed Mosbah

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Vibration analysis may be the key technique in condition monitoring used to detect early signs of failures in rotating machinery. By measuring vibrations, it helps identify problems like unbalance, misalignment, looseness, and bearing failures at their early stages. The measurements process involves collecting vibration data and analyzing frequency patterns to identify fault peaks if existed, and allowing maintenance teams to address these faults accordingly. It’s a highly effective tool for ensuring equipment reliability and minimizing downtime. Good practice is to setup a route-based measurement scheme (not a hierarchy scheme) to optimize onsite activities duration as it involves interactions with rotating machinery.

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3 Accuracy and reliability measures

Accuracy and reliability are two essential aspects of any condition monitoring technique. Accuracy measures how close the measured value is to the true value, while reliability gauges how consistent and repeatable the measurement is. To measure and enhance accuracy and reliability of thermography and vibration analysis, calibration of instruments must be done regularly and correctly to ensure accuracy. Additionally, one must choose the appropriate resolution for cameras and sensors to capture enough details and avoid noise or distortion. Furthermore, environmental conditions that may affect measurements, such as ambient temperature, humidity, lighting, or background noise, must be controlled or accounted for. Lastly, a consistent and standardized procedure must be followed for taking and analyzing measurements, such as selecting the same points, angles, distances, and settings for each machine and each test.

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Ahmed Mosbah

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As much as we can, we should avoid any repeatability or inconsistent data problems. By setting a detailed working procedures or work packages that identify sensor type, measurement locations, data configuration, environmental context, and operating conditions, this reduces probability of human-related errors of data interpreatation for the asset. Some data acquisition activities should be assigned for quantitative assessments (e.g. overall vibration for equipment or a surface temperature using a thermal imaging), and others for dynamic data or qualitative assessments (e.g. vibration spectrum analysis or thermogram analysis). Also, calibration shall be conducted according to data variation threshold with a pre-detrmined reference point

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4 Tips and best practices

To get the most out of thermography and vibration analysis, you should follow some tips and best practices. Combining these two methods can provide more information than either one alone. Additionally, it’s important to train your staff on how to use them properly and safely, how to interpret the results, and how to act on them. Furthermore, you should plan your maintenance activities based on the results of thermography and vibration analysis rather than fixed schedules or assumptions. This will help prioritize the most critical and urgent issues and avoid unnecessary or premature interventions.

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Ahmed Mosbah

I help professionals to sharpen turbomachinery experience | through coaching, training, maintenance consulting, and machinery diagnostics services ← Apply Today
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Regularly, measurement tools shall be checked for operation. Normally, vibration measurement cables are the weakest points in the measurement chain. Thus, replacing cables while it is healthy is a good practice or even regular check for data redundancy with 2 cables shall be performed. For thermography cameras, infrared sensors should be protected against dust and high emission surfaces like sun rays or very hot surfaces not to destroy some measurement pixels in the sensors. Measurement tools care ensures most accurate data you can acquire from the asset to be interpreted properly.

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How do you measure and improve the accuracy and reliability of thermography and vibration analysis results?

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1 Thermography basics

2 Vibration analysis basics

3 Accuracy and reliability measures

4 Tips and best practices

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