The Use of Thermal Cameras in Fault Finding and Preventative Maintenance (Air Compressors)

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1. Introduction

The use of a thermal camera and adequate software is a useful tool to IAP’s engineers for fault finding in air compressors. The camera helps identify problems related to temperature anomalies, which are often early indicators of system inefficiencies or failures.

2. Theory

Here’s how this equipment is and can be used to assist with air compressor diagnostics.

2.1 Identifying Overheating Components

As compressors generate a lot of heat during operation, overheating in specific components can indicate faults such as:

2.1.1?? Motor Issues: Excessive heat may signal bearing failures, misalignment, or motor overload

2.1.2?? Compressor Head: A hot compressor head can indicate issues like inadequate lubrication, blocked cooling fins, or excessive friction.

2.2 Inspecting Cooling Systems

Air compressors often rely on cooling systems (e.g., fans or liquid cooling). A thermal camera can detect:

2.2.1??????? Clogged or Malfunctioning Fans: Uneven heat patterns on or around cooling fans could indicate partial or complete failure.

2.2.2??????? Blocked Heat Exchangers: Heat buildup on cooling elements might indicate dirt or debris obstructing airflow.

2.2.3??????? Inefficient Cooling: Areas where cooling is insufficient can be spotted easily by identifying hotspots.

2.3 Monitoring Connections and Hoses

Thermal cameras can help identify blocked hoses; Temperature anomalies in compressed air lines might indicate blockages, or inadequate airflow.

2.4 Detecting Lubrication Problems

Compressors require lubrication for smooth operation. A lack of lubrication can cause:

2.4.1??????? Increased Friction: Bearings, seals, or moving parts may overheat due to insufficient lubrication.

2.4.2??????? Premature Wear: Hotspots on bearings or crankcases may indicate failing lubricant or poor lubrication coverage.

2.5 Preventative Maintenance

Regular thermal inspections help monitor the health of critical components and identify gradual changes in temperature over time, allowing for proactive maintenance before costly breakdowns occur.

3. Practice

In the files attached, we provide an example of the usage of a thermal camera by Industrial Air Power’s engineers.

In Figure 1. the photographs present an oil cooler of a screw compressor. The first photograph was taken with the enabled thermal image setting, while the photograph below was taken with this setting disabled. The camera was able to effectively identify the points of the component, where the temperature was at its highest; Sp1 at 98.2°C and Sp2 at 95.9°C. The average temperature of this cooler at the point of measurement equalled 99.3°C. One of the most common causes of overheating cooling systems is dirt or debris obstructing airflow (see section 2.2.2).

Figure 2. presents the same cooler after a thorough cleaning process. The measurements have proven a lowered temperature on both recorded points – Sp1 at 76.2°C and Sp2 at 41.2°C. The average temperature of the working cooler was now at 50.9°C, lowering by 48.4°C from the initial measurement.

The thermal camera and its software have successfully helped identifying the blocked heat exchangers, allowing our engineer to solve our customer’s problem quickly and efficiently.

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4. Conclusion

Applying thermal imaging in fault finding is a powerful, efficient, and cost-effective method. It enhances safety, reduces downtime, and improves overall equipment reliability. By integrating thermal cameras into maintenance routines, businesses can prevent failures, optimise performance, and extend the lifespan of air compressor systems.