Fluke Thermography

Fluke Thermography Company Confidential 1

Agenda

• Overview of Thermography
• Benefits of Thermography
• Who Uses Infrared Cameras?
– Equipment Applications
– Vertical Segments
– Key Users
• Intro to Fluke Ti Product Family

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Thermography then and now:

A few years ago: Now:

•Avg. Price per unit > $20K •Avg. Price per unit < $10K

•Typical User – Professional •Typical User – Maintenance Tech

•Where Used – Larger •Where Used – General Mfg, Bldg

customers, government Science, Health Science

Overall improvement in the Return on Investment (ROI) for

customers has dropped from “Years” to “Months”

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Overview of Thermography
What is Thermography?
•Measurement of temperature remotely to indicate equipment health

•Thermography is the temperature measurement of several points and assigns a

color based on the temperature:
•Uses standard color palette: Red is hot/blue is cold
•Brighter colors are warmer/darker colors are cooler

•Thermography cameras produce a picture that details this information in an easy

to use format

• Easier to use

• More affordable

• Finding more applications

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Overview of Thermography
What is the Benefit?
•High heat is key indicator of equipment failure:
•Find hot spot
•Fix equipment before failure
•Equipment operating efficiently

•Average cost of downtime for a given piece of equipment is greater than

$20K/hour

•Enables Service/Installer/Maintenance technicians (YOU!) to stop fighting fires and

fix problems before they result in large-scale losses

•Measurement is…
•Non-contact
•Obtained without disturbing production
•Applies to all types of equipment
•Reliable data
•Quickly identifies specific location
•Apply to most all conditions

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Average Downtime Costs:
Lost Revenues
Industry Sector Revenue/Hour
Chemicals $704,101
Construction and engineering $389,601
Electronics $477,366
Energy $2,817,846
Food/beverage processing $804,192
Manufacturing $1,610,654
Metals/natural resources $580,588
Pharmaceuticals $1,082,252
Utilities $643,250
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Overview
Thermography
of Thermography
– High Value
Locating problems before failure has high value

•Increased safety
•Improved reliability
•Reduced fire fighting
•Reduced unscheduled outages
•Reduced maintenance and repair costs
•Improved production rate and quality
•Better assurance of repairs and new installations

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Thermography – Uses and Users
Where is Thermography Used?
•Vertical markets: industrial, utilities, local & state governments, petroleum/gas,
construction/restoration, paper & pulp mills, data centers, human & animal medical, R
& D, etc.

•Equipment Applications: engines, drives, motors, Electric Motor Bearings and

Windings, belts, electrical panels, switchgear, power lines, UPS systems

•Building Diagnostics: Furnaces, HVAC, Roofs, building envelopes including Water

Restoration, Mold Remediation and Pest Control

Overall–Most of You will be able to use thermography right

away and improve your facility’s uptime quickly.

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Infrared Camera Applications

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Industrial Equipment Applications

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 Electrical systems
Commonly inspected Typical reasons for temperature
components hotspots or deviations
• (3 phase) Power distribution • Unbalanced loads
• Fuse boxes • Harmonics (3rd harmonic current in Neutral)
• Cables & connections • Overloaded systems/excessive current
• Relays/Switches • Loose or corroded connections increased
• Insulators resistance in the circuit (typically one side of
components heats up)
• Capacitors
• Insulation failure
• Substations
• Component failure
• Circuit breakers
• Wiring mistakes
• Controllers
• Underspecified components (like fuses)
• Transformers would heat up on both side of the fuse
• Motors
• Battery banks

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Maintenance Thermography

Two lighting breakers are 35°F above ambient

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Electrical

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Overheated Transformer Report

Near catastrophic
failure! Found and
managed until
normal factory shut
down.

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Power lines and Sub-stations

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 Electromechanical
Commonly inspected Typical reasons for temperature
components hotspots or deviations
• Motors • Bad cooling- due to reduced airflow
• Pumps • PQ problems like unbalance, overload or 5th
• Heat exchangers harmonic (voltage) will cause heat dissipation
• Bad alignment
• Insulation problems with motor windings
• Bearing problems – lubrication, wear, etc.

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High Resistance Connection

3-Phase Connector Before Repair 3-Phase Connector After Repair

150 HP Motor
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 Mechanical systems
Commonly inspected Typical reasons for temperature
components hotspots or deviations
• Bearings • Friction due to wear, misalignment or
• Gearboxes inadequate lubrication
• Drive belts

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 Process installations
Commonly inspected Typical reasons for temperature
components hotspots or deviations
• Refractory insulation • Damaged structures caused by worn pipes
• Tanks and vessels etc
• Steam systems/traps • Abnormal heat flow/heat gradients
• Pipes and valves • Gas or steam leakage
• Heaters/Furnaces
• Manufacturing equipment
• Plastics Industry (Molding)
• Pulp & Paper (Rollers, handling
equipment, etc)
• Metal Foundry
• Boilers and Reactors
• Research & Development

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 Compressor for in Store Freezing Units
• Label Emis BG Ave SD Max Min
• L0 0.95 68.0 235.10 1.90 238.2 230.9
• P1 0.95 68.0 252.61 0.00 252.6 252.6
• P2 0.95 68.0 239.45 0.00 239.5 239.5
• P3 0.95 68.0 189.05 0.00 189.1 189.1
• P4 0.95 68.0 109.18 0.00 109.2 109.2

¾Problems here!

¾Caused this problem

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Steam Traps

Working Failed
Delta T = 63°F < 1°F
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Tank Levels

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 Buildings
Commonly inspected Typical reasons for temperature
components hotspots or deviations
• Walls • Insulation verification like improperly installed
• Roofs or missing insulation
• Windows • Roof inspections; leaks cause water to enter
to insulation
• Doors
• Construction evaluation
• HVAC
• Locate air leakage
• Insulation
• Moisture intrusion; damage to insulation and
• Floor heating building materials
• Mold detection
• Thermal bridging in joints between walls
• Heat loss through damaged seals in multi-
plane windows
• Damaged heat ducks/leakage of buried
steam lines
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Roof Inspection

Wet spots under roof membrane

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Building Envelope
Moisture and air infiltration

•Moisture behind sheet rock

•Air infiltration around door
•Water drops 3 hrs after a shower

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Bridge Deck / In-Floor Heating

•Hwy bridge deck with ground

water heating

•In-floor hot water heating

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 Electronics
Commonly inspected Typical reasons for temperature
components hotspots or deviations
• Electrical components and sub • Under designed components
assemblies • Component failure
• Circuit boards Assemblies • Improper soldering
• Broken traces
• Reversed polarity

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Troubleshooting Electronic Boards

Printed circuit board

testing can find either
poorly specified
components at the
design phase or failing
components in the field.

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The new face of thermal imaging

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Leading innovation
• Ti30: first fully radiometric unit under $10K

• Ti20: breakthrough price-to-performance

• FlexCam Series (Ti40/50): leading image capability

combined with ergonomic usage

• Fusion: breakthrough visual light-thermography image

management

• Ease of use: all of our products are intuitive

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 Rounding out the Ti Line
Close up circuit board
analysis, distant power
distribution scans, fast
moving equipment

High Temperature
Process/Product R&D Ti50 series
Segmentation

and field diagnosis Ti25

Basic motors, pumps Ti40 series

and electrical panels Ti20

PdM routes on the Ti10

factory floor

Finding Hot Spots

Price

4.5k 6.5k 7.5k 12-20k 20-26k

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Rounding out the Ti Line

New users Experienced users/specialists

Mostly qualitative imaging Qualitative & quantitative imaging

Industrial & building diagnostics Ind, BD, utilities, electronics

Troubleshooting, (preventive) maintenance

Predictive maintenance

In depth analysis
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Ti4X & Ti5X Series

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Ti 4X & Ti5X Families

• Full frame radiometric video, 14Bit A to D

• 512MB memory card stores
– 3,000 images IR images or 200 Fused images
• Sun readable 5” color display
• Articulating lens
• 2 - 3 hour Li-ion battery
• Annotate images
• Easy interface features
– Window CE compatible
• Full function PC software
– License Free

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Breakthrough technology
180º articulating lens

• A sharp image in every situation

– The display remains visible while viewing over high objects,
under a machine or around immoveable obstructions

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Fluke Thermography Company Confidential 36
Easy to use instrument
• AutoCapture
– The instrument is easily set up to
automatically capture only those images
where a temperature limit is exceeded
– Troubleshoot Intermittent problems
• SmartFocus
– No need to take your hand off the
instrument to turn a focus ring
• Windows CE based menu structure
– Intuitive easy to use menu, just like on any
PC
• Compact flash memory cards
– 512 MB card standard to save over 3000
IR images & 200 Fused images

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Industry leading image quality

• 5” high resolution, high contrast

display
– The biggest display in the industry

• Superior thermal sensitivity (up to

0.07 ºC using low noise VOx
technology)
– The sharpest images showing the
smallest temperature difference

• Choice of 320x240 or 160x120

models

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 Center Point
Cursor Cursor
File Nomenclature
High, Low and Median Temps

Hot
Cursor

Cold
Cursor
Temp
Color Bar
Hot
Cursor

Center
Box
w/Temp

Emissivity
Date Time Scale A/C- Battery
Function 1 and 2 buttons
Background Temp Indicator

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Level and Span
“Scaling Palette Temperatures”

• Cameras can be set for “auto” or “manual” rescaling

• Auto rescaling adjusts image to highest and lowest

temp in FOV

• Taking advantage of the manual level and scale

adjustment can give you better thermal resolution
within the FOV

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Level and Span

Manually adjusted

Auto Scaled

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Annotation Files
• The “Annotation” tool allows the user to create
routes with as much detail as needed, including:
9 Location
9 Equipment types including ID tag info
9 List suspected problems
9 Define severity
9 Recommended fix
9 No limit on categories
• Reduces typing
• Reduces report time

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 The Fluke Ti4X and Ti5X
IR FlexCam® Series Thermal Imagers

1. Unique innovative technology

2. Industry leading image quality
3. Powerful analysis and reporting
capabilities
4. Easy to use instruments
5. And ……

The thermal imagers for PdM experts and consultants

looking for the best thermal imager around
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Innovative technology
IR-Fusion™
• Infrared and visible light
images fused together on
one display
• IR-Fusion reveals more
detail and pinpoints trouble
areas quicker by
automatically relating
thermal images with the real
world
– Allows for first time right repair
by reducing the risk of replacing
“good” components

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Innovative technology
IR-Fusion™ (on FT models)
• Five viewing modes

Full IR Full Visible Light Picture in Picture

Alpha Blending IR/Visible Alarms

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Blending Example
Infrared Image Visible Image

Blended Image

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Can Read Infrared Temperatures in
Visible Image

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Innovative technology
IR-Fusion™

• Read Infrared Temperatures in

Visible Image
• Always a visual image available
for better reporting

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Picture in Picture Example
Visible Image Infrared Image

Blended Image

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Percent Blending
100 75

50 25

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Full Screen Example
Infrared Image Visible Image

Blended Image

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Color Alarm Example

Color-Alarm

Picture in Picture Full Screen

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Laser Pointer Spot Seen in Visible
and Blended Image

Visible Blended
Laser Spot

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Powerful analysis and reporting software
SmartView™ software
• Included with each IR FlexCam Thermal Imager

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Powerful analysis and reporting software
SmartView™ software
• Image viewing and editing
– Changes level and span settings
• Extensive annotation possibilities
• Detailed analysis and total image control
– Same 5 viewing modes as on the instrument

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Powerful analysis and reporting software
SmartView™ software
• Simplified report generation
– Allows for full user customization of report

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And …….
• Standard up to 600 ºC (with
option of 1200 ºC)
• All models fully radiometric
• Interchangeable lenses
– Choice of 3 high quality germanium
lenses
– Standard 20 mm,
– Wide angle 10.5 mm
– Telephoto 54 mm
• Video output
• Rugged, battery-powered, IP54
rated

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Lens Options

Wide Angle Standard Long Distance

Long Distance – Telephoto – 54mm

Long distance
• Power line insulators / transformers
• Medium distance – small IFOVm objects
• PC Board design & testing
Standard – 20mm
• Most industrial PdM
• Most building Science applications
Wide Angle – 10.4mm
• Some Building Science apps
• Close-up but where wide view area is required

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 Complete offering

• Heavy duty carrying case

• 2 rechargeable battery packs
• Battery charger
• AC adapter
(for Ti45/Ti55 model only)
• Video cable
• 512 MB compact flash card
• Compact flash card reader and
USB cable
• PCMCIA compact flash card reader
• Neck strap
• SmartView reporting and analysis
software on CD
• User manual on CD

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Introducing
Fluke Ti10 and Ti25 thermal imagers

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The new Fluke Ti10/25
One look and feel – 2 different products
• IR-Fusion® Technology
– Infrared and visual images fused
together makes Infrared easy to
understand
• Delivers the clear, crisp images
needed to find problems fast
• Rugged, easy to use
– What you expect from Fluke
Models for almost any application
and budget
– Comes as one complete package
including everything you need

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The new Fluke Ti10/25
One look and feel – 2 different products

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The new Fluke Ti10/25 with
IR-Fusion® Technology

• Makes infrared easy to understand

– Don’t need to be a specialist to see and
understand what you are looking at

• Makes reporting much easier

– The reference with the “real world” is always
there

• Provides different viewing modes to

better identify trouble areas
– On camera or in the software

• Until now only available in > $10k priced

imagers
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The new Fluke Ti10/25 with
IR-Fusion® Technology

Max IR
Mid IR Min IR
(traditional thermal imaging)

PIP Max IR PIP Mid IR PIP Min IR

Ti25 and
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The new Fluke Ti
Large crisp images

• Large, widescreen full color LCD

display shows all details

• Identify even small temperature

differences with excellent thermal
sensitivity (NETD)

• High performance, low noise

sensor provides high-quality,
stable image

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The new Fluke Ti
Made for rough environments

• Engineered and tested to withstand 6.5 ft.

drop
• Not even Fluke DMMs are tested to
this specification

• Withstands dust and water

• IP54 rating

• Innovative protective lens cover protects

lens when not in use

• Works in ambient temperatures as low as

14 ºF and high as 122 ºF and measures
up to 662 ºF (Ti25)
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The new Fluke Ti
Easy to use

• Intuitive, three-button menu

• Single-handed operation

• Adjustable (left or right) hand strap

makes imager convenient to hold

• Store more than 1200 IR-Fusion images

on memory card for later analysis or
reporting

• Supports 16 different languages

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The new Fluke Ti
Thermal Imaging made affordable

• Priced between $4500 and $7500

• One complete package includes:

• SmartView™ analysis and reporting
software (with free upgrades)
• Rugged hard case and portable soft
case
• Adjustable hand strap
• 2 GB SD memory card
• SD memory card reader
• Internal rechargeable battery
• AC charger/power supply
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Introducing the Ti20 Thermal
Imager

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Introducing the Fluke Ti20
A thermal imager for Industrial use:

• Breakthrough price/performance
– Analyze data and optimize images
– Display high quality images
– Easy to use
• Optimized for Industrial applications:
– Professional Grade
– Key measurement needs
• Great for predictive maintenance
• Complete offering

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 Breakthrough performance
Analyze Images
Fully radiometric thermal Imager
• For detailed temperature analysis and
trending
• Easily identify problems by comparing
temperature data
• Calibrated temperature points
• Stores images and the data behind the
180.1 178.4 99.1 90.2
image
181.2 178.6 98.4 91.1
Adjust key parameters in software
afterwards 182.0 179.1 98.9 91.0

• Emissivity, palette, reflective coefficient 181.1 179.3 98.7 91.1

• Saves time by avoiding second 181.3 178.5 99.1 91.1

measurements
181.4 179.2 98.8 90.4
• No need to go back on the factory floor

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Breakthrough performance
Display high quality Images

High-resolution image
• 128 x 96 resolution
Large, bright LCD display
• Uncluttered full size image with data
and separate part of the screen
• For use under every lighting condition
Separate display for picture and
measurements:
• Can always see the temperature, other
key measurements, and equipment ID
• Not so for competitors (e.g. Flir)

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Breakthrough performance
Easy to Use
Single handed point; shoot and image
capture operation:
• Press the trigger to capture the image
• Compare with other images taken
Automatically adjusts temperature level and
span to display an image without pressing
any buttons:
• Manually adjust level and span to further optimize picture
• Clearly displayed level and range indicator
Simple menu structure for intuitive use and
getting started faster:
• Only three menu button navigation
• Ideal for multiple users (common for industrial settings)

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For industrial use
Professional Grade
It’s a Fluke – rugged, battery powered unit
• Up to 6 hours battery life (using both rechargeable
batteries supplied)
• Smart design protects lens for accidental drops etc
• Survives harsh industrial environment
IP54 rated
• Water and dust proof
• Connections protected for moisture and water
Measures up to 662ºF (350ºC)
• Covers broad industrial applications

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 Overview of controls
Large bright
Focus ring Display

Lens

Laser pointer
Menu Soft keys

Trigger to store image Battery

compartment

Tripod mount
(under imager)

AC adapter terminal
FlukeUSB Port
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Protection
Ideal for predictive maintenance
Supports inspection routing:
• Clear on camera instructions
• Anyone can do the job
Periodic inspections help to detect
temperature changes:
• Establish baseline settings for
equipment
• Early indications for potential problems
Compare images to ensure that the
captured image is taken
correctly:
• From the correct position and distance
• Increases quality and confidence in
preventive maintenance program
• Reduces the need to go back and take
additional pictures
• Before image stored

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Fluke Ti20 Complete offering
InsideIR software reporting and
analysis software included:
• Allowing unlimited use by your whole
maintenance team with no additional
cost
• Allows detailed analysis, storage and
reporting.
Comes complete with all necessary
accessories to start using right
out of the box
Includes Professional application
training materials to ensure quick
learning and a fast return on
investment

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Training CD

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