Flowserve: Preventative Maintenance Thermal Survey Prevents Costly Downtime - Electrical testing and tagging professionals New Zealand

Case Studies: Thermal Imaging

In today’s fast-paced industrial environment, the reliability of heavy machinery is crucial for uninterrupted operations. Preventative maintenance plays a vital role in ensuring that equipment runs smoothly and safely. Flowserve, a leader in manufacturing and maintenance services, recently utilised our advanced thermal imaging technology as part of their comprehensive preventative maintenance program. This case study details our survey, findings, and the significant benefits of using thermal imaging to avoid costly downtime.

Background

Flowserve is a global company renowned for its high-quality pumps, valves, seals, and other industrial machinery. Their equipment is essential for various industries, including oil and gas, chemical processing, power generation, and water management. Given the critical nature of their machinery, maintaining optimal performance and safety standards is of utmost importance.

As part of their health and safety audit program, which also covers insurance requirements, Flowserve requested our thermal imaging services. The goal was to ensure that their circuit boards and other electrical components were operating correctly and safely. This initiative is part of their broader preventative maintenance strategy aimed at diagnosing and rectifying potential issues before they escalate into major problems.

Survey Execution

Preparation

Before commencing the thermal imaging survey, we conducted a thorough planning session with Flowserve’s maintenance team. This involved identifying key machinery and components that required inspection, understanding the operational parameters, and coordinating with on-site electricians to ensure a smooth process.

Thermal Imaging Process

Using our state-of-the-art infrared cameras, we conducted a detailed thermal imaging survey on various pieces of equipment, including one of Flowserve’s heavy-duty lathes. The infrared technology allowed us to detect temperature variations that are not visible to the naked eye. These variations often indicate underlying issues such as electrical faults, poor connections, or mechanical wear.

Findings

During the survey of the heavy-duty lathe, our infrared camera revealed that one phase was affected by a dirty or loose termination. This anomaly was evident from the elevated temperature in that specific phase. The accompanying electrician quickly diagnosed the issue and shut down the machine to prevent further damage.

Immediate Actions

Within 30 minutes of identifying the problem, the electrician re-terminated the affected phase. This swift intervention was crucial in preventing a potential failure. The repair process involved cleaning the termination point and securing the connection to ensure proper electrical contact.

Results

The immediate repair reduced the cable’s temperature from 55 degrees Celsius to a safe operating temperature of approximately 32 degrees Celsius. This rapid response not only prevented a potential breakdown but also ensured that the machine could continue operating without any significant downtime.

Importance of Thermal Imaging in Preventative Maintenance

Early Detection

Thermal imaging is a powerful tool for early detection of electrical and mechanical issues. By identifying temperature anomalies, we can pinpoint areas that require attention before they develop into serious problems. This proactive approach is essential for maintaining the reliability and safety of industrial machinery.

Safety Benefits

One of the primary advantages of regular thermal imaging surveys is enhanced safety. Electrical faults can lead to severe consequences, such as fires or injuries. By detecting these issues early, we can mitigate risks and ensure a safer working environment for employees.

Cost Savings

Preventative maintenance through thermal imaging offers significant cost savings. Unplanned downtime due to equipment failure can be extremely costly for businesses. Regular surveys help avoid these disruptions by addressing potential issues before they cause major breakdowns.

Conclusion

Our thermal imaging survey for Flowserve demonstrated the effectiveness of this technology in preventing costly downtime and ensuring the safe operation of heavy machinery. By incorporating regular thermal imaging surveys into their preventative maintenance program, Flowserve can maintain high safety standards and operational efficiency.