Thermal Imaging for Predictive Maintenance and Fault Finding In Zone 1 Hazardous Areas

For general industry, the last ten years has seen a revolution in the power of thermal imaging cameras and a dramatic decline in the cost of thermal imaging cameras.

Cameras have reduced from shoulder mounted monstrosities to almost “pocket” size over the last 20 years, and they are usable for anyone who can operate a digital camera – and that means everyone. That is not to say that there (Read More) is a significant body of knowledge in thermography, and advantage in using skilled and trained operators, but significant VALUE can be achieved in the maintenance field with very limited skill and experience. Let us propose an unskilled operator could achieve an 80% result with little training – or looking at it another way – detect correctly 8 out of 10 potential faults, while an experienced thermographer may achieve 99%.

Until now there have been no Intrinsically Safe Thermal Imaging cameras available – so for hazardous areas, the analysis could only be done with hot work permits – and when no hazard is present. Imagine the benefit of doing regular inspections of critical components, regardless of the atmosphere.

Thermal images present information on the condition of electrical and mechanical components in the most intuitive way possible for humans. The saying “A picture is worth a thousand words” applies especially to thermal images and their interpretation. Given a thermal image of a conveyor with 100 rollers visible, any fault is immediately obvious through the difference in colour [temperature] of the bearing housing. The same applies to electrical cabinets and switch gear, bus bars and cables.

The First Fully Radiometric Intrinsically Safe Thermal Imaging Camera

Previously there wasn’t a fully radiometric intrinsically safe thermal camera available on the market, but that has now changed due to the recently released TC7000 with the following Gas, Dust & Mining certification:

• Exib IIC T4 Gb Tamb-10+40C (Vapour)
• Exib IIC T4 Gb Tamb-10+40C (Dust)
• Exib I Mb (Mining)

A few technical specifications show that the TC7000 is comparable to the current cameras used in general industry. The detector is 320x240 un-cooled microbolometer with NETD 50mK and range -20 to 600C. The display is 80mm with backlight and a minimum focus of 100mm will give very high resolution in close-up.

In cases where electrical cabinets cannot be opened, CorDEX also has a range of IR windows to allow continuous access to survey critical components. These windows have built in RFID tags to automatically identify the location to the RFID reader in each camera.

Increase Plant Availability with Intrinsically Safe Thermal Imaging

The CorDEX TC7000 is the same as any modern thermal imaging camera and behaves much the same as a normal Digital Camera. It stores images and attaches voice annotations AND links RFID
tags to the image files which can subsequently—in a safe area—be downloaded to a PC for archiving or more detailed analysis.

The RFID feature is a labour saving benefit when the maintenance plan requires a fixed audit route covering critical elements of important plant or infrastructure. This can be a way to assure all points are covered, and a consistent history obtained. Analysis is improved by making valid comparisons of these points over time. When you move to more advanced skill sets you will be able to determine the potential reduction in service life, or service criticality indicated by a given temperature. Of course temperatures are also related to loading—whether of mechanical or electrical components—recording of load conditions validates comparisons.

CorDEX Instruments Ltd. has a long history of manufacturing certified, high quality, handheld digital cameras for hazardous areas. The TC7000 Intrinsically Safe Thermal Imager represents the culmination of extensive research and development resulting in the ultimate thermal imaging tool for hazardous area professionals.

For more information:
Marcus Halliday, Business Development Director
Tel: 44 (0)1642 454373 Fax: 44 (0)1642 424737
E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.
Web: www.cordexinstruments.com
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