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Infrared Windows 101 – The Basics You Need to Know – Presentation

Introduction

Advantages of Infrared Electrical System Surveys

  • Locate loose connections, faulty equipment, over/unbalanced loads
  • Help identify problems before a failure, allowing a scheduled repair
  • Improve reliability and decrease downtime
  • Comply with insurance company requirements
  • Meet industry specific inspection requirements

Challenges of an Infrared Survey

  • Requires a direct line of sight to the target
  • Electrical equipment must be open at the time of the survey
  • Time and cost of preparing for the Survey
  • Arc Flash requirements must be followed
IR Device IR Device

Overcoming Challenges of an Infrared Survey

  • Use in-house staff to open and close equipment
  • Hire an outside contractor to open and close equipment
  • Install Infrared Windows
IR Device IR Device

Window Types

Ports or Fish Eyes

  • Consists of a metal or plastic frame
  • Has a single, small diameter opening (< 0.5 inches)
  • Usually require the use of special wide angle or ‘fisheye’ lenses
  • Thermal imager must be designed to accept such lenses


Grills

  • Similar to ports – Larger diameter than ports
  • Contain a metal plate – Multiple small diameter openings or do not have a solid barrier or pane
  • Thermal image may show the metal plate
  • Electrical components visible through the openings

 

 

 

 

 

 

Infrared or IR Window

  • Specially engineered optic – Designed to permit infrared inspections of electrical components or crystal or polymer material that is infrared transmissive
  • Metal or plastic frame to support the optic pane
  • May or may not have a grill in place
  • Protective covering when they are not in use
  • Various shapes and sizes are possible

 

IR Window Components

  • Backing Ring or Plate
  • Lens or Optical Plane
  • Front Ring or Plate
  • Cover
  • Optional – IR Label & Equipment ID

 

 

 

 

 

Crystal Panes

  • Original material used for Infrared Windows
  • Germanium, Zinc Selenide, Calcium Fluoride and Sapphire
  • CorDEX, FLIR, Fluke and IRISS

 

Crystal Advantages Crystal Limitations
Ideal for high ambient temperatures Limited to 4″ diameter Limited to 4″ diameter
Withstands extreme environments Round shape only
Allows visual inspections Not impact resistant
Compatible with all IR Imagers Usually more expensive than polymer

 

Polymer Panes

  • In use since the late 1990’s
  • Opaque or clear
  • With or without reinforcement
  • Exiscan, IRISS

 

Polymer Advantages Ploymer Limitations
Ideal for industrial environments Not suitable for high temperature environments (over 200°C)
Stable, consistent transmissivity An expert should be consulted before ordering custom sizes or shapes
Compatible with all IR Imagers Not all are clear
Impact resistant
Size and shape options available
Less expensive than crystal

 

How IR Windows Work

  • Optic lens are infrared transmissive
  • Data collection point installed in the metal
  • Infrared imager lens is placed directly on the window
  • Thermal data is recorded same as with equipment open

Advantages

Data Management

    • Same target, location, distance and angle
    • Consistent trendable data in any PdM process
    • Use IR Labels for standardization

Risk Management

        • Eliminate risk where possible
        • No longer required to open and close panels

Safety

        • Survey energized electrical equipment
        • No removal of the panels
        • Reduces the risk of an arc flash incident


Standards Compliant

        • Equipment remains enclosed and guarded condition
        • Reduces potential electrical hazard during inspection
        • Survey equipment not previously accessible

Selecting IR Windows

Facts to Consider

        • Available Field-of-View
        • Camera lens compatibility
        • Environment
        • Need for visual or ultrasonic

Components to be inspected

Where to Install IR Windows


Considerations

  • Frequency of the equipment to be inspected
  • Complexity of opening the panels
  • Arc flash precautions
  • Facility safety requirements

Common Equipment

  • Dry-type Transformers
  • MCC
  • Distribution Panels
  • Switchgear Cabinets
  • High & Medium Circuit Breakers
  • Control Cabinets
  • RestrictedAreas


Qualified, trained personnel

  • Must understand proper window placement
  • May opt to work with an experienced thermographer

Identify all targets

  • Fuses, breakers
  • Cable and bus connections
  • Any mechanically fastened connection

IR ID labels ensure repeatable data collection

 

How to Pay for IR Windows

Number electricians required to open/close X Number of days to perform the Survey = Number of Electrician Man
Days
Number of Electrician Man Days X Cost per electrician per day = Total Cost of Electricians
Number of days to perform the Survey X Cost of Thermographer per day = Thermographer Cost
Total Cost of Electricians X Thermographer Cost = Cost of Traditional Infrared Survey

 

One Time Costs

Number electricians required to open/close X Number of days to perform the Survey = Number of Electrician Man Days
Purchase of IR Windows X Cost of Installation = Permanent Solution
Number of Electrician Man Days X Cost per electrician per day = Total Cost of Electricians

 

Cost of Future Infrared Surveys

Number of days to perform the survey X Cost of Thermographer per day = Thermographer Cost

 

How to Start an IR Window Program

When purchasing IR Windows

  • Consider bulk purchases
  • Possible discounts
  • Prevent any delays during installation
  • Possibly allow additional windows to be installed

Possible Sources of Funds

  • Money left in your budget
  • Capital Improvement
  • Safety Budget
  • Insurance Reductions
  • Reliability or Cost Avoidance
  • Regulation Compliance

List of all equipment that should have IR Windows

  • Prioritize each piece of equipment

Make inventory of all needed IR Windows

    • Type of window, location, installation schedule

Plan the installation of the windows

  • Start with highest priority
  • Availability of equipment
  • Frequency of inspections
  • Safety hazardous risks