Feature Thermal Imaging
ees, BASF’s Antwerp plant is the second largest of the company’s sites and for more than 15 years has been reliant on FLIR P-Series thermal imag- ing for trouble-free, 24/7 production. Historically this task was out- sourced. When the preventative main- tenance programme was introduced and with the need to conduct inspec- tions on a routine basis, the company decided to purchase its own camera. This investment has already paid for itself many times over. The company now has a full time thermographer who follows predefined routes and responds to any calls for help in the event of a technical problem.
Insulation integrity
The camera is used for a wide variety of applications that extend from checking the integrity of insulation and level measurement to electrical inspection and process optimisation. A spokesman for the preventative maintenance department explains: “It’s the perfect tool for us. It gives us a full picture of the thermal situation in a non-contact mode and allows us to detect faults before they lead to real problems. As a result we save BASF Antwerp at lot of time and money.” More than 6000 electrical cabinets are now examined at least annually and many problems have been discov- ered that could have resulted in a fire. The ammonia plant is a particular focus where the maintenance team primarily looks at the temperature of pipes. An abnormally high tempera- ture is taken very seriously as it could indicate inadequate insulation or even
worse, a leak. This is a potentially dan- gerous situation as not only does it require production to be suspended, it also brings the risk of explosion.
Non-contact temperature checks In the past these temperature checks were carried out with measuring probes but the advantage of FLIR infrared is that BASF can now mea- sure temperature much more rapidly without any contact and engineers can get a complete picture of the situation. The maintenance team uses its FLIR P-Series camera to conduct mechanical inspections.
It has, for example, a large number of vertically positioned engines at the plant. Dust settles on their ventilator hoods which increases the operating temperature, leading to greater compo- nent wear. With the help of the FLIR camera, it is easy to tell when the dust
Industrial grade infrared windows
RISS, a leader in the industrial infrared (IR) window market for electrical safety has introduced the CAP 4” IR windows protected by their Unconditional Lifetime Warranty in response to customer demand. Now IRISS has over 50 standard IR window designs making them the only IR window manufacturer with standard options for customers to fit their needs. Additionally, for customers needing exceedingly unique IR windows, IRISS offers custom solutions. The IRISS CAP 4” is available with either
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transparent or opaque polymer both complying with all mandatory impact, load and flammability requirements.
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It features an increase in the field of view when compared to traditional round IR windows. Several major OEMs throughout the US and Canada are among the first to adopt the IRISS CAP 4” IR windows. IRISS IR windows allow for safer, more efficient electrical inspections. IRISS is the manufacturer of the world’s first and only industrial-grade IR windows capable of meeting OSHA’s NFPA 70E requirements for arc flash safety.
IRISS T: +44 (0)1245 399713
www.iriss.com
Electrical
inspections and level detection of tanks are just a few infrared applications at BASF
needs to be removed. A further mechanical inspection example is in the production of fertilisers. Granulation occurs in the large drums so the camera allows maintenance engineers to spot alignment faults and other defects through abnormal ther- mal profiles. Each of the team’s find- ings are committed to a report with full thermal data and a visual image and emailed to the department con- cerned. This provides everything that is needed to allow an informed deci- sion to be made on remedial action.
Process optimisation
In addition, the FLIR camera allows the team to undertake process optimi- sation tasks. The heat exchangers involved in the production of ethylene oxide, for example, are regularly examined. The infrared image pro- vides visual evidence of any blockages and deposits so they may be cleared to improve performance.
A further role for the camera is checking new plant for compliance with specification and standards. To ensure safety, the temperature is taken regularly at a number of critical locations and the settlement level in chemical storage tanks is checked. Such has been the success of FLIR thermal imaging at BASF Antwerp, the company is now actively extending its thermal imaging programme.
FLIR Systems T: +44(0)1732 220011
www.flir.com
NOVEMBER/DECEMBER 2013 Factory Equipment
Trouble-free 24/7 production O
One of the largest international chemical groups in the world relies on thermal imaging solutions from FLIR to ensure around the clock production, safety and process optimisation at its Antwerp plant
ne of the largest international chemical groups in the world with more than 110,000 employ-
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