Thermography (Infrared Inspection) for heat exchangers
Thermography (Infrared Inspection) is one of the most effective ways to monitor heat exchangers: it catches developing faults — fouling and scaling on heat-transfer surfaces, tube blockage and flow maldistribution, corrosion and tube leaks — early, so repairs are planned rather than forced by a breakdown.
Why thermography (infrared inspection) suits heat exchangers
Heat exchangers foul gradually, quietly cutting heat-transfer effectiveness and raising energy use long before they cause a problem. Because the degradation is in process data rather than vibration, analytics that model expected performance are the right tool — flagging when cleaning will actually pay back, rather than cleaning on a fixed, often wasteful, schedule.
How thermography (infrared inspection) works
An infrared camera images the heat radiated from surfaces, turning temperature differences into a picture. Because most developing mechanical and electrical faults generate abnormal heat, a thermal survey finds them without shutting equipment down — a hot connection, an overheating bearing, a stripe of missing insulation. It is widely used both for condition monitoring and for energy audits, where it quickly shows where heat is escaping.
Faults it catches on heat exchangers
- Fouling and scaling on heat-transfer surfaces
- Tube blockage and flow maldistribution
- Corrosion and tube leaks
- Gasket failure
What the data shows
A localised hot spot on an electrical connection flags a loose or corroded joint; a hot bearing housing flags developing bearing failure or poor lubrication; a cold steam trap flags one failed closed; a warm patch on a vessel flags missing or wet insulation.
Thermography (Infrared Inspection) on heat exchangers: implementation
Implementation on heat exchangers: Start by establishing a baseline — what thermography (infrared inspection) looks like on a healthy heat exchangers. This typically takes 2–4 weeks of normal operation. Once baseline is established, any divergence from the norm signals a developing fault. Most plants find that a threshold alert (warn if exceeding baseline +X%) is simpler to manage than complex signal-processing algorithms.
Fault progression: The faults caught by thermography (infrared inspection) on heat exchangers typically develop over days or weeks, not hours. This means you have a window to schedule repairs during planned downtime, avoid emergency callouts, and reduce parts inventory for emergency spares. That window is the value of the technique — it transforms random failures into managed maintenance.
Integration with maintenance: Condition monitoring data works best alongside a predictive or preventive maintenance schedule. Use thermography (infrared inspection) to trigger or validate the need for an intervention, rather than relying solely on calendar-based overhaul. This data-driven approach often reduces maintenance cost by 10–20% while improving reliability.
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Predictive maintenance for heat exchangers · Thermography (Infrared Inspection) overview · Thermography (Infrared Inspection)