JNARDDC helps lndian aluminum industry save energy and optimize productionprocess with thermal cameras.

Aluminum is the second nrost abundant metallic element in the earth’s crust after silicon and has been produced in comrnercial quantities since 1886. lt is the world’s second most used metal. Aluminum’s many properties and qualities explain the magic surrounding this metal and the reason rvhv its popularitv continues to grow among new product designers who are constantly adding to its already wide range of applications

The advanced P660 thermal
imaging camera

Monitoring aluminum production
Alumlnum production is an energy inten- sive process and saving energy at each step of the prodr,rction process is the primary aim of process engineers and designers. lnfrared thermography lras played an important role in predictlve malntenance of these processes in terms of time and money. The predictive maintenance by means of thermal imaging has also helped to perform timely interventions of fault detection and to schedule equipment maintenance. Monitoring a production process can of course be performed best when processes are running. And it is with this so-called bnline monitoring’ that thermal imaging can really show its value. Slight temperature variations across a surface will indicate failing components, such as degrading electrical contacts. But thermography can also successfully be used to inspect furnace ducts, bus isolator jumpefs, casings, heating chambers or tanks.

Early fault detection
lnfrared thermography has proven to be an el’fective and beneficial tool to rhe industry, because it allows production managers to schedule their maintenance routines well before anything critical happens. This saves valuable time and significantly reduces the production downtime. Predictive maintenance schedules heip the industfy to arrange tools and spares for repair in time. Whether it is switch yard joints, current transformers, insulation of turbines, pumps, motors, hot patches in kiln, furnaces etc., all of the them can be surveyed with thermal cameras for early detections of fau lts.

By means of thermal cameras and other l’reat measuring devices like heat flux meters, it is also possible to discover scaling, the unwanted deposits in pipelines, storage and processinq units. With thermal cameras you can estimate the tlrickness of scales and take corrective action when needed.

lndian center of excellence
The lndian .lawaharlal Nehru Aluminium Researcl.r Developnrent and Design Centre (JNARDDC) has been using thermal imaging cameras for years. The institute is e located in Nagpur, lndia, was set up in 1989 and is fully functional since 1996. JNARDDC is an established center of excellence in the lndian aluminum industry. Next to the conduct of research, the center also offers a variety of R&Q testing and training services to the aluminum industry.

ln order to better support its aluminum production customers with high-quality services, .INARDDC decided to purctrase FLIR thermal cameras in 2002. The institute was supported by FLIR’s local Cistributor PC{ Limited, sitLrated in Mumbai, who recommended INARDDC to use the FLIR P560 professionai thermal imaging camera for predictive maintenance purposes.

For JNARDDC, the P660 camera
is an ideal solution for cost-effective
& efficient predicative maintenance.

lnspection frequency
ln India, aluminurn production cornpanies usually carry out thermographv inspectiorrs only when the need arises. Others will perform inspections on a yearly or half- yeai’ly basis. The advent of thermal imaging in predictive maintenance proqrams has resultecj in willingrress to perform these maintenance routines more frequentl,v, because inspection with thermal cameras no longer requires shutting downproduction.

The FLIR P650 thermal camera is now frequently used by the team of Mr. Anupam Agnihotri, Head and Scientist at JNARDDC, and consisting of fvlr 5 KThokal (Electrical Engineer) and Mr N Warhadpande (Electronics Engineer).. Altlrough the institute is enthusiastic about the use of FLIR’s technology, customers were a little hesitant at flrst.

“The operations people were little hesitant at the initial period of inspection, because they conceived infrared to be some kind of X-ray, which would allow them to see inside the equipmenl,’ comments Mr. Agnihotri. ‘Others thought of infrared as being emitted by the camera and thought that it might lrarm their equipmentl’ Conceptions like these are indicative and typical lor the low a”/areness of thernral imaging technology. Fortunately, it was an easy task for FLIR Systems and its lndian distributor PCI Lirnited to explain the many benefits and background of therrnal ima-qing. After a slrort training program, JNARDDC custornels were convinced and understood the importance of online condition monitoring with thermal imaging. “Now operations managers demand to cover the problematic area more frequently than other areasi comments Mr. Agnilrotri. 1JNARDDC is now assisting witlr the design of predictive prograrns for a breakdown-free plant environment with the help of plant people and their managementl’

High-performance P660 camera
The FLIR P660 camera is the highest performing infrared inspection systern available. Wth its state of the art technology, including 640×480 detecl.or resolution and unique ergonomic design, it is the natural clroice for professionals tlrat want the rnost efficient instrument producing professional results.

The FLIR P560 is an al’fordable, easy-to- operate and high-performance infrared camera that delivers accurate [emperature measurements at productive and sate distances. This makes the P660 camera an ideal solution for cost-effective and efficient predictive maintenance programs. The P660 includes an integrated 3.2 megapixel camera to aid in reporting. lnfrared and visual images taken with the P660 can be storeC in standard JPEG formats. The P660 visual camera includes matching Field Oi View lenses, so lR and visual images are slrown at similar long distances using the same Field Of View.

For more information
FLIR Systems India Pvt. Ltd.
1111, D-mall, Netaji Subhash Place, Pitampura, New Delhi – 110034
Tel: +91-11-45603555 Fax: +91-11-47212006
E-mail: [email protected], Web: www.flir.com