Mechanical maintenance

Reliable early detection of damage to production-relevant system components is essential in order to guarantee the safety and reliability of the system. This means that costly downtimes can be avoided. Heat generation, especially from mechanical components, may indicate an elevated level of stress. With thermal imagers, you can detect critical heat conditions directly during operation. Thermography in industrial maintenance also involves regularly monitoring the fill level of sealed fluid tanks. Non-contact thermographic measurement enables you to recognise when a fill level is too low, thus helping to prevent machine damage and resultant production losses.

Applications with high scene temperatures, such as in the metal industry, chemical industry or construction materials industry, require a flexible measuring range of up to 1,200°C. Testo thermal imagers meet this requirement with their high-temperature option.

Condition monitoring/ Fill level monitoring

Maintenance rather than repair

Mechanical maintenance industry
Thermal image mechanical maintenance industry

Repairing mechanical components should always only be considered as a last resort. This is because those responsible for smooth operation and for maintaining mechanical production plants naturally wish to avoid downtimes and malfunctions as far as possible. Innovative thermal imagers from Testo assist with the detection and analysis of thermal anomalies.

Non-contact and carried out during operation

Signs of wear in machinery often become apparent long before a malfunction, due to an increase in temperature. Possible causes are friction, incorrect adjustment, tolerances of mechanical components or a lack of lubricant. With a thermal imager, any suspicious changes can be spotted immediately. The main advantage of infrared measurement in a maintenance operation: it is non-contact and can therefore be carried out on all mechanical installations during operation and from a safe distance.

Efficient fill level monitoring using thermal imagers

Fill level monitoring
Thermal image fill level monitoring

The level control in sealed fluid tanks has proved to be a sensible method for avoiding machine damage and as a result production losses.

Non-contact fill level check with a thermal imager

Non-contact thermographic measurement will allow you to check whether an oil separator is full, for example, in practically no time at all. Dangerous overheating in coolant tanks can be prevented: if the fluid contained in them falls to a dangerously low level, machines are no longer being sufficiently cooled. An automatic fill level monitoring device often regulates the level of the refrigerant and triggers an alarm if the fill level is too low. However, the automatic monitoring system can also fail. With this in mind, it will also pay you to take a regular look using a thermal imager from Testo. Monitoring using thermography ensures that systems operate safely.

High temperature measurement

Preventive maintenance

High temperature industry
Thermal image industrial furnace door

High process temperatures require regular thermographic inspection of the system's insulation with respect to damage that may occur over time, e.g. due to material fatigue or wear. This includes, for example, using thermography to examine industrial furnaces and ladles for defects, material fatigue and coking.

Using the thermal imager's high-temperature measurement means that the system can be checked quickly and non-contact, from a safe distance.

Quality assurance and process optimisation

High temperature industry
Thermal image steel slabs in a cooling store

In thermographic quality assurance or process optimisation, the temperature distribution of the product to be manufactured is checked as a matter of priority. Conclusions are drawn as to whether the requisite target process temperature has been uniformly attained. This enables us to ascertain whether the quality of the final product will prove satisfactory.

The main advantage of thermography: this high-temperature measurement can be carried out while the process is ongoing.

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Practical guide on thermography in preventive maintenance

Thermal imager guide
Find out on 16 pages how you can use thermal imagers to optimize processes and plant availability.

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