Periodic Infrared Inspection Best Practices - Route Based Surveys

Introduction

Beginning in the late 1960's, thermal imaging was limited to power line and substation inspection of overheating electrical connections. Those systems were bulky vehicle-mounted systems that cost perhaps as much as $500,000 in today's dollars. While these systems offered for the first time an easy and intuitive method of identifying connection problems, these systems could not measure temperature or digitally record images for later analysis and reporting. The worldwide market in 1970 for infrared cameras was less than 50 units. Today the market for infrared cameras used for maintenance inspections is projected to exceed 18,000 cameras. Thermography along with vibration monitoring, oil analysis, laser sighting-based rotating machinery shaft alignment and ultrasonic testing have become the toolset used by maintenance departments at an ever increasing number of capital intensive facilities.

By adopting a route-based thermography approach along with an in-camera database and intuitive data logger PdM users can save time, get more consistent results and dramatically improve their thermography program return on investment (ROI).

Today's operations manager is under tremendous pressure to increase asset availability, decrease costs, deal with employee skill levels and turn over, safety regulations, ISO quality compliance and an ever increasing competitive environment. A new class of thermography data collectors is now available designed to create and follow user-created routes, capture in-the-field incident details and automate report generation and run database synchronization. By adopting a route-based thermography approach along with an in-camera database and intuitive data logger, PdM users can save time, get more consistent results and dramatically improve their thermography program return on investment (ROI).

CMMS Isn't Route-based Maintenance

The dilemma is that the CMMS provider does not think in terms of route-based activities at all. Their systems are driven by work orders. If each inspection is given a work order number, you can do the inspections in a route documented with more than 250 work orders. First of all, this is impractical for the person doing the inspections, and secondly, it will require a lot of time for someone to close all the work orders.   Another way route-based activities are performed in a work order-driven CMMS is to give each route a work order number and describe each inspection in a sub-work order. This still creates complications and administrative time. A third example of how some plants try to document and administer route-based activities is to give each route a work order number and have the route documented in a spreadsheet. Again, the dilemma is that this method will not support effective routes and will make it more cumbersome than necessary to change the content of inspections, transfer tasks to operators, change frequencies, merge mechanical and electrical inspections, and so forth. All of these activities are frequently done if you have a good system implemented.   The solution is, therefore, to have a standalone system for route-based activities. Even in a time when it seems like all activities must be integrated into one company-wide system that covers everything, the best solutions can still be standalone systems. There are very few things-if any at all-in a route-based system that need to be tied with other activities. Therefore, you can very well buy a standalone system for this activity. A single-user system that can do this well is not expensive.

Pen-based Computers Simplify Field Data Collection

Pen tablet computers allow the technician to collect infrared inspection data, perform temperature analysis, diagnose the problem, evaluate their urgency, suggest corrective actions and capture a visible reference image. Powerful handheld, pen-based computers are now integrated into infrared cameras that provide a field technician performing on-site inspection and maintenance all the computer power needed to do the job swiftly and efficiently-whether it is integrating their operations with the computerized maintenance management system or testing, diagnosing, and repairing equipment on the spot.

The pen tablet is the most widely used device to be deployed in field applications because of the versatility of its interface, its touch screen for data input and significant memory capability.

Handheld Pen Computers

For industry and the military, the problems with using laptops in the plant or the field are being solved by handheld pen-based computers-a pen tablet or a personal digital assistant (PDA). To date, the pen tablet-almost as powerful as a laptop but smaller and lighter-has become the most widely used device to be deployed in field applications because of the versatility of its interface, its touchscreen for data input and significant memory capability. The HotShot HD infrared camera by Electrophysics incorporates a tablet PC processor running on the Microsoft Windows CE operating system. The touchscreen features direct-function icons large enough for finger actuation and additional data-type features like file naming using a stylus. More reliable data is obtained. Error-prone, handwritten records are replaced by reliable data, automatically gathered, stored, and consistently available throughout the enterprise. Record keeping costs are reduced. Less paperwork lowers administrative overhead because data is processed more efficiently and disseminated widely without producing redundant copies-or even any printed record at all.   Decision making is faster and more cost-effective. By integrating real-time field reports with the computerized maintenance management system (CMMS), managers at all levels share complete, up-to-the-minute information, and can react quickly to changing field conditions or emergencies. Condition monitoring tests involving a number of parameters-vibration, heat, oil quality, pressure-can be compared quickly to confirm impending problems before they become catastrophic.

Data Collection

Maintenance starts with knowing what is going on-how equipment is operating, what increased stresses are being applied, how conditions have changed. Data must be collected, either by a remote monitoring system or by workers on-site. In the latter case, the handheld computer makes data collection faster, more accurate, and more flexible.

Route-based Infrared Inspection

Many PdM technicians are familiar with, or are users of, route-based vibration data collectors. Many of today's vibration instrument vendors provide software tools on both a PC platform and their portable vibration data collectors to organize and create route instructions that are uploaded into portable systems that assist the user through a series of inspection points. For example, Electrophysics' HotShot HD is the first infrared camera of its kind to integrate route logic and all the necessary interfaces to create routes and capture all the inspection details within its pen-based computer with in-camera data logger. The camera features two route programming modes.

Mode 1: Learn a Route

At most facilities it is advantageous to create a route file by simply walking along and entering each point according to the natural flow of how equipment is laid out and to optimize any support labor or the need to comply with safety regulations such as personnel protective equipment (PPE) policies. At each point the operator captures a reference image and enters location and equipment detail. At the conclusion of the walk/learn route creation the route log file is uploaded into the PC database application for editing and to add any additional information desired.

Mode 2: Create Route File in PC and Upload to Camera

In this mode the user populates the thermography asset database with data exported from a CMMS system or with new data records and creates a route by selecting files in order of intended inspection sequence. A route log file will be created and once uploaded to the camera will pull all relevant data sets into the camera. On-screen prompts will direct the user from point to point. An additional feature enables the user to add a point not on the current route and then synchronize the updated route log file if the new inspection point is intended to be included on a recurring basis.

Route Prompts Guide Data Collection

Once a route is created and uploaded to the camera, the camera presents prompts to help guide the user from point to point. It is possible to add descriptive information that gives the inspection some level of instruction about the point.

Return on Investment

In order to fully appreciate the impact of a comprehensive software suite (asset database, route management and report generation) we have constructed an analysis of costs of a thermography program and the potential improvements that can be realized with highly integrated in camera and PC host software. For this analysis we will make the following assumptions:

The cost of camera and software is $20,0001
The burdened hourly salary of an infrared technician is $60 an hour or about $125,000 per year.
The technician uses the infrared camera 50% of the hours worked.
The thermography program documents 20 incidents per week or about 1000 per year.
The camera is a capitalized asset and is depreciated over 5 years
Yearly savings of nearly $14,000 can be realized

The ROI on productivity tools is very high since they are integrated into systems available for less than $20,000.

1 - The monthly costs for the camera, based on a 5-year or 60-month depreciation schedule, are about $350 per month. The costs for the infrared camera operator will be $1200 per week or $62,400 per year.

Conclusions

The largest cost in a thermography inspection program is the camera operator/technician. By focusing on incorporating advanced features including route management and in camera data logging operators can dramatically improve their programs efficiency and cost while improving work quality and ease operator training demands. Ongoing developments to integrate infrared inspection data into CMMS and asset performance software systems will result in the next step in convergence on the plant floor and continue the development of new and innovative solutions designed to improve overall facility operation and capital equipment availability.

How To Brainstorm And Arrive At Helpful Final Decision On Time

This is not all about being or having Master degree in business management or entrepreneurship or other field, this is about taking a decision on something that seems to be at cross road and arriving at that helpful decision that brings light before the end of the tunnel. In a nut shell, it's applying wisdom to a difficult task.

I will start with these two stories of mine. I was with two young men who wanted to own their business and to partner with me. The owner of the idea of the business has good thought of how he wants the business to run but lacks the fast way to bring it to past since they were limited by finance to come out attractive to customers. The idea of the business is all about packaging gift that strikes emotion positively and putting it on a platform that is never imagined. So when this problem was brought to me, i asked them if it had a name already, that is the business name, they said no. so we thought of one, I figured out one for them, I told them if they could consider "beyond gifts" and they liked it. The next thing was the capital to start. The most funniest thing about this, is that the initiator of business was captialising on selling his blackberry phone and his partner is also hoping to sell his used laptop, but they want to lunch this business in a week time and by then the ID cards, fliers, Banners, letterhead and business name should be ready and this seems impossible because of fund..

However, when I saw their enthusiasm to lunch out, and after some days, I noticed they were till saying same thing and still at same point, I quickly outlined some things they needed to do so as to come out from their mess. I asked them to write out those things they know is necessary for the kick off of the business. They started to mention as follows.

1. Business name.
2. Letter head.
3. Fliers.
4.Office.
5. Banners.
6. Computers.
7. Website.
8. Bulk SMS.

After listing it verbally, I told them to remove office and that one of them should make his place of residence as office temporarily. And when they estimated the cost of the remaining list, it fell to N45,000. So I told them to divide the cost equally among themselves and later they can quantify their expertise and contributions to the success of the business in monetary terms, so as to arrive at the sharing ratio for the partners. Wow! This is the way out and they felt so happy.

The second illustration is the one that happened at my current local place of worship. The church wanted to buy a land, and this project has been on for long before I joined the assembly. So one Sunday, the pastor was preaching and told us how he was disturbed about the land issue of the church and the deadline for the Landlord to take over his property from the church is near. And after the service, he asked some people who have been contributing for this project for a long time to wait behind and that new member can join. And while they were having the meeting, I was eavesdropping but pretending to be discussing with a friend. I observed something that they were at cross road and don't know the way forward. And so I decided to join the meeting. And when the pastor finished speaking, he asked if anyone has anything to say, so I quickly raised my hand and he asked me to speak. So, I stood up and said that they should forgive me since I have not been part of them from onset. So, I asked them if they knew the land size they wanted and the location, to my greatest surprise this has not been thought of. Wow! And I also asked how much have they arrived at or what is their budget for the land. The answers to this question showed them the way out and everyone including the pastor was glad.

I discovered one thing from the two illustrations I gave, that they didn't understand the problem at hand very well and they were busy concentrating their effort on the finished product and forgetting the raw materials. They say the way to the top starts with the step taken at the bottom.

I know you will be saying now, you have spoken much, how can I make wise decisions. Ok, I will tell you. This was gotten from the wisdom Solomon and Jesus applied to difficult situations.

Summary of the two stories was that King Solomon was faced with two harlots with unquestionable character. They both wished each other evil. So this was a difficult task. Assuming one was not a harlot and they both lived apart, it would have been easy to decide but it is not so. Jesus was also faced with a great test, with men that didn't like him and looking for a way to set trap for him, if they know that Moses has commanded, stone any woman caught in adultery, why should they wait until they bring it to Jesus to enquire if they could stone her?

Points to Note, if you must arrive at a helpful decision.

You must be patient enough to understand the problem at hand. King Solomon and Jesus our Lord was patient enough to listen to the case at hand. They were not bias.
You must have a large heart to receive any kind of being. You mustn't be bias.
Be willing to be the solution giver to that problem. Why people remain at cross roads is because they are looking and depending on others to solve the problem at hand.
When studying the problem, look out for that bone of contention or what most people afraid of saying or scared of. And try a little to give a dare to do it, is possible to give you a lead. From the story, Solomon echoed back to the women, "So none of you agree to be the owner of the dead baby"? So he dared to kill the living baby and that gave him clue to make a wise decision. Jesus our Lord, on His own part noticed that they knew Moses has commanded to stone, so He dared them to stone and with that there was a clue and a way out.
Ask for God kind of wisdom to defeat any ill planned trap.
Luke 21:15

"For I will give you a mouth and wisdom, which all your adversaries shall not be able to gainsay nor resist."

6. Don't be quick to speak in any matter, always be attentive.

James 1:19

"Wherefore, my beloved brethren, let every man be swift to hear, slow to speak, slow to wrath: "

7. Don't make any decision whenever you are angry because it will never be a sound decision, for it is coming from a heart or mind that is not sound.

Proverbs 14:29

"He that is slow to wrath is of great understanding: but he that is hasty of spirit exalteth folly."

Proverbs 16:32

"He that is slow to anger is better than the mighty; and he that ruleth his spirit than he that taketh a city."

This Is Ikechukwu Agbapulu. I love to write to encourage people. When I do that I have this fulfillment in me.

The Blog - Is It Art, Communications or Something Else?

Is the written word within a Blog considered - first and foremost - public communications or artistic expression? This one has all the makings for an interesting debate.

The advent of Social Media has delivered to us all a huge number of Blogs on the Web - nearly 150 million. The intellectual argument centers on how might we categorize/classify the Blog in the twenty-tens? What is it and where does it fit best? Can it be considered a literary art form in its own right or is it simply a "folder" and "tool" (e.g. WordPress, share buttons, SEO strategy) for various kinds of new media communications? In that case, does it fit better with a foundation for the arts or as part of the world of editorial and public communications?

It is of some importance that we know the answer to this question, so that we may understand the proper way to categorize and value that which composes the average Blog. For example, is it appropriate to expose our children to the Blogosphere during their early education without - first - providing them with some scholarly analysis and practical advice about being somewhat more discerning with regard to Blog writing and content? Do we want impressionable young people to consider the overall quality of Blog writing unquestionably acceptable to emulate? Do we really want a world filled with 8!@#$%^&*+ for them? We can all agree that not everything that looks professionally published is fully credible and devoid of all informational, grammatical and spelling mistakes. Most adults have learned not to be fooled by the fancy formatting and slick graphics that often accompany inaccurate and poorly written articles and posts. So, what we have before us is a basic communications concern. This, before we can even consider if there is any built-in literary value in what we are reading.

Blogging is Changing the Way We Read and Write - for Better or Worse

What is the overall perception of "the Blog" in the world of today? We all have our favorite Blogs, published by those we may admire like Arianna Huffington (Huffington Post) and her team. But for every respected Blog, there are many more failures - if not in longevity, than certainly due to their poor quality. Does the Blogosphere carry with it a built-in air of sophistication equivalent to say the more respected intellectual journals or does it offer the same light weight appeal of - say - an edition of Captain Billy's Whiz Bang? What form and quality of human expression exactly is the Blog?

A closer look lets us see that Blogging is certainly altering the way we write as the Bloggers - themselves - adjust to the changing reading and viewing habits of those of us using laptops, tablets, E-readers and mobile devices to read their posts. We all seem to want this written "stuff" quick and easy to read on an eye-straining machine, so many Bloggers shortcut and shortchange on the way to satisfying us. Whether this is a good thing or a bad thing will - over time - be decided by any noticeable upward or downward shifts in the gross number of writers and readers influenced by new media to produce and consume more or less written content, respectively. But, does all of this answer the question of whether the average Blog should be considered the shell of artistic expression or a communication tool? Yes and no. It's mostly about what the individual Blog aspires to be and whether or not it succeeds. Regardless of any outcome, a Blog still belongs to the family of Blogs. It must dwell in that category and be considered part of this unique genre. The question remains: is that genre part of the world of artistic expression or the editorial and communications world? Obviously, the latter usually calls for more integrity and accountability surrounding the written word.

Graphic Design is Part Art and Part Technology

Let's consider a similar question; is graphic design a technology or art discipline? If one is designing a web site for a business client is the work considered an art form or a commercial project/product?

Many graphic artists work on strict production deadlines as do editorial free-lancers and Bloggers. They are all paid by the project and/or the hour to get the work out the door. They are often pressured to compromise and adhere to pre-set production schedules rather than to insist on their own expressions of artistic perfection. The true artist (visual or literary) has no such constraints. In fact, time is actually their ally. Consider that it took Michelangelo over four years, from July of 1508 to October of 1512, to finish painting the ceiling of the Sistine Chapel. Why did it take him so long? Michelangelo was a true artist. He wouldn't and couldn't be rushed. He intended to (and did) work in buon fresco, the most difficult method, and one which only true masters undertook. In the modern world, he may have been asked to forego his artistic preference and choose a different style of painting to finish the work much sooner. After all, the work was commissioned by the Pope. Still, artistic expression won the day and the ceiling of the Sistine chapel remains one of Michelangelo's greatest art works.

Depending on the situation graphic design CAN be considered BOTH an art form and a technology? The same rules apply as with the written word. When graphic design is used primarily for artistic expression it can be considered an art form. However, when the effort demands commercial production, it becomes something very different. That "something different" is technology, especially since the knowledge of computer software applications is a pre-requisite. And, this is regardless of the reason for whatever is being designed and for what purpose.

The Blog IS Really "Something Else"

Getting back to the Blog (regardless of its contents), under what category does it belong? Is it an art form? Is it more editorial and a communications tool? Or, might it even be something else, entirely? That something else is Social Media. Social Media is really about all of the things we have already discussed rolled into its own eco-system. By definition, "Social media are works of user-created video, audio, text or multimedia that are published and shared in a social environment, such as a blog, wiki or video hosting site. Text is a coherent set of symbols that transmits some kind of informative message. Informative message? (Wikipedia)" Hmmmm...

There seems to be no distinctions when it comes to text. Text is simply the written word. Period. Text is the written word - communications - "consisting of multiple glyphs, characters, symbols or sentences; a book, tome or other set of writings; a brief written message transmitted between mobile phones; an SMS text message; data which can be interpreted as human-readable text (all Wikipedia)." Text forms communications and any sort of writing - fictional or otherwise is communications first and foremost. We must understand what is is being written about and what thoughts and ideas are being expressed BEFORE we can appreciate these written words as an art form. If we can't read and understand the communications, there is no art to be appreciated. There are only multiple glyphs, characters, symbols or sentences. There is text. There is communications. And, communications shared over the Web is what we now call - Social Media.

So the written word and Blog - whether they are intended to share artistic expression or just serve as informative text (e.g. non-fiction) ALWAYS have communications at their core and belong to the worlds of communications and Social Media. And, by the way, Graphic Designers also fits nicely in the domain of Social Media, too. In graphic form they often illustrate those points being made on the Web.