Discover how early fire-detection technology is transforming the reliability and safety of critical power infrastructure.
FLIR’s latest Innovate & Inspire article explores how automated thermal monitoring is helping safeguard Ireland’s energy grid and prevent high-impact failures before they happen. It’s a quick, insightful read — click the link to view the full article and dive into the innovation behind keeping the lights on.
Moneypoint Power Station supplies a large portion of Ireland’s electricity, and a fire could disrupt up to 25% of the national grid. To mitigate this risk, ESB Energy and Butler Technologies deployed a thermal-monitoring system using FLIR A500f/A700f sensors and Latitude software, providing continuous, real-time oversight of high-risk areas.
24/7 visibility: Fixed thermal cameras continuously scan high-risk areas — no more waiting for weekly manual inspections.
Fast alerts: When temperature anomalies are detected, the system sends sub-second alerts, enabling shutdown within ~15 seconds.
Deep insights: Each thermal image has 16,000+ reference points, giving highly granular condition-monitoring data (transformers, valves, cabling).
Integrated solution: Fully native design (hardware + software + UI); no third-party components to manage.
Future ready: The system is built to scale with Ireland’s transition to renewables, with AI-powered anomaly detection and predictive maintenance on the roadmap.
Grid resilience: This setup is a model for safeguarding critical infrastructure — potentially rolling out to 500+ substations.
Key Takeaway:
Thermal automation isn’t just about fire safety — it’s a powerful tool for protecting national grids. By detecting heat anomalies early, Ireland’s Moneypoint Power Station is boosting resilience, improving response times, and setting a blueprint for future energy infrastructure.
Optimizing Lubrication Management with Advanced Predictive Maintenance.
Previously, traditional predictive maintenance tools failed to detect early bushing damage in a primary crusher, resulting in a catastrophic $1,000,000 failure. To enhance their lubrication management, the customer integrated Atten[2]’s OilWear S sensors after a thorough assessment of predictive maintenance technologies.
Before this, lubrication cycles took over a week, requiring sampling, lab analysis, and decision-making. With the new sensors, real-time monitoring now streamlines maintenance, reduces downtime, and improves equipment health.
Short time interval from start of damage to catastrophic machine failure
Damage difficult to detect with conventional monitoring technology
Possible mistakes during oil sampling
Long response time of the lab
SOLUTION:
Given this customer’s needs, Atten[2] recommended the installation of OilWear S sensors. The ISO code display and real-time particle shape classification enabled quick decision-making:
The lubrication management cycle went from one week to one or two days, reducing risks in sampling, reducing lab and labour costs, and thus increasing machine lifetime.
The sensors also optimized asset management and prevented a catastrophic failure that would have shut down the mine production.
SEQUENCE OF FAULT DETECTION
May 20th, 2021
“Baseline” of primary crusher operation was set to an ISO code 22/20/19, as seen in the box, the average data before the failure began.
May 22nd, 2021
At the precise moment when the values showed a notable deviation, increasing beyond the normal ISO code (24/23/21), an increase in sliding wear was detected.
Armed with this information and mindful of the previous catastrophic bushing failure, the operator conducted on-site inspections, leading to the discovery of a fault in one of the bushing.
* Note: The increase in fatigue wear (natural wear) is not in itself an abnormality that requires attention!
May 23th, 2021
The graph shows a sustained upward trend in the ISO code (25/24/22). Similarly, the classification of particulate matter indicates a continuous increase in cutting and sliding particles.
To stabilize the crusher’s performance, several corrective actions were implemented, including partial lubricant changes, enhanced lubrication practices (such as lifting and balancing the bushing with additional oil supply), reducing the machine’s operating speed, and maintaining frequent filter replacements.
June 06th, 2021
Thanks to continuous monitoring, an issue with a bushing was detected, associated with the presence of cutting and sliding particles deviating from normal operating parameters. Without Atten[2]’s imaging technology and shape analysis, detecting this damage in time would have been impossible or very difficult. The ability to provide reliable measurement results even with high oil viscosity and strong bubble formation in lower ISO classes, compared to con-ventional particle counters, is another key advantage that enables early damage detection under harsh conditions as given here with this particular crusher.
Prompt actions were taken to rectify the situation, allowing production to proceed as planned. On June 6th, 2021, corrective measures were implemented during the scheduled plant shutdown, replacing the bushing. After the crusher’s startup process, it returned to its established ‘normal line’ of operation, indicated by the ISO code (22/20/19). During the monitoring period, a bell-shaped curve in fatigue particles was noted, a typical phenomenon linked to the machine’s startup phase.
CUSTOMER ́S BENEFITS
An unexpected failure in this type of machine significantly impacts the mine’s operation, leading to substantial production losses. Atten2 technology played a crucial role in early fault diagnosis, allowing timely decisions and actions to prevent a catastrophic breakdown. This proactive approach not only extended the machine’s lifespan until the next planned shutdown but also helped the mine avoid potential failure-related costs amounting to USD$1,000,000.
This same event occurred years ago at the primary crusher, resulting in the customer reporting losses and expenses of approximately one million dollars. This includes direct costs of production hours and expenses associated with the shutdown.
Maximizing Pipe Integrity with Expert Thermographic Services: A Tailings Pipeline Success Story.
Ensuring the integrity of pipes in industrial systems is critical to maintaining smooth operations, preventing costly repairs, and avoiding unexpected shutdowns. Expert thermographic services offer a non-invasive, reliable solution for identifying pipe integrity issues across various applications, all while keeping production activities running as normal.
Thermographic inspections use infrared imaging to detect abnormal heat patterns, indicating potential weaknesses such as blockages, leaks, or worn sections in pipes. This technique is highly effective, as it can be applied without halting production or disrupting workflows, making it an ideal option for industries relying on continuous operation.
Yellotec Service Division’s Tailings Pipeline Success.
Recently, Yellotec Service Division partnered with a client to address the challenges of maintaining a tailings pipeline that carries slurry to a tailings dam. The goal was to develop an inspection regime that could be implemented during normal production, providing early detection of potential issues without requiring a complete shutdown.
Through thermographic inspection, Yellotec’s experts identified areas of concern in the pipeline that could have led to significant failures. This proactive approach enabled the client to make minor repairs during a planned shutdown, significantly minimizing maintenance costs and downtime.
The results were impressive: the inspection regime helped the client avoid potential losses and repair costs of US$43.2 million. By addressing issues early, the client was able to safeguard their operations and protect their bottom line.
Thermographic Services for Proactive Pipeline Maintenance.
With expert thermographic services, companies can detect pipe issues before they escalate into major problems. This case study highlights the benefits of partnering with professionals who have the skills and technology to keep your operations running smoothly while avoiding unnecessary risks and costs.
Using thermal imaging to see the liquids, solids and foam levels inside a tank.
The Challenge
Accurate tank level gauging in the oil and gas industry is a necessity. Maintenance teams need to be able to:
Check on product/by-product levels
Determine presence of interfaces between liquids, liquids/solids and emulsions.
Calculate tank flow rates
Calculate existing volume and remaining tank capacity
Estimate current product value, or calculate offloading requirements for transport
Traditional methods (dip-sticking and strapping) are dangerous and inaccurate.
The Solution
Thermal imaging can be done from a safe distance, and eliminates any need for direct contact. Very small internal temperature differences between liquids, solids, foams and vapours can be visually detected on the tank exterior. Such inspections can be carried out by utilising either the FLIR ONE Pro, which attaches to a smartphone and couples with an app to calculate tank volumes. Alternatively, a FLIR E-Series can be used where inspection can only be carried out at a safe distance, or higher thermal resolution is required.
The Result
Unlike traditional inspection methods, thermal imaging allows level and volumes of products/bi-products to be safely and accurately determined. Users will be able to see uneven levels such as sludge accumulation, thereby preventing sludge being sucked into pumps, and also calculate lost tank capacity from sludge build up. This further allows planning for sludge removal during shutdown – reducing downtime, costs, and improving reliability.
The Importance of Tank Level Gauging in the Oil and Gas Industry
Tank level gauging is a necessity for various applications in the oil and gas industry. Accurate monitoring of tank levels can help maintenance teams avoid tank overflows, calculate tank flow rates, and optimize storage capacity.
Benefits of Thermal Imaging for Tank Level Gauging
Thermal imaging is an advanced technology that allows oil and gas companies to gauge tank levels without direct contact. This non-intrusive method provides several advantages:
Safety and Efficiency: By eliminating the need for physical contact, thermal imaging reduces the risk of accidents and improves the efficiency of the gauging process.
Precision in Measurement: Thermal imaging can detect small changes in temperature, which is crucial for distinguishing between liquids or solids of varying densities. This precise measurement is essential for managing materials with specific heat characteristics.
Early Detection of Anomalies: Thermal imaging can identify temperature anomalies that may indicate potential issues, allowing for early intervention and maintenance before problems escalate.
In conclusion, integrating thermal imaging into tank level gauging processes offers significant benefits for oil and gas operations. It enhances safety, accuracy, and overall efficiency, making it an invaluable tool for the industry.
In the realm of motor diagnostics, two standout tools are revolutionizing the industry: the ATPOL III™ Power Quality and Motor Analyzer and the ALL-TEST PRO 7™ Professional.
These devices offer unparalleled capabilities for ensuring the health and efficiency of motors, transformers, and generators, making them indispensable for industrial maintenance and reliability professionals.
ATPOL III™ Power Quality and Motor Analyzer
Dual Functionality: Acts as both a Power Quality Analyzer (PQA) and Electrical Signature Analyzer (ESA).
Rapid Testing: Delivers comprehensive assessments in just 60 seconds.
Data Logging: Extensive data tracking, including energy usage, harmonic analysis, and voltage/current charting
Early Fault Detection: Identifies issues early to prevent motor failure.
Versatile Analysis: Evaluates incoming power, control circuits, and driven loads.
Robust Software: ESA software for tracking, trending, and reporting motor conditions.
High Compliance: Meets CAT III 1000V and CAT IV 600V safety ratings.
Comprehensive Testing: Assesses both electrical and mechanical efficiencies of AC/DC motors, generators, and transformers.
ALL-TEST PRO 7™ Professional
Comprehensive Testing: Suitable for AC and DC motors, generators, and transformers.
Quick and Efficient: Conducts tests in less than 3 minutes.
Advanced Troubleshooting: Features like the Z/θ Test for identifying specific motor issues.
Condition Monitoring: Allows continuous monitoring and trending of motor health.
Patented Technologies: Uses TVS™ and Stator and Rotor Signatures™ for precise diagnostics.
Multi-functional Analysis: Detects a variety of faults, including stator, rotor, ground, winding faults, and open connections.
Why These are Essential:
Both ATPOL III™ and ALL-TEST PRO 7™ Professional are designed to enhance productivity, ensure safety, and provide accurate diagnostics. They are built to withstand industrial environments, making them ideal for field and on-site applications.
By incorporating the ATPOL III™ and ALL-TEST PRO 7™ Professional into your maintenance toolkit, you ensure that your motors and electrical equipment are in optimal condition, reducing downtime and improving overall efficiency.
Yellotec offer a comprehensive range of products and services for Motor Circuit Analysis, Electric Motor Testing, Electrical Signature Analysis, and other.
International bowls for the disabled is hosting the world disabled bowls in Ekurhuleni from the 18-31 May 2024
In preparation for the tournament the lawn bowl greens profile/flatness needed to be tested. Yellotec rose to the challenge by performing a geometric alignment with the Pruftechnik level laser to assess the condition of the green at Kempton Park bowling club. The test area was however much larger than what is usually encountered in a machine base application that the system was designed for, and the technicians needed to perform unique post processing of the data after capturing (1296 measurements on a 36m2 surface).
Supporting our community, and disabled sportspersons to excel.The self-levelling, spinning laser in the LEVALIAGN Expert makes determining flatness and finding levels simple.
Key Features:
The LEVALIGN Expert can measure parallelism and perpendicularity, flatness and straightness, as well as the level of flanges and foundations.
The laser levels by itself, and rotates, allowing easy and efficient operation by a single person.
Sensor measurement range is 70mm at a resolution of 0.001mm and the laser reference range diameter is 200m.
Powerful PC software, “ALIGNMENT CENTRE” for professional reporting and measurement analysis.
Software functionalities include ability to compare two surfaces; for example, in a press. The measurement range for large surfaces can also be extended.
The LEVALIGN Expert communicates wirelessly.
For advanced industrial applications:
Flatness and parallelism of wind tower segment flanges
Leveling of machine foundations
Parallelism of rails
Flatness and straightness measurement in ship building
Leveling of reference surfaces and bases
Circular and rectangular surface profiles
This system will decrease production time when doing alignment on equipment as you have a geometrically flat base or surface to work from.
It will reduce soft foot probability as this can cause tension on the motor stator and will increase the power consumption, that will save energy consumption.
Yellotec helps international disabled bowling team to confirm flatness of bowling green.
Online assets undergo continuous real-time monitoring, with Yellotec personnel stationed in on-site and offsite control centres for diligent assessment, analysis, and reporting on the collected data. Remote assets are reported on weekly and monthly, with urgent changes in machine condition reported immediately.
One such customer site is a colliery involved in both underground and open-cast operations, with an annual output of approximately 8 million tons. This client entrusted Yellotec with the installation and commissioning of online vibration monitoring on 40 critical assets, including conveyors (Overland, Incline, Trunk), and Vent Fans.
As our partnership progresses into its third year of operation, the client has conducted independent assessments of all findings, meticulously calculating and verifying the realized value. Since its inception in 2021, the accrued savings to date exceed US$48 million.
Below is a case study of one such finding for this client.
Problem Category: Bearing Defect caused by Electrical Fluting
Value Realised: US$ 386 000
Diagnosis:
Alarm due to high vibration was observed on the NDE Motor Bearing. Harmonics of Outer Race Defect frequency at 177,6 Hz with side bands spaced at FTF (cage frequency) 10,67 Hz evident in the demodulation and acceleration spectral data comparisons. Gradual increase in spectral band trends noted. Also noted was a high frequency vibration in the region of 5 kHz with side bands spaced at 2X LF, confirming that the Motor is running on a VSD and suspected fluting as a secondary effect.
Notification was created and raised while it was still in initial stage and at low priority. As the defect progressed, the relevant Forman was notified and the status was changed to high priority.
Recommendation:
Initially it was recommended to ensure adequate bearing lubrication; however, no improvement was noted and as the defect progressed it was recommended to replace the Motor. The motor was then sent off site for inspection and repair.
Findings:
The NDE bearing was cleaned and opened for inspection. The bearing outer race show clear signs of damage due to electrical fluting. the NDE bearing defect identified by Condition Monitoring was a result of electrical discharge through the NDE bearing. The erosion of the raceway resulted in contamination of the grease. Continued operation with this condition would have resulted in premature failure.
Conclusion:
Specific attention should be paid on drives that are equipped with Variable Speed Drives (VSD’s), this includes Motor shaft grounding brushes that should be in place to discharge electrical currents to prevent secondary damage on motor bearings.
Cardan Shaft Alignment used to be a very expensive exercise, due to the time it took to remove the Cardan Shaft itself.
Now (thanks to Prüftechnik’s innovation), it is possible to do a Cardan Shaft Alignment, without having to remove the Cardan Shaft itself. This results in a huge Cost saving (Labor Cost and Cost due to Production loss). Let Yellotec help you to save Costs, by introducing this new Innovative method for Cardan Shaft Alignment?
See Prüftechnik Success Story below, as an example of how this was done.
For more information on this article or any of our Shaft Alignment products, feel free to contact us.
Yellotec is one of the leading suppliers of the most effective and efficient technology in machine health and reliability monitoring equipment in Africa. As well as providing services that help plant and equipment managers to predict all failures as well as prevent major failures in the future.
For expert advice and the latest in machine reliability technology Please feel free to contact us either by Contact Number, Email, Contact form or Visit us.
