ITC InfraMation - = November 2003

If you can't see the graphic version = of this=20 message please change your profile to receive text messages at=20 {{user("unsubaddr")}}
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November=20 2003

Volume 4, Issue=20 11

In This=20 Issue:=20

Welcome

IR in the News

New - ITC Website Message Board = Posts

WOW! That's the only way to describe InfraMation=20 2003!

High=20 Temperature Heat Exchanger Alloy Emissivity = Evaluation

Brainteaser of the Month

Last Month's Brainteaser

Past Issues

Upcoming Classes

About the ITC

Welcome=20 {{user("firstname")}},

InfraMation 2003 = Conference was a=20 great success. If you missed it, we have a review below and a great offer= =20 for next year's conference. If you were there, the photos will = bring back=20 some memories.

In this issue=20 we are announcing the major redesign of the ITC website including = our new=20 message boards. Check out the latest posts.

Our=20 application article this month on measuring the emissivity = of hot=20 furnace tubes was submitted by Kirk Williams of the = University of=20 North Dakota Energy & Environmental Research = Center.

And=20 we have an out of this world Brainteaser for you at Brainteaser of the Month.

If you want to=20 save this newsletter for viewing off line in your computer, just = go to the=20 web page using=20 your browser and select File....Save As or save this email = page as html in=20 your email software.

Until next=20 month keep the low emissivity side up (and the high emissivity = side=20 down),

Gary=20 Orlove,
Editor and = Publisher

IR in the=20 News [top]

Ozone = counters=20 carbon storage and other stories
Environmental=20 News Network, CA - Oct 29, = 2003
... For=20 the first time, researchers have used a combination of ocean = circulation=20 models, thermal imaging and airborne searches to = help=20 locate harmful floating ...
Nation = gearing up=20 for new SARS season / Early detection, ...
Daily Yomiuri, Japan - Oct = 26,=20 2003
... observed. Japan has installed = thermography=20 machines at all major international airports to detect people = with high=20 fevers. Under ...
Alien vs.=20 Predator Plot Summary
FilmForce - Oct 22, = 2003
...=20 Fast-forward to the present day. Charles Weyland, the = billionaire=20 industrialist, has discovered the Antarctic temple using = thermal=20 imaging satellites. ...
Breast= =20 Imaging An Early Road To Cancer Recovery
WBBM, IL - Oct 20, = 2003
...=20 can get a 95% pick-up rate if you do both a mammogram and = thermal=20 imaging ... Thermography is FDA approved, = costs=20 about $145, and insurance doesn't usually cover it = ...=20
Landslide = Warnings For Lakeside Residents
Xtra=20 News, New Zealand - Oct 16, = 2003
...=20 Taupo District Council management services manager Peter Martyn = says the=20 threat is being monitored and infra-red thermal = imaging=20 will be used to survey the ...
Fern= dale=20 company works to avoid NASA disasters
Detroit=20 News, MI - Oct 11, 2003
... = Infrared=20 thermography, as it's known, "is not your garden-variety = testing=20 system," said Shepard, the company's founder and president. = ...=20
Ferries face = =A3=20 2000 fines for carrying ' illegal immigrants '
4ni.co.uk, UK - Oct 6,=20 2003
... New detection technology such as heartbeat = detectors,=20 thermal imaging and gamma scanners in France has=20 contributed to 4,000 would-be illegal immigrants from = ...=20

ITC=20 Website Message Board Posts [top]

In the last two = months we have=20 completely overhauled the Infrared Training Center website. We have a = new design,=20 improved user interface, new features, and it runs much faster. = Among the=20 new features are a thermal image gallery and = redesigned=20 message=20 boards.

Below you will=20 find a selection the new topics started by visitors to the message = board=20 in October. Feel free to click the links, see how people have = responded,=20 and post your own response.

Water damage restoration
My company=20 specializes in structural drying and dehumidification. I am = interested=20 to learn how IR technology might be helpful in moisture = inspection=20 within a structure. If you have experience in using IR to = inspect for=20 water or moisture in a building, I would like to hear from = you.=20
IR Contracting
I'm looking = into=20 starting my own IR contracting business. Can anyone offer any=20 information about how to market this type of work? There aren't = any=20 thermography companies within a 150 mile radius of where I live. = Information regarding typical fees in any of residential, = commercial, or=20 industrial fields is appreciated. Also, I'd like to find out = what type=20 of problems people have had starting this type of business. Your = hindsight could be very helpful to me.
Thermographer business insurance
I=20 agree that this question is not specific to thermography as an=20 application, but I need some experienced individual = thermographers to=20 offer their knowledge. I am an individual, self-employed, not = connected=20 with a company. I have been running into a brick wall regarding = general=20 liability coverage. there doesn't seem to be any companies = willing to=20 cover IR work. I am not rendering opinions, only "taking = pictures" and=20 the underwriters either don't understand what I do or it seems = to be=20 unprofitable to insure a "commercial photographer"; any = suggestions as=20 to a source ?

And of course=20 if YOU have a question or want to start a discussion on a = topic, we=20 would love to hear from you. Just post a new thread on the message = board.

WOW! That's=20 the only way to describe InfraMation = 2003! [top]

By = Leonard A.=20 Phillips
Senior Writer for Infrared Applications, FLIR=20 Systems

As = many of you know,=20 this conference, the 4th annual event of its kind, was held in Las = Vegas,=20 Nevada from October 13-16th. The event exceeded all expectations, = breaking=20 all attendance records and already seeding next year=92s = conference with=20 over 100 pre-registrants!

With more than 300 delegates = InfraMation=20 2003 was the largest educational conference for thermographers in = the=20 world (see table). The delegates, who almost filled the Toulouse = Ballroom=20 at the Orleans Hotel, heard presentations on a range of topics, = including=20 thermographic applications in relatively familiar areas such as = furnace=20 tube skin temperature analysis, electrical vault inspections, = lightning=20 arrestor failure analysis, and electrical PdM, and also in = developing=20 areas of interest such as building sciences, aviation engine = diagnosis,=20 boat hull condition, high pressure metal die casting, hot-mix = asphalt road=20 construction, and aerial detection of storm water discharges into = streams.=20 Developments in the use of IR windows (also called =93sight = glasses=94) in=20 high-voltage electrical cabinet inspections, and in the remote = monitoring=20 and control of substations by integrating a SCADA system and = networked IR=20 camera were described. Still other presentations focused on non-IR = test=20 methods, including ultrasound and motor circuit analysis.

Corey Maple,=20 President of MiniMax Corporation and Paul Czerepuszko of = FLIR=20 Systems share a laugh at the FLIR booth while holding the = new=20 ThermoVision A20 infrared camera. Maple=92s presentation = =93Secure Plant=20 Monitoring through Remote Substation Monitoring=94 described = the=20 integration of the A20 camera and the MiniMax ScadaCam = system. The=20 camera is networked and is accessible and controllable via a = Web=20 browser. Try it! Go to http://www.scadacam.net/ and log=20 on.

Two = PhDs share a=20 moment on the podium as Bob Madding presents Howard Penrose, = PhD=20 with a speaker=92s award. Penrose spoke on =93Financial = Impact of=20 Electric Motor System Reliability Programs,=94 in which he = highlighted=20 the complementary roles of several inspection methods in = detecting=20 malfunctions and determining the root cause of electric = motor=20 failures.

And then=20 there were the remarkable presentations by a retired physician and = a=20 nurse. The first described the use of thermography in indoor track = and=20 field shot put events, illustrated with two shot puts dutifully = brought to=20 the podium by the presenter. A respectful hush came over the = audience=20 during the presentation on the use of thermography to monitor the = skin=20 temperature of low-birth weight infants by the Director of the = National=20 Association of Neonatal Nurses. The buzz among the rugged PdM guys = during=20 the following break included numerous references to the = thermographs of=20 the little babies. For a list of papers and to obtain a copy of = the=20 Proceedings of InfraMation 2003, please go to http://www.infraredtraini= ng.com/store/=20 .

Shay Edwards, regional science and = engineering fair winner from Highland Elementary School in = Norco=20 California, with ITC=92s Gary =93Glo=94 Orlove. Shay = displayed and=20 explained his project, "Emissivity: A Study in Infrared = Viewing" to=20 numerous grown-up thermographers. IR=20 thermograph from the presentation given by Kimberly M. = Horns, PhD,=20 APRN, =93Innovative Non-Invasive Measures of Thermal = Stability in Low=20 Birth Weight Infants.=94 Her research at the = University of Utah=20 Medical Center held the audience spellbound as she = demonstrated the=20 value of IR thermography in a setting far removed from = substations=20 and manufacturing = facilities.

The=20 youngest presenter was Shay Edwards of Highland Elementary School = in=20 Norco, California, fresh from his regional win at the Science and=20 Technology Education Partnership (STEP) annual Inland Science and=20 Engineering Fair in the Junior Division (grades 6-8) held in San=20 Bernardino in April. He displayed and explained his project, = "Emissivity:=20 A Study in Infrared Viewing" to numerous =93grown-up=94 = thermographers at the=20 registration desk. A thermographer in development, he=92s = definitely on his=20 way to a successful career!

Here are a=20 few comments from the delegates:

=93I agree! The conference was a great = success.=94
=96=20 Delegate MIKE RALPH, Excelon Nuclear--LaSalle Nuclear=20 Station

=93It was a=20 pleasure speaking and writing the article. We will be interested = in next=20 years as well.=94
=96 Presenter EDWARD FRONAPFEL, Professional=20 Investigative Engineers

=93It was such=20 a great conference for us that we plan to be there next year for = sure.=94=20
=96 Presenter Mark=20 Goodman, UE Systems

=93I would=20 like to participate in next year=92s conference and have already=20 preregistered. Thank you very much and best regards to the = InfraMation=20 team!=94
=96 Presenter RAFAEL ROYO, Universidad Polit=E9cnica = de Valencia=20

=93The 2003=20 conference was my first thermographers conference and what a great = way to=20 start. The papers presented were excellent, the clinics were even = better,=20 the food was almost too good, and I had the opportunity to meet = and talk=20 with many people that have an excellent knowledge and skill in=20 thermography. Our program will become much better for having = attended.=20 Please convey my regards to all those involved with the = conference. I=20 cannot express how grateful I am. I will find a way to be with you = next=20 year.=94
=96 Delegate GLEN WARNIK, Utah State University,=20 Facilities

Clearly, InfraMation has grown into a =93must-attend=94 = event . In fact=20 fully ONE-THIRD of this year=92s delegates have ALREADY signed up = for=20 InfraMation 2004! What makes this conference so different? =20

Overall view of the InfraMation = 2003=20 audience in the Toulouse Ballroom of the Orleans Hotel with = EPRI=92s=20 Bill Woyshner, the keynote speaker, on the podium and Bob = Madding=20 waiting in the wings. One of the many packed clinic=20 sessions.

We are committed to assuring that InfraMation = provides=20 educational, networking and career-building value. Sure, we = attract=20 exhibitors that want to show you the latest technologies and = tools=20 available, but, our main focus is to help you be the best = infrared=20 thermographer you can be, bar none.

So join us for InfraMation 2004! We encourage you = to sign up=20 today and take advantage of the valuable early registration = offer,=20 which includes a valuable FREE gift. Click=20 here for more information .

If you=92d like to submit a paper presentation for = next year,=20 exhibit a new product or service, lead a clinic or workshop, = or, if=20 you just have some ideas on how we can do a better job, = please hit=20 =93reply=94=20 and give us your thoughts.

See you next year!

Bob Madding presents a speaker=92s award to Doug = Corley, M.D.=20 in recognition of his presentation =93Use of Infrared = Imaging for=20 Track & Field.=94 The impact of a shotput generates heat = that is=20 detectable for several minutes, greatly facilitating = judges=92=20 = decisions.

High = Temperature=20 Heat Exchanger Alloy Emissivity Evaluation = [top]

by Kirk=20 Williams
University of North Dakota Energy & Environmental = Research=20 Center

The Energy=20 & Environmental Research Center (EERC) identified an = opportunity to=20 utilize an unprotected alloy-based high-temperature heat exchanger = (HTHX)=20 that could reduce the size requirements for this component and=20 significantly lower the overall cost of the system. The EERC is = involved=20 in the experimental development of an advanced coal-based power = system=20 that involves a pilot scale; high-temperature heat exchanger = fabricated=20 from oxide dispersion strengthened (ODS) alloys. The two alloys = are MA754,=20 a nickel=96chrome alloy, and MA956, an iron=96chrome=96aluminum = alloy. When=20 subjected to oxidizing conditions, the MA754 forms a = greenish-black=20 chromium oxide layer and the MA956 forms a light-grey aluminum = oxide=20 layer. Each alloy has its own characteristic ambient emissivity = value that=20 proves to be different at very high temperatures.

The advanced HTHX design can be an integral part of an = indirectly=20 fired combined-cycle (IFCC) power plant and is currently being = carefully=20 tested in a coal-fired slagging furnace system (SFS) at the EERC. = The HTHX=20 is composed of three vertically oriented 6-foot-long by 2=BD-inch = diameter=20 tubes of ODS alloys which were originally protected from the = products of=20 combustion by ceramic panels.

In subsequent tests, the bare alloy tubes were exposed = directly to=20 the products of combustion in the SFS, which significantly = increased heat=20 exchange coefficients. The bare-tube HTHX is typically operated = with inlet=20 process air temperatures at 1000=B0-1020=B0F and alloy tube = surface=20 temperatures are 1380=B0-2010=B0F. The low end of the alloy tube = surface=20 temperature range represents the backside of the tubes at the = process air=20 inlet, with the high end of the range representing the front side = of the=20 tubes at the center of the HTHX. A schematic of the system is = shown in=20 Figure 1. The SFS is designed for a maximum furnace exit = temperature of=20 2900=B0F but is typically run at 2800=B0F to maintain desired slag = flow while=20 extending the furnace lifetime.

Figure 1. Schematic of the EERC = high-temperature=20 slagging furnace system (click for larger image).

EXPERIMENTAL PROCEDURES

Recent=20 developments in a joining design and assembly technique were used = to=20 replace the center tube of the all-MA754 HTHX, with a tube = designed and=20 fabricated entirely from MA956 alloy. The modified HTHX is shown = in Figure=20 2 as a visible light image taken at ambient temperature before the = test.=20 Note the lack of an oxide coating on the center MA956 alloy tube = as=20 compared to the outer MA754 alloy tubes. In visible light, the = difference=20 in the appearance of the tubes is due to the oxide layer. The = MA956 is an=20 aluminum oxide forming alloy and does not yet have the familiar, = light=20 aluminum colored outer layer. The INCONEL 625 = thermocouple-mounting pad on=20 this tube can be used as a visual reference in the thermal=20 image.

Figure 2. Visible light image of the = alloy heat=20 exchanger tubes. The middle tube is MA956 and the outer two are = MA754 ODS=20 alloy. Note the thermocouple pad and thermocouple wire on the = middle tube.=20 Also note the differences in oxidation layers on the tube surfaces = that=20 suggest emissivity differences will be likely (click for larger=20 image).

The images used for this report represent a small part of = a single=20 test from a multi-year DOE project. These images show the = pilot-scale SFS=20 operating at 2800=B0F using natural gas-fire. The focus of this = project was=20 to accurately determine the surface temperature of MA754 and MA956 = ODS=20 alloy tubes during operation in a SFS while being internally = cooled by the=20 low-pressure air to just below their melting temperature. For = metals,=20 sustained high temperature exposure close to their melting point = can be=20 very damaging. Add the corrosive properties of flowing slag and = the=20 structural properties of the metal quickly diminish. The ODS = alloys are=20 designed to retain most of their mechanical properties at high=20 temperatures and provide an oxide layer that can increase their = resistance=20 to coal-slag corrosion at the same time. However, it is this oxide = layer=20 in combination with the basic emissivity variation of the alloy = that=20 causes difficulties in obtaining accurate surface temperatures = while in=20 the operating environment. It has been determined that accurate = surface=20 temperatures of the tubes are needed to minimize the alloy = corrosion due=20 to flowing slag. The outer most surface of the tubes must be = controlled=20 such that this temperature is just below the melting point of the = flowing=20 slag. This temperature has been experimentally determined to be = 2000=B0F.=20 This means to maintain structural integrity of the HTHX array and = still=20 keep a high efficiency heat exchange process, the tube surfaces = must not=20 exceed 2000=B0F.

RESULTS AND=20 DISCUSSION

Figure 3 is a=20 false-color thermal image taken at the same maximum gas-fire = temperature=20 by a ThermaCAM SC 1000 with a 16 degree lens and 3.9 =B5m flame = suppression=20 filter. In this thermogram, the basic thermal differences between = the=20 alloys and the refractory are clearly represented. The emissivity=20 differences between the alloy tubes can be noted by the brighter = contrast=20 of the center tube compared to the outer two tubes. The use of the = iron-bow color palette is to enhance fine detail.

Figure 3. Thermogram of the alloys at maximum gas-fire = temperature=20 (click image for larger picture)

The complexity=20 of determining accurate tube surface temperatures is significant. = In this=20 image, the target tube is in the middle, flanked on either side by = alloys=20 of different emissivities. The overall inside diameter of the = combustion=20 chamber is 6 feet and lined with high emissivity alumina = refractory. The=20 upper, natural gas-fired swirl burner directs the flame toward the = center=20 of the chamber, which is in front of the HTHX array. During = operation,=20 installation of a 6-inch diameter =BC-inch thick sapphire crystal = view port=20 permits the alloy tubes to be directly viewed and photographed.=20

To = determine=20 the alloy surface temperature, multiple direct and indirect = temperature=20 sources must be known. Although the combustion chamber is a = dynamic=20 environment, the temperature is fairly uniform. The tubes = uniformly=20 reflect the apparent temperature radiation that is emitted = from the=20 flame and the surrounding heated refractory toward the IR = detector. This=20 reflected IR radiation must pass through the heated sapphire view = port=20 that further restricts radiation transmission due to the slight = thermal=20 opacity of the crystal. Temperature of the optics, both external = (the view=20 port) and internal (the camera lens) must be accounted for since = this can=20 be considered additional source for thermal radiation (although = very small=20 in this case, it still must be considered important).

SUMMARY AND=20 CONCLUSIONS

Emissivity=20 values of the alloy itself change with different surface finishes = and=20 different temperatures. To account for all material and surface = finish=20 differences is challenging at best, so multiple applications of=20 thermocouples were used on the middle tube as a method of = referencing the=20 actual temperature of that tube close to where the targeted spot=20 temperature was taken. Each tube has its own thermocouple array = that was=20 used to correlate the actual temperature to the appropriate = thermogram=20 during the recording sequence. The final surface temperatures for = the two=20 outer MA754 alloy tubes of 1988=B0F and 1981=B0F compared to the = middle MA956=20 tube at 1985=B0F, were determined by continuously adjusting the = emissivity=20 values of the alloys (0.95 for MA754 at 2000=B0F and 0.77 for the = MA956 at=20 2000=B0F) and reflected apparent temperatures (approximated at = 2600=B0-=20 2800=B0F), within known (reasonable) parameters, to match the = actual=20 recorded thermocouple temperatures (1985=B0F) as closely as = possible. All=20 well-known or previously documented parameters such as optics = temperature=20 (sapphire 250=B0F, camera lens 110=B0F), and transmissivity (83%), = target=20 distance to lens (2 m), and ambient air temperature (100=B0F) = remained fixed=20 during the post-imaging analysis. It should be noted; the SFS is a = thermally dynamic environment. Obtaining an accurate, reproducible = alloy=20 surface temperature that coincides with the mechanically bonded=20 thermocouple that is in intimate contact with the surface at all = times=20 remains a challenge.

Editor's=20 note: Kirk receives an InfraMation Executive Attach=E9 for his = article=20 contribution. Thanks=20 Kirk.

Brainteaser of the Month =20 [top]

Here is this month's = brainteaser.=20 First reader to email me with the correct explanation of the = thermogram=20 receives a gift from ITC. Please put "Brainteaser" as the = subject=20 of the message.

Click=20 here to email your guess

Do you have an interesting image that you think would = stump other=20 thermographers? If so please email=20 me your image (preferably in native .img, .jpg, .tif, .tgw, or = .tmw=20 format) with an accompanying visible photo and explanation. If = your image=20 is used, you receive a gift as=20 well.

Last Month's = Brainteaser=20 [top]

Our winner for last month's = Brainteaser is=20 Brian Fortney from Manitoba Hydro in Canada. Most of the guesses = were of=20 the moon behind a tree. But some of you caught my clue=20 "a honey of a Brainteaser" and = guessed=20 correctly that it is a hornet's nest in a tree, but Brian sent me = the=20 first correct guess.

Brian receives our=20 special low emissivity traveling coffee mug for his guess. Thanks = to Ron=20 Lucier for the = image.

Past Issues =20 [top]

Click the links = below to view=20 past issues of this newsletter:

All past issues from February 2000 through = December=20 2002

October=20 2003

September=20 2003

August=20 2003

July=20 2003

June=20 2003

May=20 2003

April=20 2003

March=20 2003

February 2003

January=20 2003

Upcoming Classes =20 [top]

Click the links = below to see our=20 latest course calendars (in local language).

Americas - Level I

Americas - Level II

Americas - Application, Level III, = R&D

Eurasia

Deutschland

France

Italia

United = Kingdom

About=20 the Infrared Training Center =20 [top]

The Infrared Training Center offers training and = certification in=20 all aspects of infrared thermography use. Our world-class training = facilities are located near Boston, Massachusetts, USA and = Stockholm,=20 Sweden and have the world's most extensive hands on laboratories = for=20 infrared applications. Please join us in exploring the fascinating = world=20 of the infrared!

Your comments and suggestions about this newsletter are = welcomed=20 and encouraged. If you have an interesting application or case = study to=20 share, we encourage you to submit it for publication. Published = articles earn credit towards = recertification.

Please e-mail Gary = Orlove or=20 send regular mail to the Americas office.

Visit our website:

ITC Americas, BOSTON

16 Esquire Road
N. Billerica, MA 01862, = USA

Tel: +1-978-901-8405
Toll free:=20 = +1-866-TRAINIR
&= nbsp; =20 (866-872-4647)
Fax: +1.978.901-8832
E-mail: mailto:info_us@infraredtraining.com

ITC Eurasia, SWEDEN

Rinkebyv=E4gen 19
SE-182 11 Danderyd, = Sweden

Tel: +46 (0) 8 753 25 00
Fax: +46 (0) 8 753 26 = 01
E-mail:=20 mailto:itc@flir.se

THIS DOCUMENT IS FOR INFORMATIONAL = PURPOSES ONLY.=20 INFORMATION PROVIDED IN THIS DOCUMENT IS PROVIDED 'AS IS' WITHOUT = WARRANTY=20 OF ANY KIND. The user assumes the entire risk as to the accuracy = and the=20 use of this document. The Infrared Training Center newsletter may = be=20 copied and distributed subject to the following conditions: 1. All = text=20 and images must be copied without modification and all pages must = be=20 included; 2. All copies must contain the Infrared Training Center=20 copyright notice and any other notices provided therein;
3. = This=20 document may not be distributed for profit

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