The Infrared Development and Thermal Structures Laboratory (IDTSL) is an undergraduate research laboratory in the College of Integrated Science and Technology (CISAT) at James Madison University (JMU) in Harrisonburg, Virginia. During the 1997-98 academic year, Dr. Jonathan Miles established the IDTSL at JMU with the support of a collaborative research grant from the NASA Langley Research Center and with additional support from the College of Integrated Science and Technology at JMU. The IDTSL supports research and development efforts that feature non-contact thermal and mechanical measurements and advance the state of the art. These efforts all entail undergraduate participation intended to significantly enrich their technical education. The IDTSL is funded by major government organizations and the private sector and provides a unique opportunity to undergraduates who wish to participate in projects that push the boundaries of non-contact measurement technologies, and provides a model for effective hands-on, project oriented, student-centered learning that reinforces concepts and skills introduced within the Integrated Science and Technology (ISAT) curriculum. The lab also provides access to advanced topics and emerging measurement technologies; fosters development of teaming and communication skills in an interdisciplinary environment; and avails undergraduates of professional activities including writing papers, presentation at conferences, and participation in summer internships. This paper provides an overview of the Infrared Development and Thermal Structures Laboratory, its functionality, its record of achievements, and the important contribution it has made to the field of non-contact measurement and undergraduate education.
Steel pipes used at Alaskan oil-producing facilities to transport production crude, gas, and injection water between well house and drill site manifold building, and along cross-country lines to and from central processing facilities, must be insulated in order to protect against the severely cold temperatures that are common during the arctic winter. A problem inherent with this system is that the sealed joints between adjacent layers of the outer wrap will over time degrade and can allow water to breach the system and migrate into and through the insulation. The moisture can ultimately interact with the steel pipe and trigger external corrosion which, if left unchecked, can lead to pipe failure and spillage. A New Technology Evaluation Guideline prepared for ConocoPhillips Alaska, Inc. in 2001 is intended to guide the consideration of new technologies for pipeline inspection in a manner that is safer, faster, and more cost-effective than existing techniques. Infrared thermography (IRT) was identified as promising for identification of wetted insulation regions given that it offers the means to scan a large area quickly from a safe distance, and measure the temperature field associated with that area. However, it was also recognized that there are limiting factors associated with an IRT-based approach including instrument sensitivity, cost, portability, functionality in hostile (arctic) environments, and training required for proper interpretation of data. A methodology was developed and tested in the field that provides a technique to conduct large-scale screening for wetted regions along insulated pipelines. The results of predictive modeling analysis and testing demonstrate the feasibility under certain condition of identifying wetted insulation areas. The results of the study and recommendations for implementation are described.
In August 2003, NASA's In-Space Propulsion Program contracted with our team to develop a prototype on-board Optical Diagnostics System (ODS) for solar sail flight tests. The ODS is intended to monitor sail deployment as well as structural and thermal behavior, and to validate computational models for use in designing future solar sail missions. This paper focuses on the thermography aspects of the ODS. A thermal model was developed to predict local sail temperature variations as a function of sail tilt to the sun, billow depth, and spectral optical properties of front and back sail surfaces. Temperature variations as small as 0.5 oC can induce significant thermal strains that compare in magnitude to mechanical strains. These thermally induced strains may result in changes in shape and dynamics. The model also gave insight into the range and sensitivity required for in-flight thermal measurements and supported the development of an ABAQUS-coupled thermo-structural model. The paper also discusses three kinds of tests conducted to 1) determine the optical properties of candidate materials; 2) evaluate uncooled microbolometer-type infrared imagers; and 3) operate a prototype imager with the ODS baseline configuration. (Uncooled bolometers are less sensitive than cooled ones, but may be necessary because of restrictive ODS mass and power limits.) The team measured the spectral properties of several coated polymer samples at various angles of incidence. Two commercially available uncooled microbolometer imagers were compared, and it was found that reliable temperature measurements are feasible for both coated and uncoated sides of typical sail membrane materials.
Thermal signature may be one of the defining factors in determining the applicability of fuel cell auxiliary power unit (APU) technology in military applications. Thermal characterization is important for military applications given that identification and detection may be accomplished through observation of its thermal signature. The operating modes and power takeoff operations of a vehicle will likely determine the thermal profile. The objective of our study was to develop and implement a protocol for quantifying the thermal characteristics of a methanol fuel cell and an idling tractor engine under representative characteristic operations. APU thermal characteristics are a special case for which standardized testing procedures do not presently exist. A customized testing protocol was developed and applied that is specific to an APU-equipped vehicle. Initial testing was conducted on the methanol APU-equipped Freightliner tractor using a high-performance radiometric infrared system. The APU profile calls for a series of infrared images to be collected at three different viewing angles and two different elevations under various loads. The diesel engine was studied in a similar fashion using seven different viewing angles and two different elevations. Raw data collected according to the newly developed methodology provided the opportunity for computer analysis and thermal profiling of both the fuel cell and the diesel engine.
A dual-waveband, fiber-optic/infrared (F-O/IR) temperature measurement system was enhanced with incorporated optical chopping and applied to measure the surface temperature of a coated (aluminized) Kapton HN sample. The F-O/IR system provides a non-contact means for accurate membrane temperature measurement without distorting surface contour. An FTIR spectrometer was used to measure the absorptance and reflectance properties of the Kapton HN sample. A long-wave IR scanner was used to validate and enhance results obtained from the spectrometer and predict temperature dependence of optical properties. Data are presented that demonstrate the feasibility to apply the F-O/IR system for non-contact temperature measurement of highly reflective surfaces at low temperatures.
The campus of a comprehensive, residential university is in many respects a small city unto itself. All the amenities and services one would expect in a typical community are readily available on a college campus, including residences, athletic and dining facilities, libraries, and stores. A large campus, therefore, requires a reliable energy plant to provide steam, hot water, chilled water, and electricity. James Madison University supports two power plants: a vintage steam plant and a modern resource recovery facility comprising two solid-waste incinerators and two gas-fired units for steam generation, three steam-driven absorption- chilling units, and a single steam-driven generator for peak electricity production. Infrared imaging, as a teaching tool, was introduced in the Program of Integrated Science and Technology at James Madison University in 1997. The Infrared Development and Thermal Testing Laboratory was established at the university later in 1997 with government and industry support, and it is presently equipped with infrared imagers and scanners, single-point detectors, and data-acquisition systems. A study was conducted between 1998 and 1999 to test the economic feasibility of implementing an IR-based predictive maintenance program in the university steam plant. This paper describes the opportunities created at James Madison University to develop IR-based predictive maintenance programs that enhance the operation of the university energy plants; to establish IR-related research and development activities that support government and industry activities; and to enhance a science- and technology-based curriculum by way of unique, IR-based laboratory experiences and demonstrations.
The Electric Power Research Institute and member utilities have sponsored since 1993 the Advanced Leak Detection - Research Evaluation Demonstration (all red) Project. The all red project utilizes an IR thermography system equipped with a high-temperature lens to detect internal boiler deficiencies and measure temperatures. Two high-temperature IR lenses were developed to perform internal boiler investigations. The lenses can operate in an environment that may reach as high as 2500 degrees F. The internal boiler areas and phenomena that are investigated include: tube temperatures, tube leaks, bowed tubes, and restricted flow; flame shape, flame temperature, and flame location; field distribution and identification of gas species. Detection of parameters that may assist with environmental NOx concerns is also desired. The results of the current study of radiative interactions indicate that IR temperature measurements made inside large commercial gas-fired furnaces are feasible, but acquisition of accurate and repeatable data requires special consideration of radiative phenomena. This study comprised three related efforts - an extensive literature survey and analysis of existing data acquired with a high-temperature lens; an experimental study including acquisition and analysis of spectroradiometric data; and the development of techniques to correct IR thermographic data. Concerns regarding default imager temperature-conversion algorithms and reliability of system calibration are also discussed. This paper represent the culmination of investigations that shed new light on the complexity involved in making in-situ measurements of boiler stream tubes with an IR thermography high-temperature lens system.
Many utilities throughout the United States have added infrared scanning to their arsenal of techniques for inspection and predictive maintenance programs. Commercial infrared scanners are not designed, however, to withstand the searing interiors of boilers, which can exceed 2500 degrees Fahrenheit. Two high-temperature lenses designed to withstand the hostile environment inside a boiler for extended periods of time were developed by the EPRI M&D Center, thus permitting real-time measurement of steam tube temperatures and subsequent analysis of tube condition, inspection of burners, and identification of hot spots. A study was conducted by Sunderland Engineering, Inc. and EPRI M&D in order to characterize the radiative interactions that affect infrared measurements made inside a commercial, coal- fired, water-tube boiler. A comprehensive literature search exploring the existing record of results pertaining to analytical and experimental determination of radiative properties of coal-combustion byproducts was performed. An experimental component intended to provide data for characterization of the optical properties of hot combustion byproducts inside a coal-fired furnace was carried out. The results of the study indicate that hot gases, carbon particles, and fly ash, which together compose the medium inside a boiler, affect to varying degrees the transport of infrared radiation across a furnace. Techniques for improved infrared measurement across a coal-fired furnace are under development.
Fuel accounts for an average of seventy percent of the yearly operational and maintenance costs of all the fossil stations in the United States. This amounts to 30 billion dollars spent for fuel each year. In addition, federal and state environmental codes have been enforcing stricter regulations that demand cleaner environments, such as the reduction of nitrogen oxides (NOx), which are a by-product of the fossil fuel flame. If the burn of the flame inside a boiler could be optimized, the usage of fuel and the amounts of pollution produced would be significantly reduced, and many of the common boiler tube failures can be avoided. This would result in a major dollar savings to the utility industry, and would provide a cleaner environment. Accomplishing these goals will require a major effort from the designers and operators that manufacture, operate, and maintain the fossil stations. Over the past few years re-designed burners have been installed in many boilers to help control the temperatures and shape of the flame for better performance and NOx reduction. However, the measurement of the processes and components inside the furnace, that could assist in determining the desired conditions, can at times be very difficult due to the hostile hot environment. In an attempt to resolve these problems, the EPRI M&D Center and a core group of EPRI member utilities have undertaken a two-year project with various optical manufacturers, IR manufacturers, and IR specialists, to fully develop an optical lens that will withstand the high furnace temperatures. The purpose of the lens is to explore the possibilities of making accurate high temperature measurements of the furnace processes and components in an ever-changing harsh environment. This paper provides an introduction to EPRI's internal boiler investigation using an IR high temperature lens (HTL). The paper describes the objectives, approach, benefits, and project progress.
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