I have been asked so many times, “What does it take to startup an IR program?”Surprisingly, I never have the same answer. Not because I am inconsistent, but rather that there is no one correct answer. Each site, plant, or organization is going to have different needs, obstacles, or other variables. This topic could cover many pages getting into specific details or, as I’m about to do, is just going to span a few paragraphs, giving the basics to give you an idea of the basics. These can then be applied to your own facility or program’s needs.
I would say the first step is to determine whether or not you need/want an in-house program or you’d like to contract the service from a qualified vendor. Some of the plants I have provided service for had determined that the cost of equipment, training, and manpower were prohibitive to starting an in-house infrared program, and have opted for contracted service, letting the contractor handle all of the inspection details and providing them with a report of the findings. Some have opted to do both and use a mentoring program to help develop their program while getting the quality results that a high quality contractor can provide until their program is ready to “take over” without interruption or loss of quality.
Considerations for starting an in-house program include but limited to:
- Vision: What is the goal for the program, to satisfy an insurance requirement? To reduce operating costs for the plant by reducing down time? Or, are you looking to reduce process interruptions and reduce maintenance costs?
- Cost: The cost can sometimes grow beyond what was originally accounted for. Most of the time the cost of the equipment and the training is all that was accounted for. Make sure that you have an accurate and realistic cost in mind at the beginning of your planning.
- Opportunities onsite: Is there enough work on the site to justify the expense of an in-house program? Are just going to conduct electrical inspections? Or, perhaps you want to expand into mechanical applications as well?
- Culture of the site: Will all of the departments on the site support an in-house program? The program is not just the thermographer conducting inspections. A program is the coordinated efforts of maintenance, operations, management, purchasing, scheduling, and planning. It requires that all departments work with each other to utilize the data inputted by the infrared program.
- Training: A good program requires the commitment of the site to provide continual training for all of the PDM team members.
The answers to the above questions will normally generate additional questions. The persons involved in the decision making process will have to work through all of the possible directions this may lead to. Seek out advice from organizations that have successfully developed quality programs.
Good luck!