In today’s episode of the Dust Safety Science podcast, Drew Hanover, CTO at Avian, discusses the use of infrared monitoring in wood products facilities. He goes over how these types of devices are being used so that listeners can understand and better detect fire hazards in wood processing sites.
Why Is Fire Risk a Significant Concern in Wood Facilities?
Wood processing facilities are inherently at risk for fires due to the presence of combustible dust and ignition sources. Equipment such as saws, hoggers, and dust collection systems generate dust, which, when combined with heat or sparks, can lead to dangerous incidents. Historically, fires often precede larger safety issues like deflagrations or explosions.
Examples include catastrophic events at sawmills in Canada and the UK, where fires escalated into explosions with devastating consequences. Drew stated that fires not only jeopardize worker safety but also strain local economies and disrupt supply chains. Preventing fires at their source is essential for maintaining safe and efficient operations. Moreover, the economic impact extends beyond direct losses to include downtime, fines, and potential regulatory penalties for non-compliance with safety standards.
How Do Infrared Monitoring Systems Work?
Infrared monitoring systems provide 24/7 surveillance of critical equipment and processes within a facility. Avian’s technology involves installing infrared cameras at key points, such as near motors, bearings, and conveyors. Over time, these cameras learn the normal operating temperatures of machinery, enabling them to detect abnormal heat patterns early.
Instead of waiting for a high-temperature alarm, the system identifies subtle increases in temperature that signal potential issues, such as a failing bearing or overheating motor. This proactive approach allows maintenance teams to address problems before they escalate into fires or operational failures. Additionally, the collected data supports long-term maintenance strategies, helping facilities operate more efficiently and reducing unexpected downtimes.
Which Areas Are Monitored in Wood Facilities?
Infrared monitoring systems are installed in various areas prone to fire hazards, including:
- Machinery: Equipment like planers, edgers, and pellet presses are common monitoring targets due to their susceptibility to overheating.
- Boiler Rooms: Cameras monitor these high-risk areas for early signs of overheating or equipment failure.
- Electrical Systems: Control rooms and PLC cabinets are equipped with cameras to detect electrical hazards, a significant source of industrial fires.
- Outdoor Mulch Piles: Infrared cameras identify hotspots in mulch piles, helping operators determine when to turn the piles and prevent ignition.
These systems provide peace of mind by continuously monitoring areas that are often overlooked or hard to access. Drew explained that some facilities even use the data collected from infrared monitoring to demonstrate compliance during safety audits or to provide evidence of proactive measures to insurers and regulators.
Can Infrared Monitoring Be Used Inside Silos?
While infrared cameras excel in open-line-of-sight applications, monitoring inside silos presents challenges. Heat must transfer through the silo walls to be detected externally, which requires substantial energy. As a result, infrared monitoring is better suited for areas with direct visibility, such as conveyor systems or exterior mulch piles.
However, facilities can combine infrared monitoring with other technologies, such as temperature probes, to address this limitation. This hybrid approach ensures comprehensive coverage of fire-prone areas, even those that infrared cameras alone cannot monitor effectively.
How Is a Monitoring System Mapped to a Facility?
Drew explained that mapping a monitoring system to a facility involves a detailed consultation process. For insurance-driven installations, coverage is based on the percentage of floor space monitored. Avian’s team conducts on-site walkthroughs using handheld infrared cameras to identify optimal mounting points. Floor plans are analyzed to ensure comprehensive coverage while minimizing the number of cameras needed.
For more specific needs, facilities may start with monitoring known problem areas, such as planers or edgers. Over time, additional cameras can be added to expand coverage. Integration with PLC systems allows for automated emergency shutdowns, further enhancing safety.
This mapping process not only ensures effective monitoring but also supports long-term scalability. Facilities can start small and gradually expand their systems as operational needs evolve or as budgets allow.
What Are the Data and Maintenance Benefits of Infrared Monitoring?
Infrared monitoring systems offer significant data and maintenance advantages:
- Trend Monitoring: By tracking equipment temperatures over time, the system identifies deviations from normal operation, enabling predictive maintenance.
- Training Tool: Temperature data can highlight operational inefficiencies, helping train new operators to run machinery more effectively.
- Preventative Maintenance: Systems detect issues like belt misalignments and overheating motors before they lead to costly breakdowns or fires.
For example, operators can see differences in equipment temperatures when inexperienced personnel are running machines. This feedback helps refine training and improve efficiency. Additionally, infrared systems provide actionable insights into operational patterns, such as peak usage times, enabling facilities to optimize their workflows and energy consumption.
Are There Case Studies That Highlight the System’s Effectiveness?
Drew provided some recent examples demonstrate the impact of infrared monitoring:
- Ducting Fire Prevention: At a pellet press facility, an infrared camera detected a hotspot in ducting, providing alarms seven minutes before personnel noticed the issue. Early detection prevented a potential $20 million loss.
- Mulch Pile Monitoring: Infrared cameras helped automate mulch pile management, reducing labor costs and minimizing fire risks.
- Belt Misalignment Detection: Systems identified conveyor belt misalignments early, preventing motor damage and costly downtime.
These success stories underscore the system’s ability to enhance safety and operational efficiency. Beyond fire prevention, these systems deliver measurable returns on investment by reducing equipment wear and extending operational lifespan.
Conclusion
Infrared monitoring systems represent a significant advancement in fire safety for wood product facilities. By providing early detection, trend monitoring, and actionable data, these systems empower operators to address issues before they escalate. Facilities adopting this technology can enhance safety, reduce downtime, and safeguard their operations against preventable losses.
Incorporating these systems into your fire prevention strategy is an investment in safety, efficiency, and peace of mind. Whether mitigating risks in high-temperature machinery or maintaining compliance with safety regulations, infrared monitoring is a valuable tool for the modern wood processing facility.
If you would like to discuss further, leave your thoughts in the comments section below. You can also reach Drew Hanover directly:
Website: https://www.avian-iot.com/
LinkedIn: https://www.linkedin.com/in/drew-hanover-b1b9baa5/
Email: [email protected]
If you have questions about the contents of this or any other podcast episode, you can go to our ‘Questions from the Community’ page and submit a text message or video recording. We will then bring someone on to answer these questions in a future episode.
Resources mentioned
The resources mentioned in this episode are listed below.
Dust Safety Science
Combustible Dust Incident Database
Dust Safety Science Podcast
Questions from the Community
Companies
Avian
Download the episode
DSS292: Using Infrared Monitoring in Wood Products Facilities with Drew Hanover
