Infrared Thermal Imaging Surveys

Seminar:
PREDICTIVE MAINTENANCE PROGRAMS (PMP’S)
Refrigerating, Engineers & Technicians Association
Plant City, FL
October 2002

Presented by:
Harry Tittel
Vice President
TEAMWORKnet, Inc.

Prepared by:
Florida Electrical Resources
A Division of TEAMWORKnet, Inc.
6550 New Tampa Highway, Suite B
Lakeland, FL 33815
Phone: (863) 327-1080
Fax: (863) 327-1091
Email: info@ferinc.com

PRESENTATION

Introduction
Historical Maintenance Perspective
Typical Predictive Maintenance Activities
Damage Photographs
FER Qualifications & Mitigation Services

PARTIAL CLIENT LIST

APPLICATION CHART

CLASSIFICATION OF ABNORMALITIES TABLE

SAMPLE GENERAL FIELD OBSERVATIONS

THERMAL IMAGES

REFERENCE MATERIALS

Presentation

INTRODUCTION:

BuShea, Seelig & Associates (BSA) was formed in 1978 to provide Professional Engineering Services to our commercial, utility and industrial clients. During the past 20+ years, BSA has determined that Predictive Maintenance Programs (PMP) and problem solving technologies such as thermal imaging would provide our clients with the latest tools to increase plant reliability, safety and bottom line economic return. To this end, Florida Electrical Resources (FER) was formed. FER’s fast paced growth caused us to combine our efforts, thus we formed TEAMWORKnet, Inc. (TWN), which is comprised of the following divisions: BuShea, Seelig & Associates (BSA), Florida Electrical Resources (FER), CADnet and PCnet. TWN also owns a percentage of a wireless communications company called MCIS. Through TWN, we provide a fully coordinated service organization for our clients. FER now provides a full line of Predictive Maintenance Programs.

HISTORICAL MAINTENANCE PERSPECTIVE:

Breakdown Maintenance - Traditional
Preventive Maintenance - Post WWII
Predictive Maintenance - Newest Method

TYPICAL PREDICTIVE MAINTENANCE ACTIVITIES:

FLIR (Inframetrics) SC-1000 Thermacam

Thermal Imaging Survey
Electromagnetic Testing
Eddy-Current Analysis
Magnetic Particle Inspection
Ultrasonic Detection
Vibration Analysis
X-ray and Gamma Radiography
Transformer Oil Analysis and Testing
Breaker - Relay Testing
Visual Testing
Leak Testing

DAMAGE PHOTOGRAPHS:

Through our experience in the utility and industrial industries we have witnessed a number of mishaps that led to considerable economic loses. We have included photos from some of these experiences.

DON’T LET THIS HAPPEN TO YOU!

USE A PREDICTIVE MAINTENANCE PROGRAM (PMP) UTILIZING INFRARED THERMOGRAPHY TO SEE IT BEFORE IT HAPPENS.

Reduce your total maintenance budget through a planned Predictive Maintenance Program that only focuses on repairs of the critical equipment in a timely fashion. No need to do a complete Preventative Maintenance Program on all of the equipment when only 30% of it actually needs immediate attention.

FER QUALIFICATIONS AND MITIGATION SERVICES:

FER is a full service testing and mitigation services company. Our company utilizes only highly qualified field engineers to do the thermal imaging and analytical work. Please visit our web page (www.TEAMWORKnet.com) for the resumes and Infrared School Certification of individuals who perform these services for FER. We utilize the newest thermal imaging camera technologies on the market, the Inframetrics SC1000 & PM380, and the associated Thermogram, ThermaCAM, and Thermonitor analytical software.

Our work for clients covers a wide variety of thermal imaging needs, as can be seen from our client list under Tab 2.0, and the Application Chart under Tab 3.0. From these diverse backgrounds we have discovered that most of our clients have a fundamental need to satisfy an insurance carrier's policy requirements, while meeting their own maintenance needs. Standard insurance coverage for most industrial plants typically have requirements that infrared thermal imaging surveys be performed on an annual basis. Therefore, FER has developed a thermal imaging survey report that comports with all insurance company requirements, while providing detailed information for our industrial clients. The thermal imaging reports are visually accurate, through the combined use of infrared thermography and standard digital image photography. Please see sample thermal images under Tab 6.0. Our full reports also include a detailed and concise presentation and analysis of the equipment under study.

FER provides a certified, degreed Engineer to do the Thermal Imaging Surveys, thus providing added benefit to the client in the field of electrical system analysis and review. In the area of mitigation work, FER can offer a wide range of services from problem correction recommendations to the actual repair services if required. Under Section 1.4, are some sample damage photographs to show the destructive power of neglected electrical systems. Although thermal imaging is only a part of predictive maintenance programs, it is your first line of defense.

Over the past year, FER has added a number of new features to our thermal imaging services. We have added a new sign-off / checklist page to the back of each thermal image. This feature helps management or the insurance companies verify that the mitigation work has been completed. Another feature is the use of clamp-on ammeter readings taken on each phase of the electrical system to verify suspected imbalances or loading problems of the equipment under study. For improved color and visibility of the thermal images, FER has upgraded its printing capabilities to a color laser printing system. All of the above features enhance our product while providing our clients with the latest in thermal imaging technologies.

PARTIAL CLIENT LIST

Amercord, Inc. - Lumber City, GA		International Paper - Folkston, GA
Amoco Fabrics & Fibers Co. - Bainbridge, GA		Invostyle - Eastman, GA
Albion Kaolin - Milledgeville, GA		Ionics/RCC - Watertown, MA and Trinidad, W.I.
Anniston Army Depot - Anniston, AL		JC Penney - Atlanta, GA
Auburndale Power Partners - Auberndale, FL		Johns Manville - Winder, GA
Brown & Williamson - Macon, GA		Kimberly - Clark - Nova Scotia, Canada
Busch Gardens - Tampa, FL		Lakeland Electric Utilities - Lakeland, FL
Case Engineering - Lakeland, FL		Lakeland Regional Medical Center - Lakeland, FL
Cervasive - Panama		M & H Valve Company - Anniston, AL
C.F. Industries, Inc. - Wauchula, FL		Marriott Suites Midtown - Atlanta, GA
Cherokee Brick & Tile Co. - Macon, GA		Maxwell Air Force Base - Montgomery
Citrosuco North America - Lake Wales, FL		Orlando Regional Healthcare System - Orlando, FL
City of Melbourne - Melbourne, FL		Owens-Brockway Glass - Atlanta, GA
CKS Packaging, Inc. - Atlanta, GA		Progress Energy Corporation - St. Petersburg, FL
Coca-Cola Foods - Auburndale, FL		Publix Supermarkets, Inc. - Lakeland, FL
CSR Southern Aggregates - Macon, GA		Rayonier, Inc. - Fernandina Beach, FL
Dade Juvenile Justice Center - Miami, FL		Rich-SeaPak Corporation- Brunswick, GA
Eglin Air Force Base - Ft. Walton Beach, FL		Savannah Port Authority - Savannah, GA
Ethicon, Inc. - Cornelia, GA		Savannah Power - Savannah, GA
Flint River Textiles - Albany, GA		SE Georgia Regional Medical Center - Brunswick, GA
Florida Rock Industries - (over 35 Locations)		Siemens - Atlanta, GA
Florida State University - Tallahassee, FL		Siemens Energy & Automation - Tucker, GA
Florida's Natural Growers - Lake Wales, FL		Siemens Westinghouse Power Corp. - Lakeland, FL
Food Lion - Plant City, FL		Sony Professional Products Co. - Boca Raton, FL
Frito Lay, Inc. - Perry, GA		Southern Company Energy Solutions, LLC - Atlanta, GA
Fruit of the Loom - Raybun Gap, GA		Stone Container Corp. - Chattanooga, TN
Florida Mining & Material Comp. - Leesburg, FL		Tampa Electric Company - Tampa, FL
Georgia-Pacific Corporation - (5 Locations)		Turks & Caco's - Bahamas
Gilman Bldg. Products - (6 Locations)		Tyndall Air Force Base - Panama City, FL
Grenada Electricity Services - Granada, WI		Union Camp - Folkston, GA
Hahn Engineering - Tampa, FL		United Space Alliance - Cape Canaveral, FL
Honeywell, Inc. - Tampa, FL		US Coast Guard - Mobile, AL
IBM Global Services - Coral Gables, FL		Wheelabrator - Auburndale, FL
IMC Phosphates - New Wales, FL		Yamaha Music Mfg. - Thomaston, GA

APPLICATION CHART

CLASSIFICATION OF ABNORMALITIES TABLE

A.	<5ºf	No Action Required
B.	5.1 – 25.0ºF	Correct Next Scheduled Maintenance Period
C.	25.1 – 40.0ºF	Correct Prior to Next Scheduled Maintenance Period
D.	40.1 – 65.0ºF	Correct ASAP
E.	> 65.1ºF	Correct Immediately

Notes:
These are typical temperature ranges for abnormalities. Engineering knowledge is applied in the classification process. The classification can be customized for specific corporate or insurance requirements.

Additional "Hot Spots" may be shown on the thermal image for clarity, which are higher in temperature than the specific anomaly. The equipment represented by these additional hot spots may be within thermal limits but represent the highest temperature in the thermal image.

Thermal Imaging is based on the circuit loading at the time of survey. Partially loaded or unloaded circuits may not indicate thermal anomalies that would occur at full load conditions.

Structural thermal images of buildings and roofing systems are for information purposes only. A structural engineer and/or roofing expert should be consulted for review of this type thermal image.

SAMPLE GENERAL FIELD OBSERVATIONS

Three-phase system protection is often accomplished through the use of fuses. Fuses are used to interrupt fault currents and certain types limit fault current levels to downstream equipment. The recommended practice is to have fuses of the same manufacturer in each phase of any given circuit. Fuses from different manufacturers that are rated the same may in fact have slightly dissimilar operating characteristics. These differences in operating characteristics may be caused by the use of unlike materials. Furthermore, the labels from different manufacturers may lead to maintenance personnel misreading the labels and installing the wrong fuses. Fuses of the same size may have different time delay characteristics. Mismatched fusing may reduce the overall system protection. Improperly sized fuses may create a safety hazard. The following locations have fuses of different manufacturers utilized at the same time.
- Equipment Identification

The 2002 National Electrical Code (NEC) Article 110-26 specifies that: "Sufficient access and working space shall be provided and maintained about all electrical equipment to permit ready and safe operation and maintenance of such equipment." For equipment with a nominal voltage to ground between 0 and 600 volts, the minimum clear working distance is three (3) feet. We suggest implementing an awareness program to inform your employees. This program should include the code requirements and the potential hazards of not maintaining this working clearance. The following areas did not have the minimum working distance:
- Equipment Identification

The 2002 National Electrical Code (NEC) Article 210-20 states that where a branch circuit supplies continuous loads or any combination of continuous and non continuous loads, the rating of the over current device shall not be less than the non continuous load plus 125% of the continuous load. Example, the maximum continuous load on a 20 Amp Circuit Rating is 16 Amps. We recommend reviewing the loads at the following locations:
- Equipment Identification

We recommend a review of egress from the facility and/or the need for exit signs in the following areas according to the Code of Federal Regulations, Labor 29, Parts 1910.36 & 1910.37:
- Equipment Identification

We recommend completing a facility wide labeling system of all Electrical Equipment, Electrical Rooms, Power Panels, Lighting Panels, Disconnect Switches, MCC's, Starters & Breakers. The 2002 National Electric Code (NEC), Sections 110 & 408 are a good starting point in the facility labeling process.

Consider cleaning, general and preventive maintenance of all electrical equipment such as Power & Lighting Panels, Disconnect Switches, MCC's, Starters & Breakers, etc.

Consider performing a Ground Grid Analysis & Lightning Protection Survey to determine the capability and reliability of the existing protective systems.

Consider performing the following facility wide studies: Short Circuit, Load Flow, Flash Hazard and System (Relay) Coordination. Please feel free to contact us for further details on Industry Standards, NEC Requirements, Economics and general information on Power System Studies.

The following locations require cover plates, breaker blanks (space covers) or dead front covers. These items are an integral safety design feature of the equipment, and should not be excluded.
- Equipment Identification

Note that numerous locations throughout the facility were found to have different sized cables fed from the same breaker, reference the 2002 NEC for Safe Practice.

The following locations have loose, non-terminated wires & cables:
- Equipment Identification

We would recommend implementing a Maintenance Program that includes Oil Quality and Dissolved Gas Analysis Tests on all oil field transformers. These tests are to insure the oil maintains good electrical properties by monitoring its dielectric strength.

Review use and/or maintenance of locks. Implement a locking system with a master key for maintenance personnel to prevent future complications. The following locations had locks removed:

The following abnormalities were found on these transformers:
- T34-0406, check fluid level and/or gauge.
- T20-0402, check fluid level.
- T20-0400, front right cooling fan has fallen off, motor running. Back left cooling fan has fallen off, motor running.
- T12-0401, check fluid level and/or gauge.
- T13-0415, need to add dry nitrogen. Transformer is under a vacuum (-1.0 psi).