Stockton Infrared Thermographic Services, Inc.

presents

A Qualitative
Infrared Thermographic Survey
Of Electrical Switchgear
at the facilities of

Stockton Infrared

Thermographic Services, Inc.

8472 Adams Farm Road
Randleman, NC 27317-7331
(800) 248-7226

January 1, 2005
Mr. Kevin Stephenson
Acme Widget Company
123 Main Street
Anytown, USA 12345
(555) 248-7226
kls@acmewidgets.com

RE: Infrared Survey of Electrical Switchgear

Acme Widget Company Plant #2
Anytown, USA

Dear Mr. Stephenson:

Thank you for your continued confidence in our services. Please find herein, the results
of the qualitative infrared thermographic survey which was conducted at your facilities.
This report is respectfully submitted for your review.
SECTIONS
CONTENTS
SECTION 1 Cover letter
SECTION 2 Summary & Recap
SECTION 3 Data Log (complete list of equipment inspected)
SECTION 4 Thermographic Reports (problem equipment found)
SECTION 5 Repair Guide (list of problem equipment and severity rating)
ENCLOSED CD-ROM (contains all files and software to open IR images)
ENCLOSED ...VHS Video tape (all equipment-not just problem equipment)
IMPORTANT NOTICE: Infrared Thermography is not a substitute for visual and/or other
instrumental inspection techniques and should be a regular part of the overall P/PM
(preventive/predictive maintenance) program at your facilities.
All work performed by Stockton Infrared is 100% satisfaction guaranteed. If you have a
question or comment please let us know by calling (800) 248-7226. We are looking
forward to working with you on your next scheduled survey.
Sincerely yours,

Certified Infrared Thermographer #3583

GRS/vcs
Visit us on the World Wide Web at:

www.stocktoninfrared.com
www.ElectriSCAN.com

SECTION 2A

SUMMARY

Project Information
Report to : Kevin Stephenson
Company : Acme Widget Company
Plant ID : Plant #2
Plant Location : 123 Main Street
City, Zip Code : Anytown, USA
E-SCAN Project : EGS40101GS
Thermographer : Greg Stockton, CIT #3583
Notes: Please read the Data log section of this report under "Remarks".
Some panel covers were not removed.
Some repairs were made by electrician during the survey.
Emmissivity settings = 1.0 unless otherwise noted.

SECTION 2B

RECAP OF FINDINGS

(NR) Not Rated =

(M) Minor =
(A) Alert =
(S) Serious =
(C) Critical =
TOTAL =

2
12
15
13
10
52

KEY to Data Log Abbreviations

OV= Overview(s)
NO=Not Operating
MCR=Motor Control Room
NS=Not Surveyed
MCC= Motor Control Center
LO=Locked Out
TO=Tagged Out

A=Amperage
MTS=Manual Transfer Switch
ATS=Automatic Transfer Switch
OH=Overheating
DNRC=Did not remove cover
CNTR=Contactor
CS=Combination Starter

(US) = Upstairs
(DS) = Downstairs
(F) = Front view
(R) = Rear view
(S) = Side view

FINISHING/FM #1

Panel PDP2-E/Overview

11:11:19

DC Drive Cabinet FM1-2/OV

11:16:10

FINISHING/FM #1
FINISHING/FM #1

Ch. Load/Phase

FINISHING/FM #1

B Breaker

FINISHING/FM #1

Cntrl FM1-3/Predryer Oven

11:21:55

FINISHING/FM #1

Cntrl FM1-3/Predryer Main

11:24:04

FINISHING/FM #1

Cntrl Pnl FM1-3/Predryers

11:27:50

FINISHING/FM #1

Check Fuse Clip

e
g
a
P
g

74K1/Phase A

FINISHING/FM #1

Cntrl Pnl FM1-3/Tenters

11:30:02

FINISHING/FM #1
FINISHING/FM #1

Cntrl Pnl FM1-1/Main Brkr

FINISHING/FM #1

Cntrl Pnl FM1-1/Wash Sctn

FINISHING/FM #1

Cntrl Pnl FM1-1/Wash Sctn

FINISHING/FM #1

Cntrl Pnl FM1-1/MS-0610

FINISHING/FM #1

a
t
a

o
L

11:32:39

Main Panel

11:33:15

Door #1

11:33:54

11:36:00

FINISHING/FM #1

Cntrl Pnl FM1-1/Wash Sctn

11:38:29

FINISHING/FM #1

Cntrl Pnl FM1-1/Brkr MS0610

11:44:38

D
e

FINISHING/FM #1
FINISHING/FM #1

l
p

Door #2

Door #2
Door #3

Door #3

Cntrl Pnl FM1-1/Wash Sctn

11:47:33

Door #4

Cntrl Pnl FM1-1/Wash Sctn

11:47:59

Door #5

Motor MS 0610/Overview

11:50:04

Trend Temp

Cntrl Pnl/Brusher Cabinet

11:53:29

Cntrl Pnl FM2-3/Brshr Cab.

11:56:04

FINISHING/FM #2

Control Pnl/FM 2 Winder

11:57:00

PRINTING/BATTERY CHRGRS

Panel LP-2/Overview

12:44:28

PRINTING/BATTERY CHRGRS

Panel LP-2/Circuits 14 & 16

12:48:54

PRINTING/BATTERY CHRGRS

Panel RP-2/Overview

12:53:33

BOILER RM/115VAC PNL

Panel/Overview

13:05:35

Panel/Overview

13:09:09

Starter Pnl/Sullair Cmprssr

13:10:54

Strtr Pnl/Gard Dnvr Cmprssr

13:12:13

Strtr Pnl/Ing. Rand Cmprssr

00:00:00

FINISHING/FM #1
FINISHING/FM #1

m
a
x

FINISHING/FM #1
FINISHING/FM #1

FINISHING/FM #1
FINISHING

FINISHING/FM #2
FINISHING/FM #2

PRINTING/BATTERY CHRGRS

Rise On Load

BOILER RM
BOILER RM/PNl PDP1-C-A
BOILER RM
BOILER RM/AIR CMPRSSRS
BOILER RM/AIR CMPRSSRS
BOILER RM/AIR CMPRSSRS
BOILER RM/AIR CMPRSSRS
BOILER RM/AIR CMPRSSRS

Locked Out

BOILER RM/PNL PDP1-F

Panel/Overview

13:14:19

Comb Strtr/Feed Water Pmp 1

00:00:00

Panel/Overview

13:16:27

BOILER RM
BOILER RM/FEED WATER

Not Operating

BOILER RM
BOILER RM/PNL PDP1-C
BOILER RM
BOILER RM/FOG SYSTEM

Disc/Filter Pump #1

BOILER RM/FOG SYSTEM

Disc/Filter Pump #2

BOILER RM/FOG SYSTEM

Disc/Filter Pump #3
Strtr Pnl/Joy Air Cmprssr

BOILER RM/AIR CMPRSSRS

BOILER RM/AIR CMPRSSRS

Disc/Air Dryer

BOILER RM
BOILER RM/BOILER #1

MAINT. OFFICES/PNLS
MAINT. OFFICES/PNLS
MAINT. OFFICES/PNLS

m
a
x

MAINT. OFFICES/PNLS

a
t
a

Control Pnl/Blower

D
e

l
p

Not Operating

00:00:00

Not Operating

13:19:36

BOILER RM
BOILER RM/AIR CMPRSSRS

e
g
a
P
g
00:00:00

o
L

00:00:00

Not Operating

13:22:30

Rise/Load

13:24:16

Panel PP-8-C/Overview

13:28:45

Panel RP-15/Overview

13:31:16

Panel RP-15/Circuit #21

13:32:37

FINISHING/PNL LP-8

Panel/Overview

13:45:35

FINISHING/PNL LP-8

Panel/Circuit #9

13:47:27

Panel/Overview

13:50:11

Rise On Load

Panel/Overview

13:58:18

Load Imbalance

FINISHING

FINISHING/PNL RP-7

FINISHING
FINISHING/PNL PP-8-B

Breaker 7
PRINTING/PNL PDP2-G

Panel/Overview

14:05:59

PRINTING/PNL PDP2-G

Panel/Breaker #1

14:07:21

FAN ROOM/FAN #1

Comb Strtr/Fan #1

14:15:00

Soft Start/Fan #1

14:19:37

Comb Strtr/Fan #2

14:20:38

Soft Start/Fan #2

14:25:04

FAN ROOM/FAN #1
FAN ROOM/FAN #1
FAN ROOM
FAN ROOM/FAN #2
FAN ROOM/FAN #2
FAN ROOM/FAN #2

10

Key to
Thermographic Reports
Page 1
THERMOGRAPHIC
REPORT

T-Report #

14

Report No.

BF Goodrich

Plant ID

Plant #2

Textile Performance Chemicals Division

Plant Area

AREA
WASTEWATER

Plant Location

LOCATION
Comb Starter/Aerator #6-South
Date 11/10/98
Time 09:09:08
Ambient temp.

68.1

Reference temp.

75.9

High temp.

97.4

Temp. rise

21.5

RISE ABOVE IN DEGREES F

Ambient
***
Reference
***
Adjacent phase
***
Direct measurement
AMPERAGES
A:
B:
C:

22
22
22

DESCRIPTION

Time/Date

*>89.6F

Temp. Data

85.0
80.0
75.0
70.0
65.0
60.0
55.0
50.0
45.0
40.0
35.0
30.0

High Temp.
How Measured
Amperage
Knife Connection

*<25.6F

MAIN DISCONNECT-KNIFE CONNECTION/Phase B, Line Side

Description

RECOMMENDATION
Check Knife Connection.
TEMP. RATING

***

TEMP. RISE (in F degrees)

CLASSIFICATION

Minor

1-18

Routine. Repair during regular maintenance, little chance of physical damage

Alert

19-36

Repair within 30 days, watch load and inspect for physical damage.

Serious

37-54

Repair/Replace ASAP. Inspect surrounding components for physical damage.

CRITICAL

>55

IMMEDIATE REPAIR/REPLACE. DANGER EXISTS!

Recommendation
Classification

Key to
Thermographic Reports
Page 2
*>84.6F

*>89.6F

80.0

30.0

85.0
80.0
75.0
70.0
65.0
60.0
55.0
50.0
45.0
40.0
35.0
30.0

*<28.6F

*<25.6F

75.0
70.0
65.0
60.0
55.0
50.0
45.0

Spot 1
97.4

40.0
35.0

Quantitative
Data

*>90.4F

*>84.6F

90.0
80.0

85.0

75.0

80.0

70.0
65.0

75.0

60.0

70.0

55.0
50.0
45.0
40.0
35.0
30.0
*<28.6F

65.0
Spot 1
97.4

60.0
55.0
50.0

Spot 3
75.9

Spot 4
97.4

Spot 2
68.1

Wide-Angle
Shot of the
Entire Panel

*<46.9F

Close-Up

THERMOGRAPHIC
REPORT
1

Report No.

Acme Widget Company

Plant #2
AREA
AIR COMP RM/PANEL CPAL 3

LOCATION
Breaker/Circuits #40-42
Date
Time

6/4/2002
10:02:57
85.6

Ambient temp.
Reference temp.

101.2

High temp.

123.4

Temp. rise

22.2

RISE ABOVE IN DEGREES F

Ambient
***
Reference
***
Adjacent phase
***
Direct measurement
AMPERAGES
#40:
#42:

27.9
27.6

DESCRIPTION
Breaker (30Amp) is overheating. Breaker load exceedes 80%. There is apparent internal damage.

RECOMMENDATION
Replace breaker, check ratings.

TEMP. RATING

TEMP. RISE

CLASSIFICATION

F degrees

***

Minor

1-18

Routine. Repair during regular maintenance, little chance of physical damage.

Alert

19-36

Repair within 30 days, watch load and inspect for physical damage.

Serious

37-54

Repair/Replace ASAP. Inspect surrounding components for physical damage.

CRITICAL

>55

IMMEDIATE REPAIR/REPLACE. DANGER EXISTS!

QUESTIONS ABOUT THIS REPORT?

Call 1-800-248-SCAN

THERMOGRAPHIC REPORT
Area: AIR COMP RM/PANEL CPAL 3
Loc: Breaker/Circuits #40-42

Report No.

126.0
124.0
122.0
120.0
118.0
116.0
114.0

123.4

110.0
108.0
106.0
104.0
102.0
100.0
98.0
96.0
94.0
92.0
90.0
88.0
86.0
84.0
82.0
80.0
78.0
76.0
*<75 6F

Reference
101.2

(CON'T)

Acme Widget Company

Plant #2

*>126.4F

112.0

THERMOGRAPHIC
REPORT
2

Report No.

Acme Widget Company

Plant #2
AREA
SS1/480V MAIN #1/DIST PANEL

LOCATION
Breaker 45 (NE Lights)
Date
Time

6/4/2002
10:02:57

Ambient temp.

82.0

Reference temp.

89.9

High temp.

111.2

Temp. rise

21.3

RISE ABOVE IN DEGREES F

Ambient
***
Reference
***
Adjacent phase
***
Direct measurement
AMPERAGES
Phase A:
Phase B:
Phase C:

Min Max
89.9 111.2

89
113
143

DESCRIPTION
Circuit imbalanced.

RECOMMENDATION
Balance loads.

TEMP. RATING

TEMP. RISE

CLASSIFICATION

F degrees

***

Minor

1-18

Routine. Repair during regular maintenance, little chance of physical damage.

Alert

19-36

Repair within 30 days, watch load and inspect for physical damage.

Serious

37-54

Repair/Replace ASAP. Inspect surrounding components for physical damage.

CRITICAL

>55

IMMEDIATE REPAIR/REPLACE. DANGER EXISTS!

QUESTIONS ABOUT THIS REPORT?

Call 1-800-248-SCAN

THERMOGRAPHIC REPORT
Area: SS1/480V MAIN #1/DIST PANEL
Loc: Breaker 45 (NE Lights)

Front view

Report No.

(CON'T)

Acme Widget Company

Plant #2

THERMOGRAPHIC
REPORT
3

Report No.

Acme Widget Company

Plant #2
AREA
AIR COMP SHED/A.C. #1

LOCATION
Disc/Air Compressor #1
Date
Time

6/4/2002
10:02:57
80.8

Ambient temp.
Reference temp.

138.0

High temp.

265.0

Temp. rise

127.0

RISE ABOVE IN DEGREES F

Ambient
***
Reference
***
Adjacent phase
***
Direct measurement
AMPERAGES
Phase A:
Phase B:
Phase C:

45
46
45

DESCRIPTION
SWITCH (blade connector), phase A overheating.

RECOMMENDATION
Check switch connections.

TEMP. RATING

TEMP. RISE

CLASSIFICATION

F degrees

***

Minor

1-18

Routine. Repair during regular maintenance, little chance of physical damage.

Alert

19-36

Repair within 30 days, watch load and inspect for physical damage.

Serious

37-54

Repair/Replace ASAP. Inspect surrounding components for physical damage.

CRITICAL

>55

IMMEDIATE REPAIR/REPLACE. DANGER EXISTS!

QUESTIONS ABOUT THIS REPORT?

Call 1-800-248-SCAN

THERMOGRAPHIC REPORT
Area: AIR COMP SHED/A.C. #1
Loc: Disc/Air Compressor #1

Report No.

(CON'T)

Acme Widget Company

Plant #2

THERMOGRAPHIC
REPORT
4

Report No.

Acme Widget Company

Plant #2
AREA
CHILLER PAD/CHILLER CH-2

LOCATION
Starter Pnl/Contactor #2
Date
Time

6/4/2002
10:02:57
95.2

Ambient temp.
Reference temp.

108.0

High temp.

138.0

Temp. rise

30.0

RISE ABOVE IN DEGREES F

Ambient
***
Reference
***
Adjacent phase
***
Direct measurement
AMPERAGES
Phase A:
Phase B:
Phase C:

99
96
99

DESCRIPTION
Contactor connector overheating.

RECOMMENDATION
Reinstall wire, check connection.

TEMP. RATING

TEMP. RISE

CLASSIFICATION

F degrees

***

Minor

1-18

Routine. Repair during regular maintenance, little chance of physical damage.

Alert

19-36

Repair within 30 days, watch load and inspect for physical damage.

Serious

37-54

Repair/Replace ASAP. Inspect surrounding components for physical damage.

CRITICAL

>55

IMMEDIATE REPAIR/REPLACE. DANGER EXISTS!

QUESTIONS ABOUT THIS REPORT?

Call 1-800-248-SCAN

THERMOGRAPHIC REPORT
Area: CHILLER PAD/CHILLER CH-2
Loc: Starter Pnl/Contactor #2
*>149.0F

145.0
140.0
135.0
130.0
125.0
120.0
115.0
110.0
105.0
100.0

*<95.8F

Report No.

(CON'T)

Acme Widget Company

Plant #2

THERMOGRAPHIC
REPORT
5

Report No.

Acme Widget Company

Plant #2
AREA
VACUUM FAN ROOM/MCC-A

LOCATION
Cubicle A1/Vacuum Fan #1
Date
Time

6/4/2002
10:02:57
77.7

Ambient temp.
Reference temp.

104.0

High temp.

156.0

Temp. rise

52.0

RISE ABOVE IN DEGREES F

Ambient
***
Reference
***
Adjacent phase
***
Direct measurement
AMPERAGES
Phase A: 170
Phase B: 170
Phase C: 170

DESCRIPTION
Breaker lug/phase A, line side.

RECOMMENDATION
Check breaker lug and connections.

TEMP. RATING

TEMP. RISE

CLASSIFICATION

F degrees

***

Minor

1-18

Routine. Repair during regular maintenance, little chance of physical damage.

Alert

19-36

Repair within 30 days, watch load and inspect for physical damage.

Serious

37-54

Repair/Replace ASAP. Inspect surrounding components for physical damage.

CRITICAL

>55

IMMEDIATE REPAIR/REPLACE. DANGER EXISTS!

QUESTIONS ABOUT THIS REPORT?

Call 1-800-248-SCAN

THERMOGRAPHIC REPORT
Area: VACUUM FAN ROOM/MCC-A
Loc: Cubicle A1/Vacuum Fan #1

*>150.7F
140.0
120.0
100.0
80.0
60.0
*<57.2F

Report No.

(CON'T)

Acme Widget Company

Plant #2

THERMOGRAPHIC
REPORT
6

Report No.

Acme Widget Company

Plant #2
AREA
MAINMCR #3MCC #3-2

LOCATION
Cubicle D2/Pump 3B
Date
Time

6/4/2002
10:02:57
86.0

Ambient temp.
Reference temp.

104.8

High temp.

224.2

Temp. rise

119.4

RISE ABOVE IN DEGREES F

Ambient
***
Reference
***
Adjacent phase
***
Direct measurement
AMPERAGES
Phase A:
Phase B:
Phase C:

30
28
29

DESCRIPTION
Fuse and fuse clip/phase A, load side.

RECOMMENDATION
Replace fuse and fuse clip.

TEMP. RATING

TEMP. RISE

CLASSIFICATION

F degrees

***

Minor

1-18

Routine. Repair during regular maintenance, little chance of physical damage.

Alert

19-36

Repair within 30 days, watch load and inspect for physical damage.

Serious

37-54

Repair/Replace ASAP. Inspect surrounding components for physical damage.

CRITICAL

>55

IMMEDIATE REPAIR/REPLACE. DANGER EXISTS!

QUESTIONS ABOUT THIS REPORT?

Call 1-800-248-SCAN

THERMOGRAPHIC REPORT

Report No.

Area: MAINMCR #3MCC #3-2

Loc: Cubicle D2/Pump 3B

Acme Widget Company

Plant #2
*>134.9F

130.0
125.0
120.0
115.0
110.0
105.0
100.0
95.0
90.0
85.0
80.0
75.0
*<70.9F
*>130.6F
130.0
125.0
120.0
115.0
110.0
105.0
100.0
95.0
90.0
85.0
80.0
75.0
*<71.8F

*>146.6F
145.0
140.0
135.0
130.0
125.0
120.0
115.0
110.0
105.0
100.0
95.0
90.0
85.0
*<85.0F

*>221.7F
220.0
210.0
200.0
190.0

Reference
104.8

180.0
170.0
160.0
150.0
140.0
130.0
120.0
110.0
100.0
90.0
80.0
70.0
60.0
*<57.8F

(CON'T)

High Temp
Max
224.2

REPAIR GUIDE- Equipment needing repairs

Acme Widget Company
Plant #2
Anytown, USA
T#

PLANT AREA

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

FLOCKING AREA
FINISHING AREA
FINISHING AREA
FINISHING AREA
PRINTING AREA
MAINTENANCE OFFICES
FINISHING AREA
PRINTING AREA
FAN ROOM
FAN ROOM
SUBSTATION #2
PRINTING AREA
SUBSTATION #1
CUTTING AREA
EMBOSSER
WASTEWATER AREA
3803 WAREHOUSE
3803 WAREHOUSE
PRINTING AREA
DYE HOUSE
DYE HOUSE
DYE HOUSE
DYE HOUSE
PRINTING AREA
FLOCKING AREA
FLOCKING AREA

AREA
FLOCK LINE #2 CNTRL RM
FINISHING/FM #1
FINISHING/FM #1
FINISHING/FM #1
PRINTING/BATTERY CHRGRS
MAINT. OFFICES/PNLS
FINISHING/PNL LP-8
PRINTING/PNL PDP2-G
FAN ROOM/FAN #1
FAN ROOM/FAN #2
SUBSTN #2/PNL LP-7
PRINTING/PM #4/CNTRLS
SUBSTN #1/13.2V
CUTTING/CNTRLS
EMBOSSER/HOT OIL
WASTEWATER/PUMPS
3803 WRHSE/PNL PP-4B
3803 WRHSE/PNL PP3-B
PRINTING/PM #3/PDP2-D
DYE HSE/JETS 1-4
DYE HSE/OVEN TENTER
DYE HSE/AIR CMPRSSR #1
DYE HSE/BOILER
PRINTING/PM #3/CNTRLS
FLOCK #1 CNTRL RM
FLOCK RANGE #1/DISCS

(NR) Not Rated = 2

(M) Minor = 12
(A) Alert = 15
(S) Serious = 13
(C) Critical = 10
TOTAL = 52

LOCATION
Control Pnl FL2-J/Main Brkr
Cntrl FM1-3/Predryer Main
Cntrl Pnl FM1-1/MS-0610
Cntrl Pnl FM1-1/Brkr MS0610
Panel LP-2/Circuits 14 & 16
Panel RP-15/Circuit #21
Panel/Circuit #9
Panel/Breaker #1
Comb Strtr/Fan #1
Comb Strtr/Fan #2
Panel/Circuit #13
Main Control Pnl/Main Brkr
Main 13.2V Switch/Overview
Control Pnl CT3-2/Main Disc
Control Pnl/Relay-Heaters
Pump Control Pnl/FU 36 & 38
Panel/Overview
Panel/Overview
Panel/Breaker-PM-3 Cntrls
Control Pnl/1-4-Main Brkr
Main Breaker/Overview
Starter Pnl/Overview
Control Pnl/Blr Blwr Fuses
Control Pnl 3-5/Main Switch
Cntrl Pnl-Ex. Fans/Fan M17E
Main Disc #52/Overview

CLASS
S
A
C
A
M
A
A
C
C
A
A
C
S
A
A
S
S
A
A
S
M
S
C
A
C
S

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site at:
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Environmental Impact Surveys

Building Heat Loss Surveys
Aerial Infrared Roof Moisture Surveys
258.3

258.3

251.0

251.0

246.4

246.4

Temperature profile
Min. Mean Max.
246.4 251.0 258.3

Bond Beam Incomplete

Industrial Process Monitoring

Structural Analysis

800-248-SCAN

Typical R&D test set-up