Energy Management Consultants

Sample Report
ABC Company
Property Loss Prevention Program

Electrical & Thermographic Inspection

Anywhere USA
Project No. 42
Today’s Date 2018

striving for excellence

Performed By
John E. Davis, Sr., MS AST
Master Thermographer No. 2034
Director of Consulting Services

e-mail to: energymngt@aol.com

web site: http://www.energymngt.com

1660 Landfall Circle

Bartonville, TX 76226
Cell - 931-248-3729
 Energy Management Consultants
Electrical & Infrared Loss Prevention 1660 Landfall Circle
Bartonville, TX 76226
Phone 931-248-3720

Today’s Date 2018

Mr. Gary Leslie

Facilities Engineer
ABC Company
Anywhere, USA

RE: Electrical & Thermographic Inspection

EPS - Project No. 42

Dear Mr. Leslie,

Enclosed please find the Electrical & Thermographic Survey report prepared as a result of my recent visit to your facility.
It includes a listing of the objects surveyed and a temperature severity chart to be used as a guide when prioritizing the
electrical and thermal deficiencies detailed in this report.

The scope of work included the following areas:

A. Utility incoming source, Plant/facility main power substations, Air Compressors, Selected low voltage
overhead buss systems, Selected critical process machines (frequency induction, paint cabinets, etc…).
B. Review of plants’ Business interruption or Contingency plans with regard to the repair or replacement
of electrical equipment and systems to restore electrical equipment.
C. Review of plants’ preventative/predictive maintenance plans with regard to electrical equipment operation
and distribution systems.

Equipment not surveyed during this site visit includes de-energized, lightly loaded, inaccessible and/or deemed by
Facility personnel to be non-critical or unsafe because of Arc Flash requirements.

As a result of this consulting service the following observations were rated and are presented for your review:

1 - Critical
2 - Severe
3 - Alert
0 - Advisory

Should you have any questions or comments concerning the information in this report, please contact me in
Bartonville, TX @ 208-360-1481 or e-mail me @ energymngt@aol.com. I would like to thank you, Steve Furge
and Craig Linthicum from your maintenance staff for the help and assistance we received during the inspection -
it was very much appreciated.

Best regards,

John E. Davis, Sr. MS AST, MT-2034

Director of Consulting Services

cc: file
 Energy Management Consultants

Electrical Reliability Chart - Minimum Inspection Requirements = 50

10 20 30 40 50 60 70 80 90 100
Poor Excellent

Ten Points Awarded for Each Inspection Item

Annual Minimum Requirements: (Non-Intrusive)

(X) 1. Basic Transformer Oil Testing - All Liquid Filled
( ) 2. Purchase Secondary Electrical Service
( ) 3. Dry Type Transformer - General Service
(X) 4. Transformer Oil - Gas Analysis on 2000 kVA & Above
(X) 5. Protective Device Testing (Relays-Batteries-Capacitors)
( ) 6. Complete Switchgear Visual Inspection - Record Results Quarterly
( ) 7. Full Infrared Thermographic Inspection - ISO 9000 Format
(X) 8. Fire Suppression Equipment - Adjacent to Liquid Filled Devices

Extra Credit:
(X) 1. Pro-Active Maintenance Program
( ) 2. High Voltage Disconnect Serviced with-in last three (3) years (1/2)
( ) 3. Transformer - TTR/Insulation Resistance/Hypot Testing with-in last three (3) years
( ) 4. Circuit Breaker Testing last three (3) years
( ) 5. Cable Testing with-in last three (3) years
(X) 6. Power Factor Correction Equipment - Operating correctly at time of inspection
( ) 7. Installing new High Voltage Distribution Equipment within last 5 years
(X) 8. General Housekeeping - Energy Center Material Stored Correctly
(X) 9. Correctly repairing previous findings. (1/2)

ABC Company - Reliability Rating = 75

Contingency Program and Spare Parts

There did not appear to be an alternate source of electrical power coming into the plant. There appeared to
be enough spare parts for the motors and contactors, but very little for the electrical distribution equipment.

As such, I see this plant as a medium exposure for business interruption.

R-1 ***
Perform Low Voltage Machine Electrical Infrared Inspection
 Equipment Surveyed List

1.0 Westinghouse – 3000 kVA Outdoor Sub

S/N 5066835 (Oil Filled)
12 kV / 480 kV

1.2 Outdoor 12 kV Buss Structure

2.0 Low Voltage Battery Systems Power House

3.0 333 kVA Dry Type Transformer Indoor Sub No. 1

S/N GM 346057-2 / Single Phase
480/120V

3.1 333 kVA Dry Type Transformer

S/N GM 346057-6 / Single Phase
480/120V
3.2
333 kVA Dry Type Transformer
S/N GM 346057-1 / Single Phase
480/120V

3.3 Air Compressor No. 1 Air Compressor Room

3.4 Air Compressor No. 2
3.5 2-Wall Disconnects

3.6 Gas Oven CH-21 - Main Control Panel Plant Floor

3.7 Gas Oven 02-374 - Main Control Panel
3.8 Selected Machine Panels

4.0 333 kVA Dry Type Transformer Indoor Sub No. 2

S/N GM 346057-12 / Single Phase North Building
480/277V

4.1 333 kVA Dry Type Transformer

S/N GM 346057-16 / Single Phase
480/277

4.2 333 kVA Dry Type Transformer

S/N GM 346057-17 / Single Phase
480/277V
4.3 (2) - 200 kVAr Automatic Capacitor Systems

5.0 Selected Machine Panels Plant No. 2

5.1 Gas Oven BD-15 BP-57 North Building
5.2 Gas Oven 01-030-009
5.3 Draw Furnace No. 1 - Main Control Panel
5.4 Draw Furnace No. 2 - Main Control Panel

6.0 TACCO Machine - Main Control Panel

Cooling System
 COMMENTS

The criteria used to categorize findings in this report are based on the potential effect that a
failure will have on operations and/or production.

CRITICAL - Failure of this component will have a significant impact on operations or the
+75° C Facility and require costly repairs.

SEVERE - Failure is not expected to go beyond the component listed and should have minimal
41-75° C impact on operations or the facility; repair costs could be significant.

ALERT - Failure is of a routine nature and repairs can be made easily and at a reasonable
10-40° C cost. Cost is, more often than not, limited to labor and a few minor parts.

ADVISORY- Helpful information based on sound engineering judgment.

NEC / OSHA Code Violations - Listed with specific code numbers.

Infrared Thermographic surveys are non-contact, non-destructive examinations used to find

abnormal or unexpected thermal patterns or temperature differentials. These thermal patterns
may indicate such conditions as loose connections, overloaded circuits or phases, deteriorated or
damaged insulation or refractory, or excessive or unwanted friction, among others.

To perform the Thermographic survey of your facility, Energy Management Consultants used a
Flir E-45 Infrared imaging system, S/N 21500712 calibrated on 09/16/16. This system utilizes
the latest developments in un-cooled technology to generate the most accurate data available.

The calibration for this system is certified traceable to The National Institute of Standards and
Technology, NIST, USA and the Swedish National Testing and Research Institute, SP. This
calibration is based on the International Temperature Scale (ITS-90).

The Findings of this survey are in the following pages. These conditions warrant your attention.

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any
of its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 Energy Management Consultants
1660 Landfall Circle, Bartonville, TX 76226
Bartonville, TX 76226

Finding No. 1 Category Severe

Location Area: West Primary Transformer

S/N 5833654

Equipment ID 3,000 kVA - Oil Filled

Est. Repair Cost $7,500.00

Before Failure

Est. Repair Cost $45,000 - 60,000

After Failure

Est. % Lost Production 40%

Est. Down Time 10-12 hours

Spot 1 Temperature = 1.6° C

Reference Temperature = 24.6° C

Temperature Rise = 23.0° C

Modified Delta

Reduction in oil transfer will elevate the

internal winding temperature and cause a
premature failure.

Recommendations/Comments
The thermal pattern indicates six (6) of the cooling tubes are blocking oil transfer. The transformer will be de-
rated until the blocked cooling tubes can be repaired. This was investigated and repaired by a qualified electrical
contractor using NETA MTS-2015 - 7.2.2.2 test & repair procedures. A gas oil sample was removed and tested
for combustible contaminations.
Ref.
* This is rated as “Severe” due to the high potential to business interruption costs should a failure occur.

Repair notes: Signature: . . . . . . . . . . Date:

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any
of its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 Energy Management Consultants
1660 Landfall Circle, Bartonville, TX 76226
Bartonville, TX 76226

Finding No. 2 Category Alert

Location Area Plant Floor

Equipment Location Column D-22
Equipment ID LV Disconnect to
Machine 514

Est. Repair Cost $1,500

Before Failure

Est. Repair Cost $3,000

After Failure

Est. % of Lost Production 15%

Est. Down Time 1 hours

Spot 1 Temperature = 56.2° C

Reference Temperature = 42.5 °C

Temperature Rise = 13.7° C

Modified Delta
* Internal Temperature
Ref. Approximately 2.5 X = 34.2° C

Spt. 1

Recommendations/Comments
The thermal pattern indicates the Low Voltage buss disconnect switch has an internal heating problem . This
should be investigated and repaired by a qualified electrician or electrical contractor using NETA MTS-2015 -
7.5.1.1 repair procedures.

Note second observation: NEC Code Violation - Article 110.a - Guarding of Live Parts

Repair notes: Signature: . . . . . . . . . . Date:

 Energy Management Consultants
1660 Landfall Circle, Bartonville, TX 76226
Bartonville, TX 76226

Finding No. 3 Category Severe

Location Area Indoor Sub 1-A

Equipment Location Capacitor A-4
Equipment ID Middle Cell
Front Bushing

Est. Repair Cost $1,500

Before Failure

Est. Repair Cost $1,500

After Failure

Est. % of Lost Production 0%

Est. Down Time 1 hour

Spot 1 Temperature = 122.0° C

Ref. Ref. Temperature = 81.8° C

Temperature Rise = 40.3 °C

Modified Delta

Spt. 1

Recommendations/Comments
De-energize capacitors - wait 1 minuet for discharge before servicing - remove conductor - test and repair the
capacitor under NETA 2015 MTS Guidelines - 7.20.1 - 7.20.1.A.61. Clean connections as required - if capacitor
fails NETA test - replace cell. After re-energizing capacitor system check for 5th harmonic content.

Repair notes: Signature: . . . . . . . . . . Date:

 Energy Management Consultants
1660 Landfall Circle, Bartonville, TX 76226
Bartonville, TX 76226

Finding No. 4 Category Severe

Location Area Primary Fan

Equipment ID Draft Fan No. 2

Est. Repair Cost $1,500.00

Before Failure

Est. Repair Cost $5,000.00

After Failure

Est. % of Lost Production 30%

Est. Down Time 2 Hours

Spot 1 Temperature = 58.8° C

Spot 2 Temperature = 53.6° C

Temperature Rise = 5.2° C*

Spot 2 Spot 1
Temperature is Surface Temperature -
Internal Temperature is Approximately
2.5X = 13.0° C

Recommendations/Comments
The thermal pattern indicates drive side bearing is increasing in temperature - monitor load and change bearing
assembly within seven (7) working days. If load increases monitor the bearing temperature and change when the
temperature rise is in excess of 10° C.

* This is rated as “Severe” due to the high potential to business interruption costs should a failure occur.

Repair notes: Signature: . . . . . . . . . . Date:

 Energy Management Consultants
1660 Landfall Circle, Bartonville, TX 76226
Bartonville, TX 76226

Finding No. 5 - NEC/OSHA/NETA Observations Category - Visual Observations

5.1

Severity - Severe

Indoor Sub No. 11

1000 kVA Dry Transformer - S/N 74J6142

Middle Jumper on Low Voltage Coil is arcing

against the middle tap - potential for LV coil
failure. Low Voltage Corna.

Est. Repair Cost Before Failure $ 2,000

Est. Repair Cost After Failure $14,000

Est. % Lost Production 20%

Estimated Down Time 2 hours

5.2

Severity - Alert
12 kV Utility Cabinet (Observation)

High Voltage Corona has started in main buss

insulation assembly. As the insulation value
decreases the potential for a catastrophic
failure increases.

Clean & Replace insulation system.

5.3

Severity - Critical
NEC Code Violation -
Article 110.a - Guarding of Live Parts

Plant Floor @ Column J-12

LV Buss Disconnect Missing Protective Cover

Install Protective Cover

Finding No. 5 - NEC/OSHA/NETA Observations Category - Visual Observations

5.4

Severity - Critical
NEC Code Violation - Article 240.21

Incoming 800 Amp Main Breaker is installed

with the Line and Load Conductors in Reverse.

When the Circuit Breaker is in the Open

Position the Load Conductors must be De-
energized.

Install Labels indicating Line & Load Reversed

5.5

Severity - Critical
34.5 / 12 kV
7,500 kVA Transformer
S/N 5833654

Broken Glass on Temperature Indicating Meter

Ref: NEC-370.18 / OSHA 1910-305b-1

This device operates the external fan system -

will not energize fans in present condition.

5.6

Severity - Critical
Air Compressor 3265

Contractor Installed incorrect cable termination

lugs for cable size.

Ref: US National Electrical Code-250-1 &

US OSHA Code 1910-304.f
Europe Standards VDE-0295-2
Mechanical strength of termination not as outlined in
reference codes for cable size. Remove and replace
with correct termination lugs.

Potential for corrosion and premature cable failure.

Recommendations/Comments

NETA - Preferred Crimp method = Burndy Y250 series / 1200 PSI Hydraulic Crimp.

* This is rated as “Critical” due to the high potential for business interruption costs should a failure occur.
 Inspection Summary

Finding Category Facility Location Equipment Location Equipment ID Est. Repair Cost Est. Repair Cost
Before Failure After Failure

1 Severe Right Transformer 4.2 kV Bushing Left Phase 7,500 60,000

S/N 5833654

2 Alert Plant Floor Column D-22 LV Disconnect 1,500 3,000

3. Severe Plant Floor Indoor Sub 1-A Cap Cell A-4 1,200 1,500

4. Severe Building 26 Draft Fan Area Draft Fan No. 2 1,500 5,000

5.* Visible Plant Floor Various Multiple 2,000 14,000

(5.1 - 5.6) 13,700 83,500

Total Estimated Repair Costs Before Failure $13,700

Total Estimated Repair Costs After Failure $83,500

Potential Cost Avoidance = $69,800

* Before and After costs - This estimate is based only on direct damage to the equipment
and does not include the costs of business interruption, extra expense, downtime, etc.