Stockton Infrared Thermographic Services, Inc. presents. A Qualitative Infrared Thermographic Survey Of Electrical Switchgear at the facilities of

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1 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.

2 Stockton Infrared Thermographic Services, Inc Adams Farm Road Randleman, NC (800) January 1, 2005 Mr. Kevin Stephenson Acme Widget Company 123 Main Street Anytown, USA (555) 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) 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:

3 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 = 2 (M) Minor = 12 (A) Alert = 15 (S) Serious = 13 (C) Critical = 10 TOTAL = 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

4 FINISHING/FM #1 Panel PDP2-E/Overview 11:11:19 FINISHING/FM #1 FINISHING/FM #1 DC Drive Cabinet FM1-2/OV 11:16:10 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 2 FINISHING/FM #1 Cntrl Pnl FM1-3/Predryers 11:27:50 Check Fuse Clip FINISHING/FM #1 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 11:32:39 Main Panel FINISHING/FM #1 Cntrl Pnl FM1-1/Wash Sctn 11:33:15 Door #1 FINISHING/FM #1 Cntrl Pnl FM1-1/Wash Sctn 11:33:54 Door #2 FINISHING/FM #1 Cntrl Pnl FM1-1/MS :36:00 3 Door #2 FINISHING/FM #1 FINISHING/FM #1 Cntrl Pnl FM1-1/Wash Sctn 11:38:29 Door #3 FINISHING/FM #1 Cntrl Pnl FM1-1/Brkr MS :44:38 4 Door #3 FINISHING/FM #1 FINISHING/FM #1 Cntrl Pnl FM1-1/Wash Sctn 11:47:33 Door #4 FINISHING/FM #1 Cntrl Pnl FM1-1/Wash Sctn 11:47:59 Door #5 FINISHING/FM #1 FINISHING/FM #1 Motor MS 0610/Overview 11:50:04 Trend Temp FINISHING/FM #1 FINISHING/FM #1 Cntrl Pnl/Brusher Cabinet 11:53:29 FINISHING FINISHING/FM #2 Cntrl Pnl FM2-3/Brshr Cab. 11:56:04 FINISHING/FM #2 FINISHING/FM #2 Control Pnl/FM 2 Winder 11:57:00 Example Data Log Page PRINTING/BATTERY CHRGRS Panel LP-2/Overview 12:44:28 PRINTING/BATTERY CHRGRS Panel LP-2/Circuits 14 & 16 12:48:54 5 PRINTING/BATTERY CHRGRS PRINTING/BATTERY CHRGRS Panel RP-2/Overview 12:53:33 BOILER RM/115VAC PNL Panel/Overview 13:05:35 Rise On Load BOILER RM BOILER RM/PNl PDP1-C-A Panel/Overview 13:09:09 BOILER RM BOILER RM/AIR CMPRSSRS Starter Pnl/Sullair Cmprssr 13:10:54 BOILER RM/AIR CMPRSSRS BOILER RM/AIR CMPRSSRS Strtr Pnl/Gard Dnvr Cmprssr 13:12:13 BOILER RM/AIR CMPRSSRS BOILER RM/AIR CMPRSSRS Strtr Pnl/Ing. Rand Cmprssr 00:00:00 Locked Out

5 BOILER RM/PNL PDP1-F Panel/Overview 13:14:19 BOILER RM BOILER RM/FEED WATER Comb Strtr/Feed Water Pmp 1 00:00:00 Not Operating BOILER RM BOILER RM/PNL PDP1-C Panel/Overview 13:16:27 BOILER RM BOILER RM/FOG SYSTEM Disc/Filter Pump #1 00:00:00 Not Operating BOILER RM/FOG SYSTEM Disc/Filter Pump #2 00:00:00 Not Operating BOILER RM/FOG SYSTEM Disc/Filter Pump #3 13:19:36 BOILER RM BOILER RM/AIR CMPRSSRS Strtr Pnl/Joy Air Cmprssr 00:00:00 Not Operating BOILER RM/AIR CMPRSSRS BOILER RM/AIR CMPRSSRS Disc/Air Dryer 13:22:30 Rise/Load BOILER RM BOILER RM/BOILER #1 Control Pnl/Blower 13:24:16 MAINT. OFFICES/PNLS Panel PP-8-C/Overview 13:28:45 MAINT. OFFICES/PNLS MAINT. OFFICES/PNLS Panel RP-15/Overview 13:31:16 MAINT. OFFICES/PNLS Panel RP-15/Circuit #21 13:32:37 6 Example Data Log Page FINISHING/PNL LP-8 Panel/Overview 13:45:35 FINISHING/PNL LP-8 Panel/Circuit #9 13:47:27 7 FINISHING FINISHING/PNL RP-7 Panel/Overview 13:50:11 Rise On Load FINISHING FINISHING/PNL PP-8-B Panel/Overview 13:58:18 Load Imbalance Breaker 7 PRINTING/PNL PDP2-G Panel/Overview 14:05:59 PRINTING/PNL PDP2-G Panel/Breaker #1 14:07:21 8 FAN ROOM/FAN #1 Comb Strtr/Fan #1 14:15:00 9 FAN ROOM/FAN #1 FAN ROOM/FAN #1 Soft Start/Fan #1 14:19:37 FAN ROOM FAN ROOM/FAN #2 Comb Strtr/Fan #2 14:20:38 10 FAN ROOM/FAN #2 FAN ROOM/FAN #2 Soft Start/Fan #2 14:25:04

6 Key to Thermographic Reports Page 1 THERMOGRAPHIC REPORT Report No. 14 BF Goodrich Plant #2 Textile Performance Chemicals Division AREA WASTEWATER LOCATION Comb Starter/Aerator #6-South Date 11/10/98 Time 09:09:08 Ambient temp Reference temp High temp Temp. rise 21.5 RISE ABOVE IN DEGREES F Ambient *** Reference *** Adjacent phase *** Direct measurement AMPERAGES A: 22 B: 22 C: 22 *>89.6 F *<25.6 F DESCRIPTION MAIN DISCONNECT-KNIFE CONNECTION/Phase B, Line Side 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 Repair within 30 days, watch load and inspect for physical damage. Knife Connection Serious Repair/Replace ASAP. Inspect surrounding components for physical damage. T-Report # Plant ID Plant Area Plant Location Time/Date Temp. Data High Temp. How Measured Amperage Description Recommendation Classification CRITICAL >55 IMMEDIATE REPAIR/REPLACE. DANGER EXISTS!

7 Key to Thermographic Reports Page 2 *>84.6 F *>89.6 F Spot Quantitative Data *<28.6 F *<25.6 F *>84.6 F *>90.4 F Spot Spot Spot Spot Wide-Angle Shot of the Entire Panel *<28.6 F *<46.9 F Close-Up

THERMOGRAPHIC REPORT Report No. 1 Acme Widget Company Plant #2 AREA AIR COMP RM/PANEL CPAL 3 LOCATION Breaker/Circuits #40-42 Date 6/4/2002 Time 10:02:57 Ambient temp. 85.6 Reference temp. 101.

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.

8 THERMOGRAPHIC REPORT Report No. 1 Acme Widget Company Plant #2 AREA AIR COMP RM/PANEL CPAL 3 LOCATION Breaker/Circuits #40-42 Date 6/4/2002 Time 10:02:57 Ambient temp Reference temp High temp Temp. rise 22.2 RISE ABOVE IN DEGREES F Ambient *** Reference *** Adjacent phase *** Direct measurement AMPERAGES #40: 27.9 #42: 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 Repair within 30 days, watch load and inspect for physical damage. Serious Repair/Replace ASAP. Inspect surrounding components for physical damage. CRITICAL >55 IMMEDIATE REPAIR/REPLACE. DANGER EXISTS! QUESTIONS ABOUT THIS REPORT? Call SCAN

Breaker/Circuits #40-42 Plant #2 *>126.4 F 126.0 124.0 122.0 120.0 118.0 116.

9 THERMOGRAPHIC REPORT Report No. 1 (CON'T) Area: AIR COMP RM/PANEL CPAL 3 Acme Widget Company Loc: Breaker/Circuits #40-42 Plant #2 *>126.4 F *<75 6 F Reference

THERMOGRAPHIC REPORT Report No. 2 Acme Widget Company Plant #2 AREA SS1/480V MAIN #1/DIST PANEL LOCATION Breaker 45 (NE Lights) Date 6/4/2002 Time 10:02:57 Ambient temp. 82.0 Reference temp. 89.

2 AMPERAGES Phase A: 89 Phase B: 113 Phase C: 143 DESCRIPTION Circuit imbalanced. RECOMMENDATION Balance loads. TEMP. RATING TEMP. RISE CLASSIFICATION F degrees Minor 1-18 Routine.

10 THERMOGRAPHIC REPORT Report No. 2 Acme Widget Company Plant #2 AREA SS1/480V MAIN #1/DIST PANEL LOCATION Breaker 45 (NE Lights) Date 6/4/2002 Time 10:02:57 Ambient temp Reference temp High temp Temp. rise 21.3 RISE ABOVE IN DEGREES F Ambient *** Reference *** Adjacent phase *** Direct measurement Min Max AMPERAGES Phase A: 89 Phase B: 113 Phase C: 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 Repair within 30 days, watch load and inspect for physical damage. Serious Repair/Replace ASAP. Inspect surrounding components for physical damage. CRITICAL >55 IMMEDIATE REPAIR/REPLACE. DANGER EXISTS! QUESTIONS ABOUT THIS REPORT? Call SCAN

11 THERMOGRAPHIC REPORT Report No. 2 (CON'T) Area: SS1/480V MAIN #1/DIST PANEL Acme Widget Company Loc: Breaker 45 (NE Lights) Plant #2 Front view

THERMOGRAPHIC REPORT Report No. 3 Acme Widget Company Plant #2 AREA AIR COMP SHED/A.C. #1 LOCATION Disc/Air Compressor #1 Date 6/4/2002 Time 10:02:57 Ambient temp. 80.8 Reference temp. 138.

0 RISE ABOVE IN DEGREES F Ambient *** Reference *** Adjacent phase *** Direct measurement AMPERAGES Phase A: 45 Phase B: 46 Phase C: 45 DESCRIPTION SWITCH (blade connector), phase A overheating.

12 THERMOGRAPHIC REPORT Report No. 3 Acme Widget Company Plant #2 AREA AIR COMP SHED/A.C. #1 LOCATION Disc/Air Compressor #1 Date 6/4/2002 Time 10:02:57 Ambient temp Reference temp High temp Temp. rise RISE ABOVE IN DEGREES F Ambient *** Reference *** Adjacent phase *** Direct measurement AMPERAGES Phase A: 45 Phase B: 46 Phase C: 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 Repair within 30 days, watch load and inspect for physical damage. Serious Repair/Replace ASAP. Inspect surrounding components for physical damage. *** CRITICAL >55 IMMEDIATE REPAIR/REPLACE. DANGER EXISTS! QUESTIONS ABOUT THIS REPORT? Call SCAN

13 THERMOGRAPHIC REPORT Report No. 3 (CON'T) Area: AIR COMP SHED/A.C. #1 Acme Widget Company Loc: Disc/Air Compressor #1 Plant #2

THERMOGRAPHIC REPORT Report No. 4 Acme Widget Company Plant #2 AREA CHILLER PAD/CHILLER CH-2 LOCATION Starter Pnl/Contactor #2 Date 6/4/2002 Time 10:02:57 Ambient temp. 95.2 Reference temp. 108.

0 RISE ABOVE IN DEGREES F Ambient *** Reference *** Adjacent phase *** Direct measurement AMPERAGES Phase A: 99 Phase B: 96 Phase C: 99 DESCRIPTION Contactor connector overheating.

14 THERMOGRAPHIC REPORT Report No. 4 Acme Widget Company Plant #2 AREA CHILLER PAD/CHILLER CH-2 LOCATION Starter Pnl/Contactor #2 Date 6/4/2002 Time 10:02:57 Ambient temp Reference temp High temp Temp. rise 30.0 RISE ABOVE IN DEGREES F Ambient *** Reference *** Adjacent phase *** Direct measurement AMPERAGES Phase A: 99 Phase B: 96 Phase C: 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 Repair within 30 days, watch load and inspect for physical damage. Serious Repair/Replace ASAP. Inspect surrounding components for physical damage. CRITICAL >55 IMMEDIATE REPAIR/REPLACE. DANGER EXISTS! QUESTIONS ABOUT THIS REPORT? Call SCAN

15 THERMOGRAPHIC REPORT Report No. 4 (CON'T) Area: CHILLER PAD/CHILLER CH-2 Acme Widget Company Loc: Starter Pnl/Contactor #2 Plant #2 *>149.0 F *<95.8 F

THERMOGRAPHIC REPORT Report No. 5 Acme Widget Company Plant #2 AREA VACUUM FAN ROOM/MCC-A LOCATION Cubicle A1/Vacuum Fan #1 Date 6/4/2002 Time 10:02:57 Ambient temp. 77.7 Reference temp. 104.

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.

16 THERMOGRAPHIC REPORT Report No. 5 Acme Widget Company Plant #2 AREA VACUUM FAN ROOM/MCC-A LOCATION Cubicle A1/Vacuum Fan #1 Date 6/4/2002 Time 10:02:57 Ambient temp Reference temp High temp 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 Repair within 30 days, watch load and inspect for physical damage. *** Serious Repair/Replace ASAP. Inspect surrounding components for physical damage. CRITICAL >55 IMMEDIATE REPAIR/REPLACE. DANGER EXISTS! QUESTIONS ABOUT THIS REPORT? Call SCAN

17 THERMOGRAPHIC REPORT Report No. 5 (CON'T) Area: VACUUM FAN ROOM/MCC-A Acme Widget Company Loc: Cubicle A1/Vacuum Fan #1 Plant #2 *>150.7 F *<57.2 F

THERMOGRAPHIC REPORT Report No. 6 Acme Widget Company Plant #2 AREA MAINMCR #3MCC #3-2 LOCATION Cubicle D2/Pump 3B Date 6/4/2002 Time 10:02:57 Ambient temp. 86.0 Reference temp. 104.8 High temp. 224.

4 RISE ABOVE IN DEGREES F Ambient *** Reference *** Adjacent phase *** Direct measurement AMPERAGES Phase A: 30 Phase B: 28 Phase C: 29 DESCRIPTION Fuse and fuse clip/phase A, load side.

18 THERMOGRAPHIC REPORT Report No. 6 Acme Widget Company Plant #2 AREA MAINMCR #3MCC #3-2 LOCATION Cubicle D2/Pump 3B Date 6/4/2002 Time 10:02:57 Ambient temp Reference temp High temp Temp. rise RISE ABOVE IN DEGREES F Ambient *** Reference *** Adjacent phase *** Direct measurement AMPERAGES Phase A: 30 Phase B: 28 Phase C: 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 Repair within 30 days, watch load and inspect for physical damage. Serious Repair/Replace ASAP. Inspect surrounding components for physical damage. *** CRITICAL >55 IMMEDIATE REPAIR/REPLACE. DANGER EXISTS! QUESTIONS ABOUT THIS REPORT? Call SCAN

Company Loc: Cubicle D2/Pump 3B Plant #2 *>134.

0 85.0 80.0 75.0 *<70.9 F *>130.6 F 130.0 125.0 120.

0 *<71.8 F *>146.6 F 145.0 140.0 135.0 130.0 125.

0 F *>221.7 F 220.0 210.0 200.0 190.0 Reference 104.

19 THERMOGRAPHIC REPORT Report No. 6 (CON'T) Area: MAINMCR #3MCC #3-2 Acme Widget Company Loc: Cubicle D2/Pump 3B Plant #2 *>134.9 F *<70.9 F *>130.6 F *<71.8 F *>146.6 F *<85.0 F *>221.7 F Reference *<57.8 F High Temp Max 224.2

REPAIR GUIDE- Equipment needing repairs Acme Widget Company Plant #2 Anytown, USA T# PLANT AREA AREA LOCATION CLASS 1 FLOCKING AREA FLOCK LINE #2 CNTRL RM Control Pnl FL2-J/Main Brkr S 2 FINISHING

20 REPAIR GUIDE- Equipment needing repairs Acme Widget Company Plant #2 Anytown, USA T# PLANT AREA AREA LOCATION CLASS 1 FLOCKING AREA FLOCK LINE #2 CNTRL RM Control Pnl FL2-J/Main Brkr S 2 FINISHING AREA FINISHING/FM #1 Cntrl FM1-3/Predryer Main A 3 FINISHING AREA FINISHING/FM #1 Cntrl Pnl FM1-1/MS-0610 C 4 FINISHING AREA FINISHING/FM #1 Cntrl Pnl FM1-1/Brkr MS0610 A 5 PRINTING AREA PRINTING/BATTERY CHRGRS Panel LP-2/Circuits 14 & 16 M 6 MAINTENANCE OFFICES MAINT. OFFICES/PNLS Panel RP-15/Circuit #21 A 7 FINISHING AREA FINISHING/PNL LP-8 Panel/Circuit #9 A 8 PRINTING AREA PRINTING/PNL PDP2-G Panel/Breaker #1 C 9 FAN ROOM FAN ROOM/FAN #1 Comb Strtr/Fan #1 C 10 FAN ROOM FAN ROOM/FAN #2 Comb Strtr/Fan #2 A 11 SUBSTATION #2 SUBSTN #2/PNL LP-7 Panel/Circuit #13 A 12 PRINTING AREA PRINTING/PM #4/CNTRLS Main Control Pnl/Main Brkr C 13 SUBSTATION #1 SUBSTN #1/13.2V Main 13.2V Switch/Overview S 14 CUTTING AREA CUTTING/CNTRLS Control Pnl CT3-2/Main Disc A 15 EMBOSSER EMBOSSER/HOT OIL Control Pnl/Relay-Heaters A 16 WASTEWATER AREA WASTEWATER/PUMPS Pump Control Pnl/FU 36 & 38 S WAREHOUSE 3803 WRHSE/PNL PP-4B Panel/Overview S WAREHOUSE 3803 WRHSE/PNL PP3-B Panel/Overview A 19 PRINTING AREA PRINTING/PM #3/PDP2-D Panel/Breaker-PM-3 Cntrls A 20 DYE HOUSE DYE HSE/JETS 1-4 Control Pnl/1-4-Main Brkr S 21 DYE HOUSE DYE HSE/OVEN TENTER Main Breaker/Overview M 22 DYE HOUSE DYE HSE/AIR CMPRSSR #1 Starter Pnl/Overview S 23 DYE HOUSE DYE HSE/BOILER Control Pnl/Blr Blwr Fuses C 24 PRINTING AREA PRINTING/PM #3/CNTRLS Control Pnl 3-5/Main Switch A 25 FLOCKING AREA FLOCK #1 CNTRL RM Cntrl Pnl-Ex. Fans/Fan M17E C 26 FLOCKING AREA FLOCK RANGE #1/DISCS Main Disc #52/Overview S (NR) Not Rated = 2 (M) Minor = 12 (A) Alert = 15 (S) Serious = 13 (C) Critical = 10 TOTAL = 52

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