Scheduling and Planning—Key Ingredients for Successful IR Surveys

(If you fail to plan—plan to fail)

Ken Leonard
Progress Energy, Raleigh, North Carolina
Robert Madding
Infrared Training Center, FLIR Systems, Inc.

ABSTRACT
Using a standard schedule for IR surveys has been identified as a best practice among infrared
thermographers. For electric power distribution equipment, this schedule should begin with the put-in-service
date for new equipment. Reasons for a baseline IR survey on new equipment are to ensure safety, proper
installation, identification of manufacturer defects and to ensure continuity of service for customer. Following
the initial IR survey it is recommended to repeat the IR survey in one year. Upon completion of the one year
IR survey, a three year rotation schedule should be followed. In addition to the standard schedule for IR
surveys attention needs to be placed on the planning of the timing of completing the IR surveys. By
recognizing the importance of standard scheduling and planning IR surveys, thermographers can contribute
value to their industry. This paper will address benefits and reasons for a standard schedule as well as
proper planning of IR surveys on electric power distribution equipment.

INTRODUCTION
The value of infrared thermography as a predictive maintenance (PdM) tool is well established. However, the
frequency of IR surveys and standard scheduling are often overlooked as a standard operating procedure.
Infrared thermographers often perform tasks in addition to their thermography role and these tasks often deal
with emergency situations such as ice storms, electrical storms, and unforeseen equipment breakdown and
so on. With IR survey frequency being long term and viewed as flexible, crises often preclude performing a
standard IR survey. The danger here is postponing an IR survey can lead to equipment problems creating a
crisis that further postpones the IR survey. This results in a breakdown of the IR survey routine and the IR
program is seen as ineffective. Having a standard schedule helps prevent this situation, allowing some
flexibility for unavoidable emergencies, while keeping IR thermography as an effective tool in preventing
avoidable equipment failures.

SCHEDULING CONSIDERATIONS FOR IR SURVEYS

Keeping IR thermography as an effective PdM tool for preventing electric power distribution equipment failure
that can be catastrophic significantly improves company personnel and customer safety, operational reliability
and maintenance cost optimization. IR thermography can only be an effective tool when used in a well-
defined program that includes IR survey scheduling and appropriate IR survey frequency.

Safety is of utmost concern for all industries. A standard schedule for IR surveys assures employees the fact
a line has been patrolled and all equipment presents itself in safe working conditions. Secondly, if a problem
is identified by a standard scheduled IR survey this allows for the employee to be pre-warned of a potential
hazard. Thirdly, the thermographer uses the IR camera as a safety tool. When entering a substation after a
tailboard safety meeting, the thermographer immediately does a quick IR survey of the entire substation
looking for any major problems. If none are found, the routine survey commences. If one or two are found
they’re documented and called in immediately. Appropriate safety action is taken including leaving the area.

Communication plays a key role in any PdM program. In fact many believe communication represents 70% to
80% of the effort of any good PdM program. The thermographer has as a part of his/her standard scheduling,
report generation that documents the problems found with their severity level and potential hazard. Report
routing is an important facet to this, so all relevant personnel are aware of the situation. You can only repair
problems you are aware of.

Figure 1 shows a 200 amp terminator connector with a significant problem in a PMH cabinet. This feeds the
Progress Energy distribution control center facility. Failure of this connection would force the facility to an

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

alternate backup feed and possibly force a transfer to backup generators. With all systems functioning
properly, the backup would be a seamless transition for all data and control systems, but all air conditioning
and some other systems would go out for a short period of time. Should this component fail catastrophically it
could destroy the entire PMH cabinet circuitry. Cost of catastrophic failure would cost at least 10 times more
to repair than fixing the problem as found. It also increases control center risk as now they would be relying
on a backup system for several hours instead of a few minutes.

Figure 1. 200 Amp terminator connector showing a significant problem in a PMH cabinet feeding a
Progress Energy Facility.

What actually happened was Ken called the problem in immediately to the area distribution field supervisor
and followed up with a written IR report for documentation. The problem was fixed the same day it was
found.

The initial IR survey performed on installation of new equipment and cabling provides opportunities to identify
improper installation. Figures 2 and 3 give visual and IR images of an in-service startup IR survey. New
cables were pulled and two of the three terminators were improperly installed resulting in abnormal thermal
patterns as shown in Figures 2 and 3.

This identification contributes to continuity of service and customer satisfaction. This IR survey can also
identify training needs for certain skill set employees to prevent improper installation in the future.

Figure 2. 750 kcmil terminator above left showing improper installation resulting in heating. The right
terminator above is installed correctly is not showing heat.

Trending of problems is another technique for watching minor problems and fixing them before they become
major problems. Trending also provides data for determining IR survey frequency. Timing is important. Too
frequent and you’re wasting resources. Not frequently enough and you’re going to have equipment failures.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

Figure 3. Another example of 750 kcmil terminators. The left terminator is proper installation resulting
in no heating. The right terminator is an example of improper installation resulting in heating.

TIMING CONSIDERATIONS FOR PLANNING IR SURVEYS

Put the thermographer with his/her IR camera in front of the equipment and do the IR survey. That’s it, right?
Not so fast. For electrical IR work, the preponderance of which is distribution equipment for Ken, there are
other factors to consider. Electrical systems don’t get hot when there’s no electrical load (current) and the
load in distribution systems is very customer and weather dependent. For North Carolina air conditioning is a
major load in summer with manufacturing and commercial uses adding to the load. The Raleigh and
surrounding area includes several large hospitals and other manufacturing which all demand high reliability of
electrical service.

Weather conditions will affect the integrity of IR surveys. Temperature, wind speed, humidity, and cloud cover
are all important considerations when planning your IR survey. Seasonal peak differences should be
considered when planning as well. For example the summer peak load is a different time than the winter
peak, 6:30 AM for winter and 4:30 PM for summer in the Raleigh area. But in terms of the weather, solar
loading has a severe impact on outdoor equipment and makes going at peak load times difficult in the
summertime unless the day has been cloudy. The latter can make mid-afternoon IR surveys optimal.

The time of day you begin your IR surveys can lead to some interesting findings. Ken’s day often begins at
3:30 AM. No solar loading, little wind and enough load to drive hot spots and on PMH cabinets there can be
significant condensation which have given Ken some “head-scratchin’” hot spots. Hot spots will appear on
terminators as shown in Figure 4 probably due to “tracking” or current leakage. When they dry out, the hot
spots disappear.

Figure 4. Moisture condensation induced “tracking” across a 750 kcmil terminator. Hot areas in IR image on right
indicate heating due to tracking. Concern of authors is this could eventually result in a flashover.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

Can these areas eventually flashover? Or, is this a weather related anomaly that has no overall impact on the
equipment? We just don’t know at this time.
Customer events present a strong consideration for planning your IR surveys. Access to secure facilities
often requires several days notice and strong documentation. Normal working hours are preferred to facilitate
the escort and ensure inspection of key areas.

Figure 5 shows a severely overheated fuse cutout running at 260 °F. This feeds a pharmaceutical
manufacturing facility that runs 24 hours per day 7 days per week. An outage would severely impact their
process and could result in significant revenue loss. This particular facility does not have backup generation.
It is stub fed, not loop fed meaning the fuse cutout is a single point of failure for them. There’s no automatic
way to get power to their facility. During normal working hours they could be down for 2 hours, double that
after normal working hours.

HOT: 260°F

REF.: 83°F

Figure 5. Fuse cutout showing severe thermal problem that if failed would generate an outage for a
pharmaceutical manufacturer that operates 24/7.

SUMMARY
Safety of both employees and customers is a primary consideration of all utilities and Progress Energy is no
exception. IR surveys enhance safety as personnel know ahead of time where the problems are and can
avoid encroachment until repairs are implemented.

To keep the electrical distribution system reliability high, Progress Energy relies on IR thermography as a key
PdM tool. To be effective there needs to be a plan and the plan needs to be followed. Progress Energy
schedules IR surveys on a routine basis, considers all the factors in the timing of the surveys and
communicates IR survey results to key personnel in a timely fashion. Their IR program has saved them
millions of dollars over the years in avoided maintenance costs. And customer satisfaction for reliable
delivery of service is high. Progress Energy management supports the IR program and they have been
rewarded with a successful effort.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14