CHAPTER - 5

MECHANICAL PROBLEMS

5.1 MECHANICAL

Compressors, motors, fans, pumps, vacuum sets, conveyors, etc, generally

referred to as Mechanical plant, all benefit from IRT inspection because they
include components such as, bearings, gears, shafts, couplings, v-belts, pulleys,
chain drives etc, all of which are designed to efficiently transfer mechanical
energy by minimizing losses such as friction. This friction not only generates
thermal energy but also reduces the component’s operating life due to wear.
However, friction can never be completely eliminated and thermal energy
+y will always be generated at transfer points, making these ideal candidates for
IRT inspection.

i) incorrect or missing anti-vibration couplings or mounts.

ii) Misalignment of bearings.
iii) Imbalance.
iv) Under or over lubrication of bearings.
v) Misalignment in the drive train (i.e. motor to driven machine).
vi) Over tightened drive belts.
vii) Poor maintenance and operating practices.

All machines or mechanical devices will, as a result of friction, generate heat,

even under normal operating conditions. And as such will exhibit a thermal profile
that is recognizable to the experienced thermographer. Therefore, variations in a
machine or component thermal signature provides thermographers with a means
of problem identification.

5.1.1 BASELINE IMAGES

A thermogram of a machine operating in a healthy state can be used as a

baseline image.

Subsequent images may be compared to the baseline image for signs of

increased radiosity and used to determine rates of component deterioration, and
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to initiate corrective action as appropriate. Before a baseline image is created, it

is important to take into consideration a number of factors:

a) All machines are manufactured within certain tolerances. The degree of

tolerance will vary on each component and in each assembled machine;
therefore, the level of friction may vary between identical machines;
b) After the initial installation of a new machine, setting-up will be required,
namely pulleys and couplings correctly aligned and belts correctly
tensioned. Incorrect alignment and adjustment of belts will almost always
result in increased friction through slippage or abnormal forces;
c) New or reconditioned machinery must be allowed time to ‘bed-in’ so that
friction levels can normalize in bearings, belts, gear trains etc;
d) Target surfaces must be clean and surface features such as labels,
scratches, corrosion, flaking paint, etc. should be recorded to prevent
misinterpretation and the reporting of non-problems;
e) Environmental conditions such as ambient temperature, wind, sun,
moisture etc. as appropriate must a also be considered and recorded;
f) Before recording baseline images, time must be allowed for machines to
reach normal operating temperature;
g) The specification or details of the IRT instrument, including lens selection,
should also be recorded.

Poor installation and set-up will result in reduced operational life due to increased
friction and wear. Figures 19 to 22 illustrate some examples of machines
exhibiting high friction symptoms. There are, however, tools and technologies
available to assist in the machine ‘setting-up’ process. The use of multiple CM
technologies provides a powerful approach to machine condition assessment,
IRT, for example, will identify over-stressed bearings and over-tensioned drive
belts, while vibration measurement devices can locate the cause of excessive
vibration such as misalignment, poor isolation damping and imbalance. Laser
alignment tools can ensure accurate drive train and pulley alignment, and strobe
lamps can identify drive belt slippage.

When a new machine has been installed, set-up correctly and a suitable period
of time has lapsed for ‘bedding-in’ purposes, a few minor adjustments may be
required before the machine would be ready to ‘baseline’. Comparisons with IRT

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baseline images are used to assess machine deterioration or to verify that

remedial work has been carried out to an acceptable standard.

Before subsequent images are recorded, however, it will be necessary to ensure

that machine operating and environmental conditions are reproduced and
recorded. The machine’s temperature will vary if operating with a fixed or variable
load, and/or fixed or variable speed.

Another consideration worth recording is the machine’s operating cycle and

function or purpose. For example, a pump may be used to pump chilled water or
hot water; therefore the temperature of the water will affect the pump body
temperature. Most machines operate in a production or plant room environment
where there is the likelihood of interference from other sources of thermal energy
such as other machines, room heaters, hot water pipes etc; therefore target
emissivity, viewing angle, and ambient temperature should also be considered
and recorded.

Close duplication of operational and environmental conditions is best achieved if

the thermographer is equipped with a copy of the original baseline image and a
record of the original operation and environmental conditions.

5.1.3 DRIVE TRAINS

Misalignment of drive pulleys and couplings is a common cause of premature

failure in components such as drive belts, bearings and seals. Friction is
generated within these components due to the abnormal forces created by the
misalignment. This additional friction generates thermal energy that will be visible
to the thermal imaging camera. For direct-drive machines, misalignment of the
driver and driven unit will produce excessive vibration which will stress the
coupling and bearings.

These effects are easily detected using vibration measurement instruments but
can also be detected using IRT if misalignment is significant.

Drive belts will operate at elevated temperatures if they are too loose, too tight or
are an unmatched set (see Thermogram 13). Belts that are too tight will run hot

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and apply high radial forces to the drive bearings of the driver and driven units,
which in turn will also run hot. Loose belts, however, will become hot due to
friction caused by the slippage, furthermore the drive bearings will not be
influenced by high radial forces and should, therefore, not exhibit elevated
temperatures.

Thermogram 13 Figure 19

Mal-adjusted or mismatched drive belts will, if left uncorrected, result in

accelerated belt and sheave wear and, in some cases, premature bearing failure.

Pulley sheaves should be inspected when replacing worn belts, particularly

where belt slippage has been diagnosed. Worn sheaves will reduce belt life and
should be replaced where wear is significant.

5.2 MECHANICAL

5.2.1 BEARING PROBLEMS

Machine bearings come in all shapes and sizes; some have roller elements,
some are plain, some are sealed for life whilst others require periodic lubrication.
Figure 20 illustrates a typical bearing assembly identifying the components and
potential points of failure.

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Figure 20
Cross-section of motor drive end bearing housing and assembly

Normal and maximum operating temperatures may also vary depending on

bearing design and application. The same applies to the lubricants that service
the bearings. Bearings can exhibit elevated operating temperatures if the
incorrect grade of lubrication is used. Too much lubrication will result in high
friction due to the shearing action of the lubricant under pressure.

Too little lubrication will allow direct metal-to-metal contact of the internal bearing
surfaces, resulting in friction and wear.

Incorrect installation will reduce bearing life through abnormal internal forces,
stressing the bearing components. Split bearings, for example, are widely used
on large drive shafts thus enabling replacement without drive shaft removal.
Incorrect installation or inaccurate alignment will adversely affect the operational
life of the bearing (see Thermogram 14).

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Thermogram 14
Thermogram showing a split bearing
operating at an elevated temperature Figure 21

IRT will almost always detect a distressed bearing; however, the root cause for
elevated temperatures within bearings may not always be determinable. The use
of other CM technologies, such as acoustic emission or vibration analysis, may
be required to identify the foot cause of high operating temperatures and help
determine an appropriate course of corrective action.

5.2.1.1 SEALS

Seals fitted to the drive shafts of rotating machines are used for containment or
as a barrier, either to prevent the escape of the contained medium such as a gas
or liquid, or to prevent the ingress of corrosive or harmful substances such as
water or dust. Seals tend to be overlooked in many maintenance regimes, until a
problem develops, which is unfortunate because the consequences of seal
failure often result in the catastrophic failure of the machine. IRT, however, is an
effective technique for identifying poorly fitted seals as there will almost always
be friction caused by contact between fouling surfaces.

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Thermogram 15
High fan shaft temperature caused by friction
with fan shaft seal Figure 22

Thermogram 15 illustrates the overheating of the fan shaft due to excessive

friction at the fan-shaft-to-fan-casing seal. Also observe that this phenomenon
can easily be misdiagnosed as a bearing fault. Failure to address this problem,
as illustrated in Thermogram 15, can result in catastrophic failure of the fan
shaft; the seal chafes against the drive shaft surface resulting in circumferential
wear that creates a weak point on the drive shaft. If load torque is high, there is
the potential for the shaft to shear at this point. This type of problem is easily
detected using IRT upon installation or during the machine’s commissioning.

5.2.2 PUMPS

There are many pump types and designs that suit a variety of pumping
applications. The type and design of the pump used will depend on system
requirements such as throughput (litres per second), suction and discharge
pressures, and the type and suitability of liquid being pumped, for example
consistency, corrosive properties, temperature etc.

Hot and chilled water systems, for example, will affect the operating
temperauture of the pump body and therefore surface radiosity. Where system
temperature indicators are not permanently installed, the system water

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temperature can usually be determined by measuring the temperature of

adjacent pipework (where lagging does not interfere).

Thermogram 16 shows a bank of hot water circulating pumps. Pumps of this

type have very low operating noise levels, making it very difficult to determine
which pumps are operating and which are not. However, careful examination of
the IRT image in Thermogram 16 reveals sufficient information to carry out an
evaluation of the operational circumstances for this bank of pumps.

Thermogram 16
A bank of hot water circulating pumps

By comparing the body temperatures for pumps A to D, it is apparent that pump

A has the highest operating temperature at > 70ºC and pump B the lowest at
50ºC, whilst pumps C and D are between the two at about 60ºC. In this particular
case, all four pumps are configured to operate in parallel, so the effect of water
temperature on each should be identical. The first assumption would be that C
and D are operating normally; this is reasonable because the pump body
temperatures are very similar to each other and to the surface temperatures of
the pump isolating valves.

Now consider Pump B. The isolating valve to its right is significantly cooler than
the other valves. Upon checking the valve, it was found to be fully open. This
indicated that pump B was either not switched on or that it had failed. The
temperature of pump B continued to be maintained, partly through thermal
conductivity, and partly through the system circulating currents generated by the
other three pumps. Pump A is significantly warmer than pumps C and D. The
isolating valve temperautes for these three pumps are identical, indicating

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comparable water temperatures. It is therefore reasonable to assume that the

failure of pump A is imminent and most likely due to a faulty electrical stator
winding or possibly defective bearings.

This evaluation demonstrated a number of important points. It demonstrated the

power of qualitative analysis, the importance of understanding the operating
principles of the machinery, equipment and systems under evaluation and heat
transfer principles. This evaluation also demonstrated the need to carefully study
all the information contained within IRT images, and the importance of the
original field assessment to determine what should be included in the image in
the first instance.

5.2.3 COMPRESSORS

The IRT evaluation of compressors should be undertaken with great care.

Compressor design and operational complexities are such that the
thermographer may face a number of thermal signature variations. The dilemma
for the thermographer, therefore, is to differentiate between those signatures that
are normal and those that are abnormal.

Reciprocating compressors can be particularly difficult to evaluated thermally,

unless the thermographer is familiar with the compressor design and operating
arrangements. A three-state reciprocating compressor, for example, has three
compression cylinders.

Compressed gas is transferred progressively from cylinder to cylinder; that is, the
gas compressed in the first cylinder is fed into the second cylinder for further
compression, then into the third where gas compression reaches the desired
system pressure. This compression sequence generates a substantial amount of
thermal energy and the compressed gas temperature increases after each
compression stage. The temperature of gas leaving the first cylinder will be
significantly higher than that on entry; equally, the hot gas entering the second
cylinder and being further compressed, thus raising its temperature even higher,
and so on.

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From the thermographer’s viewpoint, each cylinder head will show a progressive
and distinct rise in surface temperature for each stage; the experienced
thermographer will recognize this thermal anomaly as a normal operational
characteristic. To maximize the compression efficiency on multistage
compressors, intercoolers are often used between stages to reduce gas
temperature, thus reducing inter-stage gas temperature but increasing gas
density, thereby increasing compressor efficiency. However, these gains in
compressor efficiency will be reduced if the intercooler is not operating
effectively.

Figure 23
Gas compressor intercooler showing the effects of lime-scale build up

Figure 23 illustrates a chilled water intercooler on a large gas compressor. The

black arrows on photograph ‘A’ indicate the gas flow direction, and the yellow
arrows indicate the chilled water flow inlet and outlet pipes. Photograph ‘B’ shows
the extracted intercooler tube nest bundle heavily contaminated with lime-scale
deposits.

Figure 24 provides superimposed intercooler temperature profiles for

Thermograms 17 and 18. These profiles illustrate the cooling efficiency of the
intercooler by input/output temperature differential comparisons. In Thermogram
17, the effect of lime-scale build-up on the efficiency of the intercooler is clearly
visible, as the temperature differential, either side of the intercooler, is only 20º C.

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In Thermogram 18, the lime-scale has been removed, improving the efficiency
by providing a temperature differential of 40ºC across the intercooler.
This example demonstrates the use of effective plant baselining and trending;
here temperature differentials may be recorded, trended and lime-scale removal
operations planned to suit operations and resource availability.

Thermogram 17 Thermogram 18

Figure 24
Intercooler temperature profile before and after tube nest descaling

Another type of reciprocating compressor that consists of three cylinders may not
be of the multi-staged design. These compressors may be designed so that all
three cylinders operate at near identical compression and output pressure; such
a compressor is illustrated in Figure 25. Here, only two of the three cylinder

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heads are visible; the ARO1 cylinder head being clearly hotter than the ARO2. In
order to determine whether a problem exists, it will be necessary to understand
the operational set-up.

Thermogram 19 Figure 25
Variation in compressor cylinder
head temperature

The operational set-up of this compressor is such that under light load, although
only cylinder 1 operates under compression, cylinders 2 and 3 are operating but
not compressing. If demand increases, initiated by a drop in system pressure,
cylinder 2 will switch to compression mode and, if demand continues to increase,
all three cylinders will operate under compression. The surface temperature of
any of the cylinder heads will therefore depend upon the cylinder’s current duty
mode and the position of each head in the thermal cycle as it heats up and cools
down with demand. Thermographers must familiarize themselves with
compressor design and operating arrangements, otherwise the reporting of non-
problems is possible.

Recording baseline images for new compressors or after a major overhaul is

highly recommended. The baseline image should be recorded under full load and
after a period of thermal stability.
Subsequent IRT inspections must be carried out under full load conditions
(usually simulated by opening a vent valve to reduce system pressure), to ensure
accurate comparison.

Thermographers must always be aware of surface conditions. Compressor

cylinders and cylinder heads are normally constructed of cast iron and the

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surfaces of these components reach very high temperatures. Compressor

manufactures therefore paint these surfaces with high temperature-resistant
paints, some of which have low emissivity.
After maintenance, these surfaces may become contaminated with oil or grease
thereby creating areas or patches of higher emissivity. The cylinder head paint
may also become chipped and flaked, resulting in patches of differing emissivity.
The ability to recognize variations in surface emissivity is important in avoiding
mis-diagnosis.

5.2.4 LIMITATION OF IRT IN MACHINE DIAGNOSTICS

IRT is unparalleled in its ability to identify rapidly overheating components on

machinery, but IRT does have limitations in mechanical inspection in that it
cannot always establish the cause of excessive heat.

However, its value comes in the speed of inspection and location of defects
without interrupting plant and processes. For critical process machinery, vibration
readings should also be recorded to provide additional baseline information, in
addition to IRT temperature profiles.

The fault evaluation capability of vibration analysis together with the speed of IRT
defect identification makes for a powerful diagnostics combination.

5.2.5 STEAM HEATING

IRT is very effective at locating problems in industrial processes that involve the
transfer of hot and cold fluids or gases over distance. Steam systems make ideal
candidates because the high operating temperatures involved make defect
detection relatively straightforward. Thermal losses and condensate losses are
highest when transfer distances are long, due to the additional pipework,
insulation, joints and steam traps involved. Consequently, running costs and
maintenance costs can be high.

For steam heating a system, boiler steam is transferred to buildings via a steam
main consisting of insulated pipework. At each building the steam is fed into heat

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exchangers, such as calorifiers (water heaters) or radiators and fan-assisted

space heaters. Steam supply to these heat exchangers is regulated to match
demand. As the steam gives up its latent thermal energy, condensation forms on
the internal surfaces of the heat exchanger.
This condensate is then removed from the system by devices known as steam
traps and ‘Ogden’ type pumps. Failure to remove the condensate will result in the
heat exchanger filling with water resulting in little heat output and damaging
effects such as water hammer.

Industrial boilers use chemically treated water to prevent corrosion, erosion and
scale build-up on the boiler tubes, thereby increasing heating efficiency and
boiler life. However, water treatment costs are high, so, where practicable,
condensate is always returned to the boiler house for re-use. Typical component
defects may include: ‘passing’ steam traps (see Sub-Section 5.2.8.2), boiler tube
leaks, calorifier leaks, underground and over-ground pipe leaks, and insulation
damage or degradation. Steam leaks should be repaired at the earliest
opportunity because high operating pressures mean that a relatively small steam
leak or the ‘passing’ of steam through a defective steam trap not only wastes
considerable energy but will prove very costly if left unrepaired. Regular IRT
inspection provides the means of identifying steam main defects that may, under
normal circumstances, remain undetected and as such substantial savings will
be lost.

5.2.5.1 IRT INSPECTION OF STEAM SYSTEMS

There are four main areas on which to focus IRT inspection:

i. insulation defects;
ii. Steam and condensate leaks;
iii. Defective steam traps;
iv. Boiler insulation defects.

Steam systems are used to transport thermal energy. For maximum efficiency,
insulation is used extensively throughout the system. Leaks in the system can be
difficult to pinpoint when steam condenses under the insulation resulting in the
condensate traveling, by gravity, to a joint or interruption in the insulation

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cladding where the ‘leak’ becomes visually apparent. Condensate exit points are
often mistaken as the actual leak sites. Leak sites are readily detected with IRT
due to the very hot condensate saturating the insulation at a leak point thereby
raising the temperature of the metallic cladding, resulting in a hot surface
anomaly in the vicinity of the leak. Steam leaks of this nature are costly in terms
of wasted energy, repair costs and steam main downtime. These costs, however,
may be significantly reduced through IRT inspection. IRT will identify actual leak
sites and, if detected early, will reduce the extent of insulation moisture
contamination.

The ingress of rain water at the joints and junctions of steam pipe cladding is
another major contributor to wasted energy. Saturated insulation significantly
increases thermal conductivity between the surface of the hot pipe and the
metallic outer cladding.

Moisture will typically accumulate on the underside of the insulation, as illustrated

in Thermogram 20. Here, the underside of steam main pipe work (Figure 26) is
inspected for hot spots where it passes over a roadway.

The metal-clad insulation reveals a number of hot spots caused by rainwater

ingress at cladding joints and pipe supports.

The moisture affected insulation acts as a thermal bridge between the hot
surface of the steam pipe and the outer cladding. Similarly, underground steam
leaks may be identified using IRT and significant cost savings achieved, not only
in terms of energy saving, but also by minimizing the amount of excavation work
required.

Thermogram 20 Figure 26
High-Level steam main defects

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5.2.8.2 IRT INSPECTION OF STEAM SYSTEMS

Thermogram 21 illustrates an underground steam leak where the leak site has
manifested as hot spots on ground surfaces and inspection covers. This is a
particularly good application because, unlike above surface steam main
pipework, there are often no visible signs indicating a potential problem such as
escaping steam or leaking condensate, because these are absorbed by the
adjacent soil. Due to the high operating temperatures, leaks can be detected in
steam pipes several feet below ground surface.

Thermogram 21
IRT used to locate underground steam leaks

5.2.5.3 STEAM TRAPS

Steam traps are prone to malfunction, of which the most common form is
`passing’: this can often go unnoticed in a closed condensate return system, yet
the energy wasted can be high.

150

Thermogram 22
No apparent temperature differential.
Steam trap venting or may be seized
open
Thermogram 23
Noticeable temperature differential.
Steam trap not passing
Mechanical Problems
Thermogram 22 and 23 show two steam
traps apparently in different modes of
operation. However, the operational state
of these steam traps cannot be
ascertained from these images alone.
The surface temperature of the steam
trap in Thermogram 22 is high and there
is no temperature difference between the
inlet and outlet. This trap is therefore,
either venting hot condensate and steam
as a normal part of its operation cycle, or
it has seized in the open position and is
continuously `passing’ steam.
Seized steam traps are not only costly in
terms of wasted energy, but can also
result in condensate return line damage,
which in turn will result in condensate
water loss. The steam trap in
Thermogram 23 would appear to be
functioning normally; there is a good
temperature differential indicating recent
cyclic activity. Where a temperature
differential is not apparent and the overall
surface temperature is clearly below
normal operating temperature, then this
may be indicative of a blocked or seized
steam trap in the closed position. Failure
to remove unwanted condensate from a
steam system will result in reduced
system efficiency and increased
operating costs.
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Determination of steam operational condition is best achieved through

observation over several cycles. Should the operational cycles be of short
duration, the steam trap may have the appearance of continually `passing’ due to
there being insufficient time for surfaces to cool. Under these circumstances, the
application of an ultrasound listening probe, in conjunction with IRT, provides a
particularly effective diagnostic combination.

5.3 MECHANICAL PLANT

Thermography can be applied in processes and/or mechanical plant that may be

classified as static or dynamic applications, respectively:

1. Static applications, such as refractory lined furnace walls, tanks etc. In fact
the number of process applications is endless;
2. Dynamic applications such as motors, pumps, compressors in mechanical
plant, etc.

The most popular procedure for inspection of rotating equipment is `Vibration

Analysis’. However, vibration testing may not produce successful results in every
case and in such situations thermography can often be very beneficial. The
beauty of thermography is that one sees the problems that would otherwise
remain unnoticed until failure occurs. Examples of this type of defect are
illustrated in the following thermograms, such as hot pump glands, bearing seals,
blocked valves, etc.

Besides thermography, there are other inspection techniques applicable to

condition monitoring of mechanical plant, such as vibration monitoring, acoustic
emission or oil analysis. Wherever appropriate, these should be used in
conjunction with thermography.

5.3.1 DRIVES

Two different belt drives are shown in Figures 154 and 155. Both drives are
experiencing belt slip, as shown in Thermograms 176 and 177.

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Thermogram 176 Figure 154

Pump belt drive – one belt hot

Thermogram 177 Figure 155

Pump belt drive – all belts hot

Problem and possible cause: In Thermogram 176 only one belt is slipping
indicating that the set may not be matched. In
Thermogram 177 all belts are hot.

Possible corrective action: Check the load on the drive and the belt
tightness. When changing belts always replace
the full set.

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Thermogram 178 Figure 156

Fan layshaft drive

Problem and possible cause: In this survey of the fan drive assembly a
layshaft pulley side bearing was found to be
hot. This problem could be caused by a
misalignment or lubrication problem.

Possible corrective action: Check lubrication and alignments.

Thermogram 179 Figure 157

Cooling tower fan gearbox

Problem and possible causes: The cooling tower gearbox, shown in

Thermogram 179 is hot.

Possible corrective action: Check lubrication and if necessary replace

the gearbox.

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MISCELLANEOUS

With this type of refrigeration plant compressor shown in Figure 158, when
functioning correctly, cylinders within each pair should be operating at
approximately the same temperature.

Thermogram 180 Figure 158

Refrigeration plant compressor – Pair
of cylinders

Problem and possible cause: In this survey Thermogram 180 shows a pair
of cylinders where one cylinder is running
warmer. This suggests that the valves on one
cylinder may be damaged.

Possible corrective action: Recondition the compressor.

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The conveyor shown removes waste from the sludge disposal plant in a paper
mill. The conveyor belt is `U’ shaped and is supported by sets of rollers, each set
comprising three rollers

Thermogram 181 Figure 159

Problem and possible cause: Thermogram 181 indicates that the front edge
of the roller is hot due to build up of waste
under the roller.

Possible corrective action: Remove all waste from under the roller.

5.3.3 PUMPS

Thermogram 182: Pump Casing Figure 160

Problem and possible cause: This survey of the pump unit indicates that the
pump casing is hot, which suggests that the
pump may be churning or there is a defective
impeller.

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Possible corrective action: Service the pump.

Thermogram 183 Figure 161

Pump output pipe

Problem and possible cause: Thermogram 183 of a pump indicates that it

may be working against a dead head, which
may cause overheating and cavitation.

Possible corrective action: Check the system and prevent the pump from
working when the valves are closed.

Thermogram 184 Figure 162

Pump shaft

Problem and possible cause: Thermogram 184 indicates a pump shaft with
a hot bearing seal caused by high friction,
probably the result of tight seals on the shafts.

Possible corrective action: Check and, if required, replace the seals

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Thermogram 185 Figure 163

Motor and pump bearing

Problem and possible cause: Thermogram 185 shows a pump assembly

where both the motor front bearing and the
pump bearings are hot. The hot motor front
bearing has been reviewed in Thermogram
138 of section 2.2.12. The other hot
component in Thermogram 185 is a hot
pump bearing which could be caused by
misalignment or defective lubrication. Note
the difference in motor bearing temperatures.
In Thermogram 185 the infrared camera
viewing angle is incorrect.

Possible corrective action: Check and, if required, replace defective

parts. Reacquire thermal image with correct
viewing angle.

Figure 164 shows a high pressure regeneration gas compressor (pump). The
piston head is on the right and part of the gearbox can be seen on the left. There
is a gas seal at the piston end and an oil seal at the gearbox end. The six pipes
shown feed the cooling water to the lubricating system and also take away any
gas leaks to the ventilation system.

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Thermogram 186 Figure 164

Problem and possible cause: One of the pipes is considerably warmer,

indicating that there is a gas leak at the piston
seal.

Possible corrective action: The unit will need to be serviced to eliminate

the leak.

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SAMPLE THERMOGRAPHY REPORT – A

THERMOGRAPHIC SURVEY REPORT FOR BUILDING A

REPORT NO.005 DATE: DD/MM/YYY

REPORT DISTRIBUTION

COMPANY COPY NOS’

CUSTOMER
MAINTEANCE ENGINNER
SURVEYOR

REPORT AUTHORISATION

NAME:
IRT SURVEYOR (LEVEL 1) NAME: SIGNATURE
IRT SURVEYOR (LEVEL 2) NAME: SIGNATURE
CUSTOMER NAME: SIGNATURE
DATE

EQUIPMENT DETAILS
CAMERA
MANUFACTURE
SERIAL NO.
CALIBRATION DATE
RE-CALIBRATION DATE
CALIBRATION NO.
ACCURACY

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INTRODUCTION

This report details the infrared thermographic survey conducted in building A.

The survey includes all electrical distribution equipment, control panels, and
rotating machinery as detailed in the report checklist (Annex 1) together with any
additional equipment as specified by the customer.

The survey, report generation, distribution and Quality Assurance arrangements

are detailed in the IRT Safe System of Work and associated method statement.

Where abnormalities are detected, colour thermograms and digital images are
presented indicating specific problem areas. The report incorporates technical
analysis with likely fault causes and recommendations. “Spot temperatures” of
specific problem areas are given as well as the differential temperatures with
respect to local ambient or atmospheric temperature.

The object of this report is to highlight only those items of equipment that appear
defective

Surveys normally cover large numbers of plant and equipment that appear
defective.

Surveys normally cover large numbers of plant and equipment, therefore;-

Plant and equipment found to be free of fault will not feature in the thermographic
report pages, however they will be identified in the checklists located in the
annex to this report.

RECOMMENDATIONS AND DISCLAIMER

“The recommendations given in this report are intended as a guide only,

therefore IRT & Co cannot accept responsibility for inappropriate actions taken
because of the issue of this report.”

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CUSTOMER COMMENTS / FEEDBACK

Each report page provides an opportunity for the customer or Maintenance

Engineer to provide details of any remedial action undertaken and any
observations made with regard to the anomalies detailed in this report.

This should be encouraged so that a record can be made of work undertaken.

This feedback will enable the IRT surveyor to evaluate the effectiveness of repair
work when conducting subsequent thermographic surveys.

In addition, the feedback information will be used to continuously improve the

quality of service provided, by improving surveyor fault diagnosis and route
cause identification capability.

Note. Comments are required only in report copy No.1 held by the customer or
Maintenance Engineer.

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REPORT NO.005 DATE: DD/MM/YYY

IR Image No.1 Photo No.1

INTRODUCTION

PLANT DESCRIPTION DISTRIBUTION FUSE BOARD AMBIENT TEMPERATURE: 18.0ºC

PLANT ID : DFB 12 EMISSIVITY : 0.95
LOCATION : ROOM 1 TIME: 10:15

ANALYSIS DETAILS

IMAGE POINT Description Image Point Temp Tamb

POINT 1 Fuse holder to busbar interface (R) 30.3ºC 12.3ºC
POINT 2 Fuse holder to busbar interface (Y) 42.0ºC 24.0ºC
POINT 3 Fuse holder to busbar interface (B) 28.9ºC 10.9ºC
POINT 4

EQUIPMENT DETAILS

Fault / Cause: Fuse holder to busbar interface warm (cct 1&2) most noticeably on the yellow
phase.
Cause due to sub-standard electrical contact.

Recommendations: Disassemble fuse holders and inspect the busbar lug for condition.
Clean contact surfaces and reassemble.

Note: This anomaly was not present during the thermographic survey and should
therefore be addressed at the earliest opportunity.

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 Mechanical Problems

REPORT NO.005 DATE: DD/MM/YYY

IR Image No.2 Photo No.2

SURVEY DETAILS

PLANT DESCRIPTION DC CHARGER / SUPPLY UNIT AMBIENT TEMPERATURE: 18.0ºC

PLANT ID : DC SUPPLY TO EXTRACT FAN EMISSIVITY : 0.95
LOCATION : SWITCH ROOM 2 TIME: 10:30

ANALYSIS DETAILS

IMAGE POINT Description Image Point Temp Tamb

POINT 1 PANEL AMBIENT 24.4ºC 6.4ºC
POINT 2 FUSED LINK (DC LOAD) 60.7ºC 36.3ºC
POINT 3 FILTER CONNECTION TOP LEFT 61.6ºC 37.9ºC
POINT 4

COMMENTS

Fault / Cause: Left-hand fused switch hot due to poor electrical contact (SPo2).
Top left filter connection hot, due to poor internal or external contact (SPo3).
Recommendations: Inspect fuse carrier contacts, ensure good electrical contact between fuse and
holder, replace if necessary.
Check fuse rating is correct for the load and circuit specifications.
Inspect cable termination (or internal connection if possible) to filter for looseness
and corrosion. Re-terminate as necessary.
Note: These anomalies have shown a temperature increase since the last survey
suggesting a deteriorating condition. These faults should be rectified at the earliest
opportunity

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 Mechanical Problems

REPORT NO.005 DATE: DD/MM/YYY

IR Image No.3 Photo No.3

SURVEY DETAILS

PLANT DESCRIPTION BATTERY CHARGER CONTROL PANEL AMBIENT TEMPERATURE: 14.0ºC

PLANT ID : BCCP1 EMISSIVITY : 0.95
LOCATION : SWITCH ROOM 1 TIME: 11:00

ANALYSIS DETAILS

IMAGE POINT Description Image Point Temp Tamb

POINT 1 LOCALISED AMBIENT 18.0ºC 4.0ºC
POINT 2 FUSE BODY (RHS) 75.0ºC 57.0ºC
POINT 3 FUSE BODY (LHS) 56.8ºC 38.8ºC
POINT 4

COMMENTS

Fault / Cause: Left-hand fused switch hot due to poor electrical contact (SPo2).
Top left filter connection hot, due to poor internal or external contact (SPo3).
Recommendations: Inspect fuse carrier contacts, ensure good electrical contact between fuse and
holder, replace if necessary.
Check fuse rating is correct for the load and circuit specifications.
Inspect cable termination (or internal connection if possible) to filter for looseness
and corrosion. Re-terminate as necessary.
Note: These anomalies have shown a temperature increase since the last survey
suggesting a deteriorating condition. These faults should be rectified at the earliest
opportunity

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 Mechanical Problems

REPORT NO.005 DATE: DD/MM/YYY

IR Image No.4 Photo No.4

SURVEY DETAILS

PLANT DESCRIPTION BREATHING AIR COMPRESSOR B AMBIENT TEMPERATURE: 10.0ºC

PLANT ID : STARTER CONTROL PANEL EMISSIVITY : 0.95
LOCATION : COMPRESSOR HOUSE TIME: 11:15

ANALYSIS DETAILS

IMAGE POINT IMAGE POINT DESCRIPTION IMAGE POINT TEMP Tamb

POINT 1 LOCALISED AMBIENT 38.0ºC 28.0ºC
POINT 2 KM3/F4 CONTACTOR TO OL INTERFACE 95.0ºC 57.0ºC
POINT 3
POINT 4

COMMENTS

Fault / Cause: Sub-standard electrical contacts between the contactor and overload KM3/F4.
Alternatively, incorrect overload fitted.

Recommendations: Check overload rating and setting, and replace or adjust as required. Disassemble
contactor / overload assembly, examine contacts and interface components for
signs of deterioration, repair / replace as necessary.

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 Mechanical Problems

Note: These recommendations should be implemented as soon as possible; fault

temperature has increased since the last report.

REPORT NO.005 DATE: DD/MM/YYY

IR Image No.5 Photo No.5

SURVEY DETAILS

PLANT DESCRIPTION FAN BEARINGS AMBIENT TEMPERATURE: 20.0ºC

PLANT ID : FAN 20B EMISSIVITY : 0.75
LOCATION : EXTRACT PLACT ROOM TIME: 11:30

ANALYSIS DETAILS

IMAGE POINT IMAGE POINT DESCRIPTION IMAGE POINT TEMP Tamb

POINT 1 BEARING (NON-DRIVE END) 72.5ºC 52.5ºC
POINT 2 BEARING (DRIVE END) 44.0ºC 24.0ºC
POINT 3
POINT 4

COMMENTS

Fault / Cause: NDE bearing running much hotter than the DE bearing. Typically, DE bearings run
hotter than NDE bearings.

Recommendations: Confirm when last lubricated and lubricate if appropriate. Conduct vibration analysis
to determine cause and rectify.

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 Mechanical Problems

Note: Monitor bearing for continued deterioration as lubrication may only provide a
temporary solution if bearing damage has occurred.

REPORT NO.005 DATE: DD/MM/YYY

IR Image No.6 Photo No.6

SURVEY DETAILS

PLANT DESCRIPTION SWITCH GEAR TRIPPING BATTERIES AMBIENT TEMPERATURE: 20.0ºC

PLANT ID : BATTERY NO. 15 EMISSIVITY :
LOCATION : SWITCH ROOM 1 TIME:

ANALYSIS DETAILS

IMAGE POINT IMAGE POINT DESCRIPTION IMAGE POINT TEMP Tamb

POINT 1 BATTERY TERMINAL POST 78.0ºC 54.0ºC
POINT 2 CABLE INSULATION 62.0ºC 38.0ºC
POINT 3 LOCALISED AMBIENT 24.0ºC 4.0ºC
POINT 4

COMMENTS

Fault / Cause: Battery terminal hot due high resistance internal connection between terminal post
and battery plates.

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 Mechanical Problems

Recommendations: This is a sealed-for battery and should therefore be replaced.

Note: Internal temperatures will be higher than those measured.

Therefore, this recommendation should be undertaken at the earliest opportunity.

THERMOGRAPHIC SURVEY REPORT SHEET FOR BUILDING A

LOCATION: RIM 1 REPORT DATE: 08/03/04 DISK NO.
IR FRAME CAMERA MAINT RESULT
TIME PLANT DESCRIPTION FAULT DESCRIPTION/COMMENTS
NO. FRAME NO. ID NO. CODE*
1 1 10.15 1 DFB 12 CCTS 1 & 2 Y PH. BUSBAR CONTACT SR
LOCATION: ROOM 6
2 DFB 49 S
3 DFB 7 S
LOCATION: MAIN M/C SHOP EXTRACT
4 EXTRACT FAN (BEARINGS) S
5 EXTRACT FAN (MOTOR 1) S
6 EXTRACT FAN (MOTOR 2) S
7 DFB E54 S

LOCATION: Switchroom 2 REPORT DATE: 08/03/04 DISK NO.

IR FRAME CAMERA MAINT RESULT
TIME PLANT DESCRIPTION FAULT DESCRIPTION/COMMENTS
NO. FRAME NO. ID NO. CODE*
8 DFB EL2 S
9 DFB EL1 S
10 DFB 24 S
ESSENTIAL BUSBARS &
12 S
ASSOCIATED
NON-ESSENTIAL BUSBARS &
13 S
RING MAIN
NON-ESSENTIAL BUSBARS &
14 S
ASSOCIATED
15 DFB E21 S
16 DFB E20 S
2 2 10.30 17 DC SUPPLY TO ETRACT FAN FUSES DC LOAD & FILTER TOP SR

DISK
LOCATION: Plenum Plantroom (Rm 726) REPORT DATE: 08/03/04
NO.
IR FRAME CAMERA MAINT RESULT
TIME PLANT DESCRIPTION FAULT DESCRIPTION/COMMENTS
NO. FRAME NO. ID NO. CODE*
18 PLENUM FAN 15 (BEARINGS) S
19 PLENUM FAN 15 (MOTOR 1) NOT RUNNING NS
20 PLENUM FAN 15 (MOTOR 2) S
21 CALORIFIER PUMP NO. 1 NOT RUNNING NS
22 CALORIFIER PUMP NO. 2 S
LOCATION: SWITCHROOM 1
23 DFB E2 S
24 ESSENTIAL BUSBARS & ASSOCIATED S

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 Mechanical Problems

25 NON-ESENTIAL BUSBARS & ASSOCIATED S

3 3 11.00 26 BATTERY CHARGER CONTRL PANEL MAIN LOAD FUSES SR

SURVEY RESULT CODES: S (Surveyed) = Object surveyed and found to be free of abnormalities
NS (Not Surveyed) = Object no surveyed (ie not running or unavailable)
SR (Surveyed & = Object surveyed and abnormalities found which will
Reported) feature in the report

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 Mechanical Problems

THERMOGRAPHIC SURVEY REPORT SHEET FOR BUILDING A

LOCATION: Refrigeration Plantroom REPORT DATE: 08/03/04 DISK NO.
MMS
IR FRAME CAMERA FAULT RESULT
TIME OBJECT PLANT DESCRIPTION
NO. FRAME NO. DESCRIPTION/COMMENTS CODE*
NO.
27 WATER PUMP NO.3 MOTOR AND STARTER NOT RUNNING NS
28 CHILLED WATER PUM NO.1 MOTOR AND S
29 CHILLED WATER PUMP NO.3 MOTOR AND S
LOCATION: COMPRESSOR HOUSE
30 BREATHING AIR COMPRESSOR A NOT RUNNING NS
31 BREATHING AIR COMPRESSOR A CONTROL NOT RUNNING NS
32 BREATHING AIR COMPRESSOR B S
4 4 11.15 33 BREATHING AIR COMPRESSOR B CONTROL KM3/F4 OVERLOAD INTERFACE
34 MCB 1 S
35 MCB 2 S

LOCATION: Extract Plantroom REPORT DATE: 08/03/04 DISK NO.

MMS
IR FRAME CAMERA RESULT
TIME OBJECT PLANT DESCRIPTION FAULT DESCRIPTION/COMMENTS
NO. FRAME NO. CODE*
NO.
43 FAN NO. 9 (BEARINGS) S
44 FAN NO. 9 (MOTOR NO.1) S
45 FAN NO. 9 (MOTOR NO.2) NOT RUNNING NS
46 FAN NO. 10 (BEARINGS) S
47 FAN NO. 10 (MOTOR NO.1) UNDERS SIZED MOTOR S
48 FAN NO. 10 (MOTOR NO.2) UNDER SIZED MOTOR S
5 5 11.30 49 FAN NO.20B (BEARINGS) NDE BEARING HOT SR
50 FAN NO.20B (MOTOR) S
51 FAN NO.20A (BEARINGS) NS
52 FAN NO.20A (MOTOR) NS

LOCATION: Corridor Switchroom REPORT DATE: 08/03/04 DISK NO.

MMS
IR FRAME CAMERA RESULT
TIME OBJECT PLANT DESCRIPTION FAULT DESCRIPTION/COMMENTS
NO. FRAME NO. CODE*
NO.
SWITCHGEAR TRIPPING
6 6 10.45 53 BATTERIES
BATTERY 15 (HOT TERMINAL POST) SR
54 DFB E14 S
55 DFB 11 S
56 DFB 8 S
57 DFB 5 S
58 DFB 7 S

SURVEY RESULT CODES: S (Surveyed) = Object surveyed and found to be free of abnormalities
NS (Not Surveyed) = Object no surveyed (ie not running or unavailable)
SR (Surveyed & = Object surveyed and abnormalities found which will
Reported) feature in the report

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 Mechanical Problems

SAMPLE THERMOGRPHY REPORT – B

THERMOGRAPHY SURVEY REPORT

REPORT NO: SIS/IR/R-64 DATE 19.06.2009

M/S. ICICI Lombard General Insurance

Company Ltd.
CLIENT NAME
Zenith House, keshavrao Khade Marg,
Mahalaxmi, Mumbai 400034

SITE Glenmark Pharmaceuticals Ltd, Nashik.

JOB TYPE TRANSFORMER

IR CAMERA MODEL FLUKE TI 32

TEMPERATURE RANGE -20°C to 350°C

IFOV 3 Millie radian at 1meter

EMISSIVITY USED 0.98

AMBIENT TEMPERATURE 33ºC

MEASURED TEMPERAURE 47.6ºC

INCREASE IN TEMPERATURE 14.6ºC

RELATIVE HUMIDITY 74%

DISTANCE 2 meter

MAX.DISTANCE 6 meter

SPAN 40°C to 50ºC

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 Mechanical Problems

The following report concerns a thermographilc survey of

• Liquid Bottle Manufacturer Machine,
• Table Packing Machine,
• Boiler,
• AHU (Air Handling Unit),
• Transformer1250kva,
• Electrical Control Panels,
• Air Compressor

for Total Factory Within GLENMARK PHARMACETICAL LTD.

The survey was conducted on June 19 2009 and examined all available above
mentioned in GLENMARK PHARMACETICAL LTD.
It should be noted that this report is limited in its scope, due to the operational
characteristics of the plant.

Where reference is made within the report concerning suspected poor

connections it does not necessarily mean that the connection is loose. Other
causes could be broken crimp connections, insufficient wire within the connector,
over tightened terminals or poor contact due to insulation material being trapped.
It is always advisable to remake the connection rather than just tighten, to ensure
the problem has been rectified.

The thermographic instrument used was a Fluke Ti 32, Professional. Each image
captured was with a nominal emissivity of .98 and target distance of 1 to 2 meter.

All visual images were captured using the Soni Cybershot 10 Mega pixel Camera
for best clarity

Green No Problem
Yellow Problem Exist – Monitor Further
Orange Serious Problem – Attend to it at the Earliest Opportunity
Red Critical Situation – Red alert. stop operation – Repair Immediately

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 Mechanical Problems

STANDARD SEVERITY CHART: FOR ELECTRICAL APPLICATION

TEMPERATURE RISE
SITUATION REPAIR PRIORITY
ABOVE AMBIENT
Immediate repairs required
Greater than 80ºC Acute overheating
Priority A
Excessive Repair as soon as possible
60ºC to 80ºC
overheating Priority B
Monitor closely
Second stage of Should be attended to at the first
40ºC to 60ºC
overheating opportunity
Priority C
Should be monitored and repaired
First stage of
20ºC to 40ºC during next scheduled maintenance
overheating
Priority D
Any way monitor routinely
10ºC to 20ºC No Problem
Priority E
Continue Normally
Less than 10ºC Normal
Priority F

LOCATION: TRANSFORMER
IDENTIFICATION: OIL TANK VALVE & FLANGE

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 Mechanical Problems

CLASSIFICATION OF SERIOUNESS Priority E

There is Thermal anomaly. But No Alarm.

FINIDINGS
Monitor routinely

REMARK Any way monitor routinely

The temperature rise is normal. So

SUGESSTION
operation can be continued

THERMOGRAPHER NAME Royston Angelo Victor

THERMOGRAPHER CERT. NO. SIS/F.NO-196

Approved By :

(K. RAVINDRAN MSc., DIP., RP)

ASNT LEVEL – III PT, MT, RT, VT, UT, LT, ET, IR, AE, NR & VA.
ID No : 141151

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 Mechanical Problems

ABSOLUTE TEMPERATURE CRITERIA

APPENDIX A:

ABSOLUTE TEMPERATURE CRITERIA BASED ON BRITISH AND

EUROPEAN STANDARDS

The following temperature criteria have been drawn from the standards to
provide general guidance for maximum operating temperatures for electrical
components and materials.
Only the information considered relevant to interpreting temperatures for thermal
imaging has been included. The original standard should be referred to where full
details are required.

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 Mechanical Problems

MAXIMUM
MAXIMUM TEMPERATURE RISE
DESCRIPTION OF
COMPONENT
TYPE TEMPERATURE (°C) RELATIVE TO AN STANDARD
(°C) AMBIENT
TEMPERATURE OF 40°C

CONDUCTORS Copper: BS 7671

70°C PVC (general (IEE Wiring
70
purpose) Regulations 16 Ed)
90°C PVC 90
60°C rubber 60
85°C rubber 85
90°C thermosetting 90
Impregnated paper 80
Mineral – plastic
covered or exposed to 70 (sheath)
touch.
Mineral – bare and
neither exposed to
touch nor in contact 105 (sheath)
with combustible
materials.
Aluminium:
70°C PVC (general
70
purpose)
90°C PVC 70 90
60°C rubber 90 60
85°C rubber 60 85
90°C thermosetting 90
Impregnated paper 80

LV switchgear and Bare copper 60 BSEN 60947-1

control gear, terminals Bare brass 65
Tin plates copper or
65
brass
1
Silver plated or nickel 701
Plated copper or brass
Other metals 2
Terminals for external
insulated
70 BSEN 60439-1
Conductors for
assemblies
LV switchgear and
Terminal for external
control gear, circuit- 80 BSEN 60947-4-1
connections
breakers

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MAXIMUM TEMPERATURE
MAXIMUM
DESCRIPTION OF RISE (°C) RELATIVE TO AN
TYPE TEMPERATURE STANDARD
COMPONENT AMBIENT TEMPERATURE
(°C)
OF 40°C

LV switchgear and
control gear switches,
dis-connectors, switch BSEN 60947-1 BSEN 60947-3
dis-connectors and
fuse-combination units
3
Insulated coils in air :
A 85
E 100
B 110
LV switchgear and F 135
control gear
H 160
electromechanical 3 BSEN 60947-4-1
Insulated coils in air :
contactors and motor-
A 60
starters
E 60
B 60
F -
H -
LV switchgear and
control gear contactors
and motor starters, AC As BSEN 60498-1 BSEN 60947-4-2
semi-conductor motor
controllers and starters
Terminals insulated
coils in air
LV switchgear and As BSEN 60947-1
Temperature class of
3
control gear, multiple insulation
function equipment, A 85 BSEN 60947-6-2
control and protective E 100
switching devices (or
B 110
equipment) (CPS)
F 135
H 160
Unenclosed/enclosed
Bare copper 55/60
Bare brass 60/65
LV fuses, terminals BSEN 60269-1
Tin plated 65/65
1 1
Silver or nickel plated 70 /70

Unenclosed/enclosed
Bare copper 40/45
LV fuses, contacts, Bare brass 45/50
BSEN 60269-1
spring loaded Tin plated 55/60
4 4
Nickel plated 70 /75
4 4
Silver plated /

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 Mechanical Problems

MAXIMUM
MAXIMUM TEMPERATURE RISE
DESCRIPTION OF
COMPONENT
TYPE TEMPERATURE (°C) RELATIVE TO AN STANDARD
(°C) AMBIENT
TEMPERATURE OF 40°C
Unenclosed/enclosed
Bare copper 55/60
Bare brass 60/65
LV fuses, contacts, bolted BSEN 60269-1
Tin plated 65/65
4 4
Nickel plated 80 /85
4 4
Silver plated /
All insulation
classes, immersed 60
in oil.
All insulation
classes, immersed
in oil and 65
hermetically
sealed.
All insulation
classes, immersed
50
Voltage transformers in bituminous
compound.
Different insulation
classes3 not
immersed in oil or 45
bituminous
compound:
Y 60
A 75
B 85
F 110
H 135

As voltage
Current transformers BS 7626
transformers

Residual current-operated Terminal for

70 BS 4293
circuit breakers external conductors

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 Mechanical Problems

MAXIMUM
MAXIMUM TEMPERATURE RISE
DESCRIPTION OF
TYPE TEMPERATURE (°C) RELATIVE TO AN STANDARD
COMPONENT
(°C) AMBIENT
TEMPERATURE OF 40°C
Terminals of circuit-breakers Relative to ambient
BS 842
fitted with copper contacts. temperature of 35°C
Terminals of circuit-breakers
fitted with contacts having
adequate and durable facings of
35
silver or similar materials not
subject to progressive
deterioration.
Handles, operating devices and
parts of enclosures likely to be
50
handled when operating the
circuit-breaker.
Earth-leakage circuit
breakers Different classes of insulating
3
material not likely to be handled
35
in service, including that of the
leakage trip coil:

Y 55
A 70
E 85
B 95
F 120
H 145

Temperature class of Insulation system

3
insulation : temperature.
A 60 105
E 75 120
B 80 130
BSEN
Transformers, dry type F 100 155
60076-25
H 125 185
C 150 220
Core, metrical parts and
6
adjacent materials

Transformers, oil- Windings, temperature class of

immersed type insulation A:
Oil circulation natural or forced
65
non-directed.
Oil circulation forced and
70
directed.
Top oil temperature rise. 60
Cores, electrical connections 7
Outside the windings, structural

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 Mechanical Problems

parts in the tank

MAXIMUM
TEMPERATURE
MAXIMUM
DESCRIPTION OF RISE (°C) RELATIVE
TYPE TEMPERATURE STANDARD
COMPONENT TO AN AMBIENT
(°C)
TEMPERATURE OF
40°C
Manual operating means: BS 7671 temperature
metallic 55 15 BSEN 60947-1
Non-metallic 65 25 temperature rise
Parts intended to be
touched but not hand-
held:
Metallic 70 30
Non-metallic 80 40
Accessible parts Exteriors of enclosures
adjacent to cable entries:
Metallic 80 40
Non-metallic 90 50
Exteriors of enclosures for
200
resistors.
Air issuing from ventilation
openings of enclosures for 200
resistors.
Manual operating means: BSEN 60947-2
Metallic 25
Non-metallic 35
Parts intended to be
touched but not hand-held
Metallic 40
Accessible parts
Non-metallic 50
Circuit-breakers
Parts which need not be
touched for normal
operation:
Metallic 50
Non-metallic 60

Manual operating means: BS 4293

Accessible parts,
residual
Metallic 30
current-operated
circuit-breakers Non-metallic 40
Other external parts
50
accessible in service

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ANNEXRURE A
IR BEAUFORT W IND SCALE
• Calm air: less than 0.5 m/sec Smoke motion vertical
• Light air 0.5 to 1.3 m/sec Smoke change direction
• Light breeze 1.8 to 3.1 m/sec Leaves move and wind felt in the face
• Gentle breeze 3.6 to 5.4 m/sec Small twigs move, Flag unfold
• Moderate breeze 5.8 to 8.1 m/sec raises paper ,dust etc. Branch moves
• Fresh breeze 8.5 to 10.7 m/sec Small tree sway, circular waves form water.

WIND CORRECTION FACTOR

IR WIND SPEED CORRECTOR

Out-DOOR

Wind Speed (meters /sec) Correction

1 (or less) 1.00
2 1.36
3 1.64
4 1.86
5 2.06
6 2.23
7 2.40
8 2.54
9 (or more) NOT Recommended

183