Infrared Thermography

Electrical Case Study

Heating of a Main Breaker

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 Situational Specifics

„ Annual Electrical Infrared Inspections have

been performed since 2001
„ Electrical Contractors have been called in
to assist in some of the repairs
„ A Follow-up Inspection was performed
after the 2nd year
„ 480 Volt 450-600 Amp Fused Disconnects

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600 Amp Fused Disconnect

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 2001 Infrared Inspection Results
Bucket 1
This is One of 4 Issues Found that will be shown traced throughout the
Case Study Time Period.
Note the
Temperature Repair Recommendations
Scale Inspect fuses for loose or fatigued
indicating the clips, corrosion build up, incorrect
temperature connection and bolt installations
of panel and and types, and improperly torqued
room connections. Insure clip tension and
connection torque is set to
manufacturer's recommendations.
Check amperage loads for
overloading and imbalance. Balance
if the load difference exceeds 5% of
the total load value. All fuses are
operating at a higher temperature
than they should be.

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2002 Infrared Inspection Results
Buckets 2 and 3
228.4°F
„ 2 of the Panels that
220

Panel Temperature: 120.3°F

200
continued showing an
Bad Connection: 226.8°F

180
issue the following year.
160
„ Panel Temperature again
Good Connection: 152.4°F
140
above 100 degrees F
120
117.1°F
156.5°F
Repair Recommendations
There is a suspected issue with the
150
connections behind the buckets;
Bad Connection: 153.8°F 140 possibly a loose connection to the
buss bar. Remove the bucket and
130
inspect the connections to the buss
Good Connection: 132.1°F 120
bar. In addition, inspect the
connections of the buss bar for
114.6°F
looseness and corrosion buildup.
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2002 Follow-up Infrared Inspection
Bucket 3
Original Issue in August 156.5°F

Repair Recommendations
150
There is a suspected issue with the
Bad Connection: 153.8°F 140
connections behind the buckets;
possibly a loose connection to the
130 buss bar. Remove the bucket and
inspect the connections to the buss
Good Connection: 132.1°F 120
bar. In addition, inspect the
114.6°F connections of the buss bar for
Follow-up in September 177.0°F
looseness and corrosion buildup.
Bad Connection: 172.6°F Additional Recommendations
160
The room temperature is above normal for
an electrical room and is causing the switch
140
gear to operate above normal also. Add
external cooling to this room to lower the
120
temperature and humidity level in the room.
This will increase the efficiency of your
100
Panel Temperature: 105.4°F
electrical system.
93.4°F

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 2004 Infrared Inspection Results

Bucket 1 232.1°F

220
ood Connection: 157.0°F
200

180
Panel Temperature: 107.6°F

160

Bad Connection: 236.2°F 140

120 173.3°F
114.0°F

Repair Recommendations 160

There is a suspected issue with the

Bad Connection: 172.9°F
connections behind the buckets; 140
possibly a loose connection to the buss
bar. Remove the bucket and inspect
the connections to the buss bar. In 120

addition, inspect the buss bar

connections for looseness and Bucket 3 105.5°F

corrosion buildup. Predictive Maintenance Technologies

 Repair Cost Analysis
Cost Justification for Immediate Repair
600Amp Bucket– Heating show Loose Bus Connection
Estimate Cost for Repairs at Estimated Cost for Repairs Cost Savings of
Current Condition: after Failure: Maintenance Action Now:
Motor Control Center
Misc. Bolts and Parts
Material Repairs $19,800
$200
$20,000
2 Company Mechanics x 6 2 Company Mechanics x 16
hours removal, replacement hours removal, replacement
Labor $1,650
and alignment @ O/T rate and alignment @ O/T rate
$990 $2,640
Unplanned 30 Hours @ $3,000
$0 $90,000
Downtime $90,000

Total Savings for Maintenance Actions Performed Now: $111,450.00*

Other Cost Factors to Consider: Power Consumption, Personnel Injury Costs
*These numbers were calculated using industry standards for an approximate equipment size. These may
need adjustment to fit your specific equipment. You are strongly encouraged to use your own numbers or
contact Predictive Maintenance Technologies for a more specific cost justification.

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 Testing Cost Analysis

„ A Return On Investment of $20.77 was possible if the

issue would have been correct in the beginning.

Repair Before Complete Repair After Complete

Failure Failure

Repair Costs $ 1190 $ 21,450

Difference $ 20,260
Cost of Annual Infrared Inspection $ 975

Return on Investment (Per Dollar Invested) $ 20.77

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