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Thermography Report

Inspection Site:
Lucky Mining Co.
Rocky Rd
Smithville, NSW


Requested By:
John Seemore

Date of Inspection:
27-10-2006

Reference Number:
2710061

Thermographer:
John Crawford

Thermal Imaging Camera:
Make: FLIR
Model: ThermaCAM E45
Serial: 24307146




REFERENCE NUMBER:2703071


2





INSPECTION GENERAL INFORMATION


This thermographic inspection is designed to assess the performance of all switchgear on site
and to highlight any areas which require attention. Recommendations listed within this report
are given only within our area of expertise and we recommend you discuss the implementation
of remedial works with your maintenance service provider.


Scope

Infrared Thermal Scanning of all electrical switchgear and associated conductors to detect
evidence of equipment operating near or above rated temperatures. Load readings are also
taken of prospective faults to assist in the accurate diagnosis of the prospective fault.
A detailed log of inspected assets is provided which includes a Pass or Fail status. Those items
failing the inspection are reported on through a thermal and digital image, a priority rating &
possible recommended action.
An initial scan of all items is carried out with the Infrared Radiometer set to alarm at
temperatures above 40
o
C. Items displaying temperatures above 40
o
C are further investigated
based on application, equipment type, load measurement & spot temperature readings.


Overview of Fault Priority Ratings

0 No abnormality No Action
1 Alert To be monitored rescan when recommended
2 Severe Repair at scheduled shutdown, not longer than 30 days
3 Critical Repair immediately or as soon as possible
4 Immediate Notification Shutdown & repair immediately
















REFERENCE NUMBER:2703071


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Location: Motor Control Room Page: 3
Section: Relay Compartment Priority: 2
Equipment: Mains indicator lamp, white phase Item: 3


IR Image Visual Image
Ar1
Sp1
22.4
63.1 C
40
60
FLIR Systems


Analysis
Label Value
Sp1 23.6 C
Ar1: Max 59.2 C


Comments
Pilot lamp assembly should be replaced.
Priority Level 2 Repair at next scheduled shut down, no later than 1 month.

REFERENCE NUMBER:2703071


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Location: Motor Control Room Page: 4
Section: MDB-1 Section 1 Priority: 2
Equipment: 160amp Pan A & Pan B Fault Limiting Fuses Item: 10

IR Image Visual Image
Ar2
Ar4 Ar3
Sp1
Ar1
45.8
69.2 C
50
60
FLIR Systems



Analysis
Label Value
Sp1 68.6 C
Ar1: Max 76.4 C
Ar2: Max 76.8 C
Ar3: Max 72.5 C
Ar4: Max 71.1 C


Comments
The fault current limiting fuses are operating at excessive temeratures considering the
operating load of 100 amps per phase. The rating of the fuses are 160amps.
Priority level 2, the fuses & fuse carriers should be replaced at the next scheduled shutdown.

REFERENCE NUMBER:2703071


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Location: Motor Control Room Page: 5
Section: Cable Zone Priority: 1
Equipment: CR3 sub-main circuit breaker terminations Item: 13

IR Image Visual Image
Sp3
Sp1
Sp2
38.3
62.9 C
40
50
60
FLIR Systems



Analysis
Label Value
Sp1 42.5 C
Sp2 49.1 C
Sp3 47.7 C


Comments
All 3 phases are equally loaded at 540amps per phase, phase temperatures should be equal.
Priority Level 1, monitor condition & re-scan in 3 months.
REFERENCE NUMBER:2703071


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Location: Workshop Distribution Board Page: 6
Section: D.B.W.S. Priority: 2
Equipment: Precoat plant circuit breaker Item: 15

IR Image Visual Image
Sp2
Li1
Ar1
Sp1
40.7
68.1 C
50
60
FLIR Systems



Analysis
Label Value
Sp1 49.7 C
Sp2 43.3 C
Li1: Max 63.5 C
Ar1: Max 64.6 C
C
42
44
46
48
50
52
54
56
58
60
62
64
66
68
Label Label Label Label Cursor Cursor Cursor Cursor Min Min Min Min Max Max Max Max
Li1 - 42.2 63.5


Comments
Circuit breaker rating is 25amps, sub circuit cable size is 2.5mm, load current is 21amp per
phase.
The cable size is under rated for the existing load, either the load & circuit breaker size needs to
be reduced or the cable size increased.
Priority Level 2, remedial work should be carried out next scheduled shutdown.


REFERENCE NUMBER:2703071


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Location: Main Switch Board Page: 7
Section: Priority: 2
Equipment: Main Switch MDB-1 Item: 20


IR Image Visual Image
Sp3
Sp1
Sp2
Sp5
Li1
Sp4
45.2
76.4 C
50
60
70
FLIR Systems



Analysis
Label Value
Sp1 71.3 C
Sp2 65.9 C
Sp3 61.3 C
Sp4 57.6 C
Sp5 59.4 C
Li1: Max 71.9 C
C
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
Label Label Label Label Cursor Cursor Cursor Cursor Min Min Min Min Max Max Max Max
Li1 - 65.5 71.9


Comments
Blue phase bus bar on the circuit breaker load side is operating approx. 10 deg C higher than
the adjacent 2 phases, load per phase is 1180amps & balanced within 4%. The temperature
profile indicates the temperature rise origin to be either at the circuit breaker/bus bar
termination point or internal to the circuit breaker. It is recommended the circuit breaker be
removed, inspected & all termination points dressed. The breaker should then be
recommissioned & monitored
Priority Level 2, remedial work should be carried out next scheduled shutdown.


REFERENCE NUMBER:2703071


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LOG OF INSPECTED ASSETS

LOCATION EQUIPMENT ITEM
NUMBER
RESULT
Motor Control Room PLC Cubicle PLC-1 1 P
Motor Control Room Cable termination compartment 2 P
Motor Control Room Relay Compartment 3 F
Motor Control Room MCC-1 4 P
Motor Control Room Contactor Compartment No.2 5 P
Motor Control Room VSI Crusher CR3 6 P
Motor Control Room Crusher Starter CR2 7 P
Motor Control Room Crusher Starter CR1 8 P
Motor Control Room Circuit Breaker Compartment 9 P
Motor Control Room MDB-1 Section 1 10 F
Motor Control Room MDB-1 Section 2 11 P
Motor Control Room MDB-1 Section 3 12 P
Motor Control Room MDB-1 cable zone 13 F
Motor Control Room Distribution Board DBX-1 14 P
Workshop Workshop Distribution Board DBWS 15 F
Main Office Office Distribution Board 16 P
Main Switch Board Mains Connection Section 17 P
Main Switch Board C.T. Section 18 P
Main Switch Board MCR Sub-main connection section 19 P
Main Switch Board Main switch MDB-1 20 F
Main Switch Board Local D.B. mainswitch 21 P
Main Switch Board Local D.B. section 22 P

F Failed inspection P Passed Inspection NIO Equipment Not In Operation
at time of inspection


















REFERENCE NUMBER:2703071


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ACTION TAKEN:




















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