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PreDiCon Engineering
Predictive Maintenance Report

Report for: Customer

Telephone:
Fax:
e-mail:
Report Date:
Report prepared by:
Wilmar House, 23-25 Windermere
Road
Blackpool FY4 2BX
Tel: +44 (0)1253 400541
Fax: +44 (0)1253 400552
email: [email protected]

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

Area
System
Location

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Predictive Maintenance Work Request

PDC

PreDiCon Ltd.

Maintenance

Thermography
Work Request #

Customer

Priority No

Electrical Distribution

Priority Description

Substation #1

234
1
Within 2 days

Analyst

Ron Frend

Equipment

Transformer #3

Reports Date

20-Feb-02

Component

Connection Box

Inspection Date

20-Feb-02

Analysis and
Comments
Recommendations

While the body of the transfomer is no more than 35'C at any point, the top of the connection box
is showing a high temperature at over 57'C. The most probable casue for this high temperature is
a resistance connection inside the connection box.
Check the connection box internals as a matter of urgency and remake all electrical connections
therein.

Figure #1

Figure #2
59.0C

Transformer Body Top: 26.9C

20
15.6C

Completion Date:
Comments on Completion

Approved for Issue by:

Print Name Above

Sign Above

Issue Date
Please complete this form and return to PreDiCon on completion of work on Fax (01253) 400552

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

Area
System
Location

Maintenance

Priority No
Priority Description

Top left fuse

235
3
When convenient

Analyst

Ron Frend

Reports Date

21-Feb-02

Inspection Date

20-Feb-02

Boiler House

Component

Recommendations

Work Request #

Electrical Distribution

EP713

Analysis and
Comments

Thermography

Customer

Equipment

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Predictive Maintenance Work Request

PDC

PreDiCon Ltd.

The left most fuse on the upper bank is considerably warmer than all others.

The circuit should be checked for load. Then replace the fuse, clean the fuse clips and check
terminations for security.

Figure #1

Figure #2

Fuse: 33.0C

32.2C
32

30

Background: 27.9C

28

26

24
23.6C

Completion Date:
Comments on Completion

Approved for Issue by:

Print Name Above

Sign Above

Issue Date
Please complete this form and return to PreDiCon on completion of work on Fax (01253) 400552

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

Area
System
Location

Maintenance

Priority No
Priority Description

Gearbox

236
2
Within 1 month

Analyst

Ron Frend

Reports Date

21-Feb-02

Inspection Date

20-Feb-02

Mill Room

Component

Recommendations

Work Request #

Conveyors

Elevator E4

Analysis and
Comments

Thermography

Customer

Equipment

re
i

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Predictive Maintenance Work Request

PDC

PreDiCon Ltd.

The input shaft on this gearbox is hot at over 80'C. This is most likely indicative of a bad bearing
or possibly bad gears.

The gearbox should be overhauled.

Figure #1

Figure #2
62.6C

Background: 19.0C
60

50

Input Shaft: 80.1C

40

30

20
18.6C

Completion Date:
Comments on Completion

Approved for Issue by:

Print Name Above

Sign Above

Issue Date
Please complete this form and return to PreDiCon on completion of work on Fax (01253) 400552

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

Area
System
Location

Maintenance

Priority No
Priority Description

Gearbox

237
3
When convenient

Analyst

Ron Frend

Reports Date

21-Feb-02

Inspection Date

20-Feb-02

Underneath Mash Tuns 1/2/3

Component

Recommendations

Work Request #

Mash Tuns

Discharge Screw

Analysis and
Comments

Thermography

Customer

Equipment

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Predictive Maintenance Work Request

PDC

PreDiCon Ltd.

Even though the discharge screw was lightly loaded at the time of measurement, the input shaft
bearings were over 40'C. This is indicative of overloaded bearings or low oil level.

Check the gearbox oil level. If oil level is OK then overhaul the gearbox. On reassembly pay
particular attention to the mounting arrangement for the motor to avoid misalignment.

Figure #1

Figure #2
40.5C
Background: 26.2C

40

Gbx Brgs: 40.5C

30

25
22.5C

Completion Date:
Comments on Completion

Approved for Issue by:

Print Name Above

Sign Above

Issue Date
Please complete this form and return to PreDiCon on completion of work on Fax (01253) 400552

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

Area
System
Location

Maintenance

Work Request #
Priority No

Hot Liquor Ring Main

Priority Description

Component

Motor

238
2
Within 1 month

Analyst

Ron Frend

Reports Date

21-Feb-02

Inspection Date

20-Feb-02

Cellar #2
Hot Liquor Ring Main Pump #1

Recommendations

Thermography

Customer

Equipment
Analysis and
Comments

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Predictive Maintenance Work Request

PDC

PreDiCon Ltd.

The pump drive motor drive end bearing is relatively hot at over 50'C. This could be caused by
over greasing, misalignment or bearing deterioration.

Monitor the bearing temperature in the short term. Arrange to change the motor bearings and
carry out an alignment of the motor to the pump.

Figure #1

Figure #2
Background: 15.1C

Drive End Bearing: 52.0C

54.2C
50

40

30

20
17.1C

Completion Date:
Comments on Completion

Approved for Issue by:

Print Name Above

Sign Above

Issue Date
Please complete this form and return to PreDiCon on completion of work on Fax (01253) 400552

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

Area
System
Location

Maintenance

Priority No
Priority Description

Fuse 18

239
3
When convenient

Analyst

Ron Frend

Reports Date

21-Feb-02

Inspection Date

20-Feb-02

Switch Room G

Component

Recommendations

Work Request #

Electrical Distribution

Panel EP301

Analysis and
Comments

Thermography

Customer

Equipment

re
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Predictive Maintenance Work Request

PDC

PreDiCon Ltd.

This fuse is warmer than all others on this panel. Cause may be load or a resistance connection
or even a bad fuse.

Check the load. If the load is low then replace the fuse and remake all connections including
cleaning the fuse clips.

Figure #1

Figure #2
27.4C
26

Fuse 18: 29.4C

Background: 15.3C

24
22
20
18
16

14.1C

Completion Date:
Comments on Completion

Approved for Issue by:

Print Name Above

Sign Above

Issue Date
Please complete this form and return to PreDiCon on completion of work on Fax (01253) 400552

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

Area
System
Location

Maintenance
Customer

Priority No

Electrical Distribution

Priority Description

Component

Transformer

240
2
Within 1 month

Analyst

Ron Frend

Reports Date

21-Feb-02

Inspection Date

20-Feb-02

Filtration Control Room

Recommendations

Thermography
Work Request #

Equipment
Analysis and
Comments

re
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Predictive Maintenance Work Request

PDC

PreDiCon Ltd.

The bottom right connection on the front of the transformer is hot almost 70'C while the
transformer is only 45'C. The pattern of heat distribution indicates a resistance joint in the
connection block.
Clean and retighten the connections.

Figure #1
Cable temp: 54.1C

Figure #2
65.7C

60

Btm Right Conn: 69.8C

50

40

30
28.4C

Completion Date:
Comments on Completion

Approved for Issue by:

Print Name Above

Sign Above

Issue Date
Please complete this form and return to PreDiCon on completion of work on Fax (01253) 400552

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

Area
System
Location

Maintenance
Customer

Priority No

Electrical Distribution

Priority Description

Component

Contactor CTR01

241
2
Within 1 month

Analyst

Ron Frend

Reports Date

21-Feb-02

Inspection Date

20-Feb-02

Filtration Control Room

Recommendations

Thermography
Work Request #

Equipment
Analysis and
Comments

re
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Predictive Maintenance Work Request

PDC

PreDiCon Ltd.

Connection 59 (behind connection 90) is hot. This is caused by a bad connection with the
consequent resistance causing an increase in temperature.

Remake connection 59. Clean and tighten.

Figure #1

Figure #2
55.3C

50
Conn 59: 58.3C

40

30

25.8C

Completion Date:
Comments on Completion

Approved for Issue by:

Print Name Above

Sign Above

Issue Date
Please complete this form and return to PreDiCon on completion of work on Fax (01253) 400552

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

Area
System
Location

Maintenance
Customer

Priority No

Electrical Distribution

Priority Description

Component

Connection 152

242
2
Within 1 month

Analyst

Ron Frend

Reports Date

21-Feb-02

Inspection Date

20-Feb-02

DAIKIN 1/2/3 Chiller Room

Recommendations

Thermography
Work Request #

Equipment
Analysis and
Comments

re
i

on

Predictive Maintenance Work Request

PDC

PreDiCon Ltd.

Connection 152 appears to have a resistance at the crimp causing a high temperature.

Remake the cable crimp on connection 152. Clean & retighten.

Figure #1

Figure #2
42.0C
40

Connection 152: 42.5C

35

30

25
24.1C

Completion Date:
Comments on Completion

Approved for Issue by:

Print Name Above

Sign Above

Issue Date
Please complete this form and return to PreDiCon on completion of work on Fax (01253) 400552

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

Area
System
Location

Maintenance

Priority No
Priority Description

Contactor CR017

243
2
Within 1 month

Analyst

Ron Frend

Reports Date

21-Feb-02

Inspection Date

20-Feb-02

DAIKIN 1/2/3 Chiller Room

Component

Recommendations

Work Request #

Electrical Distribution

No.1 DAIKIN Compressor Panel

Analysis and
Comments

Thermography

Customer

Equipment

re
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Predictive Maintenance Work Request

PDC

PreDiCon Ltd.

The overloads on this contactor are very hot at over 100'C. This indicates that the overloads are
nearing the end of their life.

Change the overload elements.

Figure #1

Figure #2
91.8C

80

60
Overload: 100.9C

40

20.2C

Completion Date:
Comments on Completion

Approved for Issue by:

Print Name Above

Sign Above

Issue Date
Please complete this form and return to PreDiCon on completion of work on Fax (01253) 400552

Wilmar House
23-25 Windermere Road,
Blackpool FY4 2BX
tel: (01253) 400541
fax: (01253) 400552
email: [email protected]

PreDiCon Ltd.

PDC
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on

Work Request Summary

235

236

Location

Equipment

Component

Substation #1

Transformer #3

Connection Box

Check the connection box internals as a matter of urgency and

Boiler House

EP713

Top left fuse

The circuit should be checked for load. Then replace the fuse,
clean the fuse clips and check terminations for security.

Mill Room

Elevator E4

Gearbox

The gearbox should be overhauled.

Underneath

Discharge Screw

Gearbox

Check the gearbox oil level. If oil level is OK then overhaul the
gearbox. On reassembly pay particular attention to the
mounting arrangement for the motor to avoid misalignment.

Cellar #2

Hot Liquor Ring

Motor

Monitor the bearing temperature in the short term. Arrange to

Switch Room

Panel EP301

Fuse 18

Check the load. If the load is low then replace the fuse and
remake all connections including cleaning the fuse clips.

Filtration

Filter Room PLC

Transformer

Clean and retighten the connections.

Filtration

Filter Room PLC

Contactor CTR01

Remake connection 59. Clean and tighten.

DAIKIN 1/2/3

No.1 DAIKIN
Compressor
Control Panel

Connection 152

Remake the cable crimp on connection 152. Clean & retighten.

DAIKIN 1/2/3

No.1 DAIKIN
Compressor
Panel

Contactor CR017

Change the overload elements.

237 Mash Tuns

238

239 G

240 Control Room

241 Control Room

242 Chiller Room

243 Chiller Room

Description