Power Plant Thermography - Part II

Mike Ralph
Exelon Nuclear

ABSTRACT
The infrared camera is a frequently used weapon in the integrated arsenal of Predictive Maintenance
technology. One of these cameras coupled with strong vibration and lubrication programs can help resolve
most equipment problems. Throw in some ultrasonic detection and a good process computer, and today's
PdM specialist is nearly invincible. This paper demonstrates some of the more interesting problems, and the
tools used to identify them and bring them to closure. Faults include a hot spot in a cable connection for a
large chiller, a hot bus bar connection in a critical panel, a complicated compressor issue, and a relatively
small hot spot on a terminal board that could have had severe consequences. Finding these issues early and
scheduling the repairs resulted in significant cost savings and prevented something else that executives and
investors both abhor surprise!

INTRODUCTION
Thermography is one of the mainstays of a strong PdM program. Not only is our program integrated with
other predictive technologies such as vibration and lubrication analysis, it is included in a total effort to
promote maintenance optimization. Once a problem is detected and diagnosed, often using multiple
technologies, a comprehensive approach eliminates the possibility of recurrence and improves the efficiency
of maintenance performed in the future. Our goal is not only to prevent failure, but also to exploit
opportunities for improved cost effectiveness. Achieving this goal requires intense record retention in the
form of case histories. Here are some examples from the component health database.

CASE HISTORY #1 CHILLER CONTROL PANEL HOT SPOT

During routine thermography, some potentially serious hot spots were identified in the control panel of a large
commercial chiller. This chiller utilizes four screw type compressors. A hot spot was identified on the main
power supply, B phase connection. The temperature on the main power supply lead can vary based on load
and compressor sequence. This compressor automatically adjusts to load and brings on additional
compressors based on demand. Since the hot spot was on the supply side, the breaker may not have been
able to prevent failure.

THERMOGRAPHIC OBSERVATION
Figure 1 includes the IR images of the B-phase main power supply connections on the D Turbine Building
Chiller. Delta-T between phases trended up to 57 F. This made it yellow or alert range in the component
health-tracking program. We assumed that the temperature was higher given the insulating wrap installed on
the connection.

154.3F 98.3F

95
140

90

120 85

80
100
75

86.2F 72.5F

Figure 1. Thermogram showing before image of hotspot and post-maintenance image.

InfraMation 2007 Proceedings ITC 121A 2007-05-24

SUMMARY
This issue was identified in June 16th, 2006. The repair was completed and post-maintenance testing
performed on August 29th, 2006. An analysis of the bolted connection indicated that RTV type sealant was
used between the areas of contact, causing a high resistance connection and the subsequent heating of the
connection. Repair instruction procedures were adjusted to eliminate this problem from recurring.

CASE HISTORY #2 HOT SPOT IN DISTRIBUTION PANEL

During routine thermography, a 244F hot spot was identified on a lug to the bus bar for multiple control
power breakers inside a critical panel. The delta-T from similar connections was ~165F, making this a red
component requiring immediate action. The hot spot is difficult to see in the first image of Figure 6 below.
Some covers on the front of the panel had to be removed to see the connection more clearly. The bolt that
holds the lug to the copper bus bar appeared to be visibly loose, and this bolt was carrying most of the
current. This item was detected about one month prior to a refueling outage. The nature of the repair would
have made repair to the connection while online a risky prospect. After assessing the risk, we decided to
complete the repair during the outage rather than waiting for a future outage or attempt the repair while the
unit was online.

106.9F 252.1F
250

100
200

90
150

80
100

74.3F 75.1F

Figure 6. Hot Spot on 125VDC Distribution Bus due to loose bolt.

SUMMARY
This connection would not fail at or below measured temperatures of 600F, which helped to establish an
absolute upper limit for monitoring the connection until the outage began. Thermal testing increased in
frequency, and occurred daily until repairs could be performed. Fortunately, the temperature remained stable
until repairs were completed. Electrical maintenance technicians removed the degraded hardware, cleaned
the connection and installed a new bolt on the lug assembly. Our typical scheduling period for predictive
issues requiring repair during a refuel outage is greater than one year. Unfortunately, we did not meet that
goal in this instance. However, we did identify a potentially serious problem that would likely have resulted in
lost production.

CASE HISTORY #3 CENTRIFUGAL AIR COMPRESSOR

This case history is a good example of using all the weapons in our PdM arsenal to diagnose and solve a
complicated equipment problem. Our station utilizes three centrifugal air compressors. Each compressor has
four rotors (stages) progressively increasing in rpm from 29,000 to 49,000 and is driven by a 500 HP two-pole
motor.

Between February 17, 2005 and March 14th, 2005 seal air pressure as indicated by local gauge and trended
with vibration had increased to 32 psig, which is above the vendor recommended specification for continued
operation. Vibration analysis indicated that all stages were operating acceptably. However, the vibration
level on the fourth stage (49,000 rpm) had trended down to about 50% of the amplitude seen one year earlier,
and the analyst had questioned whether the proximity probe was functioning correctly. The frequency
response and gap voltage were normal. This would become a key observation as the investigation continued.
Thermography indicated normal conditions comparable to the other compressors as indicated in Figure 2,

InfraMation 2007 Proceedings ITC 121A 2007-05-24

although temperature is notably hot on these machines, with Stage 4 typically operating at an external
temperature of 225-230F.

236.9F Stage #3 236.9F

Stage #2

200 200

150 150
Stage #4
Stage #3

100 100

86.0F 86.0F

Figure 2. Thermogram Stage 2 & 3 on the left and Stages 3 & 4 on the right. Stage #4 measured 228F

Figure 3 below demonstrates the downward trend observed prior to the increase in seal air noted in March of
2005. Vibration levels remained normal on three of the four stages, with the only abnormality being the
downward trend on Stage #4. A contingency work order had been prepared earlier based on concern for the
downward vibration trend and some previous observations on another compressor train.

LASA - U-0 SERVICE AIR COMPRESSOR

TREND DISPLAY OF Overall Value

35.0 0SA01C -SPR

5.00 PSIG

0.275 mils on 3/12/04

.30 0SA01C -4TH

Amplitude (Mixed Units)

.12 Mils

.28 0SA01C -3RD

.0800 Mils

.36 0SA01C -2ND

.0600 Mils

.24 0SA01C -1ST

.0600 Mils

Date: 15-Mar-05
0 100 200 300 400 500 600 700 800 Time: 12:59:02
Days: 03-Mar-03 To 11-Apr-05 Amp4: .138

Figure 3. Vibration level on stage four, the highest rpm stage trended downward 50% over one year. Note that
after the compressor rebuild, all values changed establishing a new baseline.

During disassembly and inspection, we noted that the journals of the rotors, especially on Stage #4 and to a
lesser degree on Stage #3, were discolored. A brown material had built up on the rotor and was assumed
that it was oil residue. Laboratory analysis of the material indicated it was composed primarily of
phosphorous and zinc. This machine has a central lubrication system utilizing synthetic oil. This same type
of oil had been used in the machine for over 15 years with no previous adverse effect, but phosphorous and
zinc were a prevalent part of the additive package for this type of oil.

InfraMation 2007 Proceedings ITC 121A 2007-05-24

Figure 4. Photograph of the fourth stage rotor showing journal discoloration.

SUMMARY
When all of the facts were gathered, we determined that a change in the additive package for the oil was the
root cause of the degradation experienced on this compressor. The change in the formulation had occurred
many years earlier and had been properly communicated by the vendor, but we did not recognize that it
would be detrimental to this type of machine. The amount of phosphorous additive was doubled during the
formulation change. Since oil at our station is changed out based on analysis, the effects of the formulation
change were not felt until an oil change out occurred late in 2003.

While the viscosity of synthetic lubricants will remain stable in a high temperature environment, sustained high
temperature can cause additives to plate out on hot surfaces, causing varnish. The vast majority of rotating
equipment would not experience a problem, but centrifugal air compressor rotors operate at extreme speeds
and the bearing clearances are tight at ~0.003 diametric. The layer of varnish actually displaced the limited
bearing clearance that was available, causing the vibration amplitude to trend down over time. When the
clearances became too tight, the bearing wiped and damaged the air seal causing air seal pressure to
increase above the limit.

This was a good example of using all the PdM tools available, including work history, to diagnose a problem
and provide a permanent solution. The oil was changed to a mineral based type of the same viscosity with
little or no additives. The frequency of oil changes may increase, but reliability of the compressors has
improved.

CASE HISTORY #4 MINOR HOT SPOT?

The following item is a good example of a problem that on the surface, appears to be minor in nature. The
risk of failure is low, but the consequences are high. We identified this hotspot through an annual inspection.
In many cases the control instrumentation of large breakers is just as important as the breaker itself. The
temperature observed was 5.5F delta-T from other terminal board connections. Most likely, this fault was
caused by a loose terminal screw or inadequate lug crimp connection. This circuit provides amp indication in
the panel and plant control room. Failure of this connection would cause a loss of amp indication and could
affect the trip function of the breaker. The trip function of the breaker not only protects the load but also the
bus. Loss of the trip function could put many large components at risk in addition to the primary load.

InfraMation 2007 Proceedings ITC 121A 2007-05-24

 85.5F

84

82

80

78.9F

Figure 5. Terminal Board connection in control panel for switchgear breaker.

SUMMARY
During inspection electricians found the terminal screw loose approximately one-quarter turn. Temperature
on the connection returned to normal after corrective maintenance was completed.

ABOUT THE AUTHOR

Mike is a Level II Thermographer, Level II Vibration Analyst, and Level II Lubrication Analyst and has been
using these technologies for nearly 18 years.

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InfraMation 2007 Proceedings ITC 121A 2007-05-24