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2Table of Contents
Introduction to Condition-Based Maintenance 04
Infrared Inspection Methodologies 06
Heat Transfer 08
Balancing Safety with Performance 10
Safer, More Efficient Electrical Inspections 12
Wide Range of EMSD Products 14
FlexIR for Isophase and Bus Bar Systems 18
Installation Services 22
Delta T Wireless Temperatue Monitoring 24
SMART Training 26
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“Condition-Based Maintenance (CBM) is maintenance conducted when the need arises. This maintenance is performed after one or more indicators show that equipment is going to fail or that equipment performance is deteriorating.”
Introduction to Condition-Based Maintenance (CBM)
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Being able to assess the condition of critical electrical assets by observing the state of the energized system is imperative for continuous operation. It allows maintenance engineers to prioritize and optimize resources by helping them identify what maintenance is required and determine the urgency level of the equipment fault; thus minimizing parts cost, system downtime and time spent on unnecessary maintenance.
There are many types of equipment used in condition monitoring of electrical assets including:
• Infrared (IR) cameras to monitor temperature• Ultrasound equipment to listen for arcing, tracking or corona• Vibration analyzers • Motor current analyzers (MCA)
The above condition monitoring equipment has one thing in common. It allows operators to monitor the actual condition of an electrical distribution system and gives the operator a physical reading of the condition of the asset while operating under load and in its duty cycle. These readings are compared against predetermined alarm limits which when breached, determine what actions are required to bring the asset back into an acceptable operating condition.
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Many engineers use infrared cameras to scan the outside of switch gear, bus bar, etc, in an attempt to determine the condition of internal components; this is known as indirect temperature measurement. The problem with this type of inspection technique is that even if you see a temperature anomaly on the outside of the equipment you are inspecting, it doesn’t show you what type of fault you may have (which may not be a fault at all) and what the actual temperature is at the source of the defect.
This type of inspection technique is extremely difficult and is really not ideal for managing critical assets. Nevertheless in some circumstances, this is all that we have available due to current construction techniques of electrical distribution equipment. Unfortunately, normally by the time you see any type of temperature profile changes with an IR camera outside of the equipment on the external surface, the damage within the enclosure is probably excessive and beyond repair.
Indirect vs. Direct Temperature Measurements
Infrared Inspection
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Heat Transfer Diagram
Fig. 1 below shows how heat transfers through the mediums of:
• Conduction: Heat transfer through a material (solid, liquid or gas)
• Convection: Heat transfer due to bulk movement of a fluid, occurs in liquids or gases
• Radiation: Heat transferred through electromagnetic wave such as sun light, campfire, etc.
Heat (thermal energy) always moves from a hot surface to a cooler surface. This is known as heat transfer.
The most difficult mode of heat transfer losses to calculate is the heat loss through convection and radiation. The diagram (Fig. 2) shows heat transfer (Tx) from hot surface (A) to cooler surface (B) across an air gap (X). Trying to calculate tempera-ture losses is difficult because there are really too many vari-ables. You will need to know the following:
1. Emissivity of oxidized metals A & B2. Reflected apparent temperature between A & B3. Air Gap (X)4. Surface area of A & B
Heat Transfer
Conduction
Convection
Radiation
*The internal air gap within electrical equipment acts as an insulator. Before an IR camera can detect a noticeable temperature difference on the outside panel covers, the heat energy generated by the fault has to travel across the air gap and warm the outer cover of the system which is typically a large mass of metal. If the equipment you’re inspecting is outside, the temperature readings are influenced by the environmental effects of atmospheric heating or cooling due to wind, snow, rain, and ice.
Fig 1. Fig 2.
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Direct temperature measurements are the only efficient way to collect conclusive evidence on the condition of the electrical equipment. Previously, direct temperature was gathered by suiting up in heavy PPE and removing covers on energized electrical equipment which is both dangerous & time consuming. Installation of Electrical Maintenance Safety Devices (EMSDs) now provides maintenance engineers instant access to perform direct measurements and to assess the condition of the internal components of electrical equipment.
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Every year thousands of electrical workers are injured or even killed while at work. Safety and trade organizations around the world are enforcing that workers do not open electrical switchgear for maintenance activities unless it is put into a safe work condition, the proper engineering controls are used and the appropiate level of safety and equipment training is given to everyone involved in the maintenance operation.
In the USA and Canada, the National Fire Prevention Association (NFPA) and Canadian Standards Association (CSA) are at the vanguard of driving a cultural change within the global electrical maintenance industry with the NFPA 70E/70B and CSA Z462/463 standards and guidelines.
Electrical Maintenance Safety Devices (EMSDs)
1. According to accepted electrical maintenance practices infrared inspections should always be completed on energized electrical equipment while under load to ensure the data is an accurate reflection of the equipment’s condition.
2. Infrared inspections can only be completed through specialized IR lens materials. Some of these materials have good IR transmission but are mechanically weak and very susceptable to damage through impact! IRISS polymer lens solutions offer the most durable cost-effective optic options available.
3. The most efficient way to perform a safe infrared inspection of electrical assets is by utilizing EMSDs to ensure that electrical enclosures remain in a fixed & guarded condition. This ensures that engineers are never exposed to the dangers of arc flash or electrocution.
Balancing Safety with Performance:
Three Irrefutable Facts about Infrared Inspections of Electrical Equipment
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Requires only one person vs. two or three.
Minimizes need for restrictive PPE.
Maintain an enclosed & guarded condition of electrical assets and reduce arc flash triggers.
IRISS IR WindowsSafe Perform IR scans without opening enclosures. Virtually eliminating arc flash hazards.
EfficientInspect a panel in seconds, not 30+ minutes.
SimpleEnsure only authorized personnel gain entry.
Use of Electrical Maintenance Safety Devices (EMSDs) such as infrared windows, ultrasound ports, voltage detection ports and online monitoring, allow energized electrical maintenance tasks to be completed while switchgear enclosure remains closed. The IRISS family of (EMSDs) includes the world’s first industrial grade infrared windows. Infrared windows are capable of meeting OSHA’s NFPA 70E and CSA Z462 requirements for arc flash safety and are UL, cUL and CSA certified.
IRISS, For Safer, More Efficient Electrical Inspections
Inspect More Often, on Your Schedule with Instant Access
Depend on IRISS for All of Your IR Inspection Support Needs to Save You Time and Money
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Wide Range of EMSD Products
CAP SeriesLarger Area Provides Easier Inspections.
VP SeriesTraditional Round with Modern Technology.
Ultrasound SeriesCombination Infrared Window / Ultrasound port. Provide 30% increase in FOV over round IR Windows and equiped to provide quality accoustic detail.
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Custom SolutionsDesigned to Fit your Application (Shape, Color, Private Label, and More).
Flex IR / CAP-FIsophase bus bar windows specifically designed for the power generation and power user market.
Provide innovative means of monitoring the heartbeat of your facility-your electrical system. Flex IR / CAP-B
Custom-sized for non-segmented bus bar to allow full visual, ultraviolet and infrared inspection of electrical connections while under full load.
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CertifiedThe most certified product lines in the market today. All IRISS products comply with UL, cUL, CSA, IEEE, IP65/NEMA 4, BSI, ABS, DNV and Lloyds of London certifications.
Visual, UV, IR Inspections All Through One IR WindowPoly-View System™ technology available in Platinum Series and
VersatileWorks with all infrared and ultraviolet cameras for low, medium, and high voltage equipment located indoors or outdoors.
Fixed and Stable Transmission (FAST)Our non-degradable polymer lens systems eliminate the need to recalculate transmittance on a regular basis.
Durable DesignOur impact-resistant designs and industrial-grade optics with reinforced grills are IEEE, UL and CSA compliant and fail-safe to IP2x standards. Our lens solutions allow for complete flexibility in our designs giving engineers options never thought possible until now.
IRISS polymer optics do not degrade when exposed to acids, alkalis, UV, moisture, humidity, vibration, and high frequency noise – a guarantee no crystal IR window can provide.
Protected by Our Unconditional Lifetime Warranty
IRISS Polymer IR Windows offer NFPA 70E / CSA Z462 compliance without compromising product performance
Award-winning,
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CAP-C-B Infrared window in use
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Inspect the Uninspectable
The power generation industry has the most vigorous electrical preventative maintenance (EPM) programs in the electrical maintenance industry. Their programs have to be better, more efficient and safer than that of their customers, and their customers demand this. There is however some areas within a critical system that leave the power generation extremely vulnerable due to inaccessibility issues, one of these areas is the isophase bus, bus way and bus bar systems.
These systems are the only critical components within the plant that usually have no redundancy and no quick replacement solutions. EMSDs such as FlexIR range of product lines are extremely useful in helping asset owners identify issues before outages, allowing for more efficient outage planning and prioritization of needed repairs.
Traditionally, the internal components of isophase bar bus systems are impossible to inspect under load because they do not have covers over each of the joints that can be easily removed. In most cases, maintenance engineers would need to schedule or wait for the next shutdown to safely de-energize, cut open the bus, inspect/repair the joint and then weld in a new cover.
Before embarking on this expensive, time consuming operation, you must make sure that your diagnosis is correct. Currently isophase bus infrared inspections are completed using indirect inspection techniques looking at the outside of the bus bar (Image 1).
FlexIR for Isophase and Bus Bar Systems
Image. 1
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Isophase Bus Heat Transfer Diagram Isophase Bus Heat Transfer Diagram through FlexIR EMSD
Inserting a FlexIR EMSD into the isophase bus system opposite the bus joint will enable the maintenance engineer to complete a visual and infrared scan while under full load at any time thus ensuring that all faults are easily identified and assessed for repair.
The IRISS FlexIR system for isophase and bus bar systems is a large format infrared and visual inspection window that is specifically designed for the power generation and large power user market. The window design also acts as an access port for repairs, once the system is de-energized it can be easily removed to allow the engineer access to repair the fault. Once refitted the isophase system can be re-energized and the repaired joint can be inspected to check the repair was effective, thus this unit is multi-faceted being a visual, ultraviolet and IR inspection window that can be used as an access and maintenance point.
Indirect Temperature Direct Temperature
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CAP-C-FInfrared window in use
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IRISS FlexIR window systems should only be installed by individuals that have been trained and certified by IRISS. Properly trained installers know how to position and set-up your IRISS infrared windows and EMSDs correctly. Your IRISS Certified Installer and specialist isophase bus system (IPBS) welders and installation teams will know all the critical steps needed to efficiently install your EMSDs and all relevant inspection parameters such as infrared target identification, emissivity and transmission rates are pre-determined for you to ensure you perform your surveys accurately while using your IRISS infrared windows and EMSDs.
Installation Services
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This graph illustrates how the Delta T temperatures decrease on the weekends as well as the 3-day Thanksgiving weekend when load is minimal.
Thanksgiving weekend
100°F
80
60
40°F
Delta T monitoring
Delta T Wireless Temperature MonitoringAll IRISS IR windows can be equipped with our patented Delta T wireless temperature monitoring system. The Delta T system measures the difference between the external ambient temperature and internal temperature at the joint location. When the temperature differences are above a pre-determined level or significantly different from other joint temperatures, the Delta T system will remotely alarm the maintenance engineers and repair teams with the temperature readings and the location of the anomaly.
The maintenance team can go to the identified location and safely perform a visual and infrared inspection of the joint under load to diagnose the cause of the alert. If repairs are needed, the infrared window can be removed once the system is safely shutdown. Once necessary repairs are completed, the system is then re-energized, tested and then the joint can be benchmarked and system reset with new baseline temperature delta.
Delta T systems are not just for isophase and bus bar systems, they are used in a vast variety of electrical distribution systems, transformers, switchgear, motors, control systems and cabinets.
Room Ambient Temperature EnclosureTemperature
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IRISS Believes Working SMART is Not Hard!The Safety and Maintenance Academy of Reliability Technologies™ (SMART) offers several unique training and certification classes that provide you and your company the knowledge and practical experience necessary to complete your electrical inspections safely and efficiently.
Designed by electricians, for electricians, these hands-on training courses are unlike any other available to date. They not only outline current industry standards and best practices, but also show you how to implement them.
IRISS training classes and products are designed on practical, real-world experience that has been hone with input from our clients, staff and countless hours of designing successful electrical maintenance programs for companies around the globe.
About IRISS SMART Training
Energized Electrical Maintenance Course with Level I or Level II CertificationLearn to safely perform energized electrical inspections with confidence by combining infrared, ultrasonic, and power quality testing technologies to give you the full picture of your assets
IRISS Certified Installer CourseBecome the preferred IRISS certified installer in your region. Grow your client base and revenue. As an IRISS certified installer, customers will turn to you to for the right infrared window in the right place.
Customized On-Site TrainingWith our traveling labs, all SMART training can be done on-site and customized to meet your specific needs.
Our state-of-the-art training center in Bradenton, FL is set up with labs so students can safely learn in a hands-on, experience-driven course.
+1 941 907 9128
iriss.comDesign and specifications are subject to change without notice. IRISS, FlexIR and all related trademarks are trademarks or registered trademarks of IRISS Group and its affiliated
companies. All other trademarks are the property of their respective owner.
© 2014 IRISS, Inc.
US EMEA APAC+44 (0) 1245 399 713
+61 (03) 9872 3000
18-4035-0000 Rev. A is for the FlexIR
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