Infrared Thermal Imaging Survey Procedure for Electrical Equipment

NIL-STD-2194(SH)
12 February 1988
MILITARY STANDARD.
INFRAREDTHERMAL IMAGING SURVEY PROCEDURE
FOR
ELECTRICALEQUIPMENT
)
AMSC N/A
FSC 5855
DISTRIBUTIONSTATEMENTA Approved for public release;distributionunlimited
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MIL-STD-2194(S11)
12 February 1988
DEPARTMENTOF DEFENSE
NAVAL SEA SYSTEMS COMMAND
Washington,DC 20362-5101
InfraredThermal ImagingSurvey Procedure for ElectricalEquipment
1. This Military Standard is approved for use by the Naval Sea SystemsCommandj
Departmentof the Navy, and is available for use by all Departmentsand Agencies
of the Departmentof Defense.
2. Beneficialcomments (recommendations,additions,deletions)and any per-
tinent data which may be of use in improvingthis document should be addressed
to: Commander,Naval Sea Systems Command, SEA 5523, Departmentof the Navy,
Washington,DC 20362-5101by using the self-addressedStandardizationDocument
ImprovementProposal (DD Form 1426) appearingat the end of this documentor by
letter.
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NIL-STD-2194(SH)
12 February 19S8
COhqENTS
Page
I
)
Paragraph 1.
1.1
2.
2.1
2*2
3.
3.1
3.2
3.3
3.4
3*5
3.6
3.7
3.8
3.9
3.10
5.
5.1
I
5.2
5.3
5.4
5.4.1
5.4.1.1
5.4,1.2
5.4.1.3
5.4.1.4
5.4.2
5.4.3
5.4.4
5.4.5
5.5
5.5.1
5.5.2
SCOPE ................OOOOOOWO.CO**O.O--*O
Scope ..........o...OO.OOOOooo--o
REFERENCEDDOCUtlENTS..............................
Governmentpublication...........................
Order of precedence . s . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DEFINITIONS .......................................
Electricalequipment .............................
Electronicequipment .............................
Phase I survey ...................................
Phase II survey ..................................
Normal loading ...................................
Thermogram ......................................,
Gray scale .......................................
Referencetemperature.............................
Hot spot ........~.0.o..c0.00.co.. G O.o.o..o...o.o
Cold spot............-................ .
GENERAL REQUIMMENTS ..............................
Phase Iand II survey.. ..........................
DETAILEDREQUIREMNTS .............................
Electricalequipmentto be surveyedduring
phase I ............-.... .o.G..*.*..**.**
Electricalequipmentto be surveyedduring
phaseII ..............+ .**s*o*.**.*
Electricalequipmentwhich does not have to
re surveyed .....................................
Survey procedures ................................
Preliminary......................................
Safety ...................................-
Ships force assistance ..........................
Equipment loading ................................
Sequenceof equipmentto be surveyed ............*
Test equipmentcalibrationand
operationalchecks ..............................
Proceduresfor checkinghot or cold spots on
electricalequipment ............................
Potentialhot or cold spot locations .............
Equipmentnot available for survey ...............
Infraredthermal imagingEEGL survey
report ...........OOOOQoOOCOOCOSOOOOOOO** G **w.
Preliminaryreport ...............................
Final report ...*..**G *.*****.-*......
1
1
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NIL-STD-2194(SH)
12 February 1988
CONTENTS - Continued
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paragraph6.
6.1
Figure 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Table I.
NOTES ...........OOO0--0--
Subject term (keyword) listing ..................
FIGURES
IRTI survey data sheet: descriptionof
individualequipmentproblems ....................
IRTI survey data sheet:
list of electrical
equipmentnot available for survey ...............
IRTI survey-preliminaryreport ....................
Abstract ..........................................
Summaryof problems and repairpriorities .........
Electricalequipmentguide list ...................
List of electricalequipmentnot available for
survey ......o.....o..o.o..Q*0****** ......
Descriptionof individualequipmentproblems ......
IRTIsurvey-final report ..........................
Abstract ..........................................
Summaryof problems and repair priorities .........
List of electricalequipmentnot availablefor
survey ...........................................
Summarymatrix of electricalequipmentproblems ...
TABLE
Severitycode .....................................
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MIL-STD-2194(SH)
12 February 1988
1. SCOPE
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1.1 Scope. This standardprovides detailed proceduresfor conductingan
infraredthermal imaging (IRT1)survey on electricalequipmentaboard ship.
An IRTI survey is recommendedfor new constructionships, pre-overhaultest and
inspection,post repair and overhaul checks, and
ships electricalsystem occur.
2. REFERENCEDDOCUMENT%
2.1 Governmentpublication. The following
whenevermajor changes to the
Governmentpublicationforms a
part of this standard to the extent specifiedherein.
OFFICE OF THE CHIEF OF NAVAL OPERATIONS (OPNAV)
OPNAVINST 51OO.19A - Navy Safety Precautionsfor Forces Afloat.
(Copiesof the Governmentpublicationrequiredby contractorsin connection
with specificacquisitionfunctionsshould be obtained from the contracting
activityor as directed by the contractingofficer.)
2.2 Order of precedence. In the event of a conflictbetween the text of
. .
this standardand the referencescited herein, the text of this standardshall
take precedence.
3. DEFINITIONS
3.1 Electricalequipment. Electrical equipment is equipment,other than
electronic,which is designedto generate,convert, distribute,control,or
utilize electricalenergy. Examples of electricalequipmentare generators,
switchboards,power panels,motor controllers,motor generators,and bus
transfer switches.
3.2 Electronicequipment. Electronicequipment is equipmentdesigned to
generate,transmit.,convey, store, process, or otherwiseuse electronic
signals. Examples of electronicequipmentare oscillators,transmitters
(sonar,radar, and radio), amplifiers,sensing devices, receivers,computers,
underwaterdetection equipment,fire control equipment,drone control, and
associatedtest equipment.
3.3 Phase I survey. The phase X survey is that part of the IRT1 survey,
specifiedherein, that is conducted at dockside for the purpose of keeping the
phase 11 survey (underway)time to a minimum. The phase I survey temperature
measurementsare performedon all electricalequipmentwhich can be operated
dockside under normal operatingconditions.
3.4 Phase II survey. The phase 11 survey is that part of the IRTI
survey, specifiedherein, that is conductedwhile the ship is underway. The
phase II survey temperaturemeasurementsare performed on all electrical
equipmentwhich can only be operated at sea under normal operating conditions,
and the balance of the electricalequipmentnot availableduring the phase I
survey.
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NIL-STD-2194[SH)
12 February 19S8
3.5 Normal loading. Normal loading is the levelof currentwhich would
be drawn by equipment,or through conductors,under normal operatingconditions.
3.6 Thermogram. A thermogramis an instanthard copy photographof
the infrared image.
3.7 Gray scale. The gray scale is a referencescale on the monitor
containingbars of differentshades from dark to light.
3.8 Reference temperature. Referencetemperatureis the enclosure
temperatureof a piece of electricalequipmentor componentoperatingunder
normal loadingconditions.
3.9 Hot spot. A hot spot is any area of the equipmentwhich is surveyed
10 degrees Celsius (C)or more above the equipmentreferencetemperature.
3.10 Cold spot. A cold spot is any area of the equipmentwhere the
surveyed temperatureis less than the referencetemperatureand where there is an
indicationof an open connectionor componentor some other similar type problem.
4. GENERAI,REQUIREMENTS
4.1 Phase I and II survey. The phase I and II surveys shall consistof
the following:
[a]
(b)
(c)
Tne IRTi survey shaii be planned and coorciina~ed wi~ilall
participatingpersonnelto ensure optimumutilizationof
docksideand underway time. The ElectronicEquipmentGuide
List (EEGL) (if available)shall be used to identifyand
locatethe equipmentto be surveyed. At the conclusionof
the IRTI survey, a report shall be prepareddetailingthe
survey results (see 5.5).
Measuringthe temperatureof the EEGL equipmentwhile in normal
operatingmode.
Determiningcause for hot or cold spots on EEGL equipmentor
identifyingpotentialproblem areas for future analysesas

appropriate.
5. DETAILEDREQUIREMENTS
5.1 Electricalequipmentto be surveyedduring P
base 1. During phase I
(dockside),as much of the electricalequipmentas possible shall be surveyed
to reduce the phase 11 (underway)workload.
Equipmentto be surveyedduring
phase I includesshore power switchboards,shore power connections,shore
power receptacles,cables, and motor controllers(exceptas specifiedin 5.3).
5.2 Electricalequipmentto be surveyedduring p
base II. During phase
XI survey, any equipment (exceptas specified in 5.3) which is on the EEGL and
could not be operatedwhile dockside, shall be surveyed. This equipmentshall
include the following-:
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NIL-STD-2194(SN)
12 February 1988
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(b)
(c)
Electricalequipmentassociatedwith the anchorwindlass motor,
whale boat, catapult,and underway replenishmentsystem.
Power panels, transformers,and load centersprovidingpower
service to electronicequipmentand motors.
Steering gear motors, direct current (de)propulsionmotors and
bow thrusters.
5.3 Electricalequipmentwhich does not have to be surveyed. Electrical
equipmentwhich does not have to be surveyed includesportableelectrical
equipment,office equipment,hand dryers, shop equipment (drillpresses,
milling machines, lathes, inductionfurnaces,and so forth),ventilationduct
heating elements,and other types of electricalheating elements.
5.4 Survev procedures. Survey proceduresshall be as specifiedin 5.4.1
through 5.4.5.
5.4.1 Preliminary. Procedurespreliminaryto the survey shall be as
specified in 5.4.1.1 through 5.4.1.4.
5.4.1.1 Safety. Ship electricalsafety proceduresshall be followedat
all times. Forces afloat shall be in accordancewith OPNAVINST51OO.19A.
Unauthorizedpersonnel shall be kept away from equipmentbeing surveyedby the
use of barricadesand warning signs. The IRTI test equipmentoperator shall
not extend the scanner across the plane of open electricalpanels or coverings.
5.4.1.2 Ships force assistance. The survey team leader shall contact
the ships electricalofficer and request the assistanceof ships personnel
to gain-accessto all equipmentto be surveyed.
5.4.1.3 Equipment loading. Electricalequipmentto be surveyed shall be
under normal loadingconditionsand in service for at least 1/2 hour prior to
being surveyed.
5.4.1.4 Sequence of equipmentto be surveyed. The ships EEGL, if
available,shall be utilized to plan sequenceof testing since equipmentis
listedby location (compartmentlevel, frame, and athwartshipposition).
5.4.2 Test equipment calibrationand operationalchecks. Only calibrated
test equipmentwill be used for the survey. IRTI test equipmentshall be adjusted
each time equipment is energized. Initiallyand when the IRTI test equipment is
operated continuouslyfor long periods of time, a gray scale check shall be made.
Proceduresfor the gray scale check shall be as follows:
(a) Turn the IRTI test equipmenton.
(b) Set the system to gray scale and adjust brightnessand
contrast for optimal viewing.
(c) Switch back to normal operation;do not adjustbrightness
or contrastwhile in normal operationalmode.
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NIL-STD-2194(SH)
12 February 1988
5.4.3 Proceduresfor checkinghot or cold spots on electricalequipment.
Procedures for checking for hot or cold spots on electricalequipmentshall be
as follows:
(a)
(b)
(c)
Scan electricalequipmentbeing surveyedwhile observingthe
monitor for hot or cold spots using the ships EEGL (if available).
Note - Most problems are due to loose electricalconnectionssuch
as fuse connections,switch connections,breaker connections,and
terminal lugs, corrosion,and improperscrew or lug material or
size. Another common problem is the breakdownof wire insulation
and open componentsor connections.
When a potentialhot or cold spot is found, the IRTI test equipment
operatorshall determinethe temperaturedifferencebetween the
hot spot and backgroundby adjustingthe necessary IRTI test
equipmentcontrols (referto specific IRTI system operating
manual).
If the EEGL equipmentis found to have a hot or cold spot, the
followingprocedureshall be completed:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
TWCIthcrrxtograms shall be taken showingthe faulty
componentwith isotherm level shown.
Two color, instant.photographsshall be taken showing
the faulty component.
A severity code shall be assignedto the equipment
as specified in table 1.
Data shall be taken listingall necessary IRTI test
equipmentsettings to verify the actual temperature
differencebetween the hot spot and background.
Data shall be listed on sheet 1 of the IRTI survey
data sheet as shown on figure 1.
An arrow shall be affixed to the thermogramsand
color photographsto identifythe faulty component.
A numberingsystem shall be devised by the survey
team leader to match the color photographswith the
appropriatethermogram.
TABLE I. Severity code.1 3
v
Severity Temperatureabove or below Remarks
code referencetemperature(C)
**
70 and above
Component (electrical)
failure inuninent.zStop
survey. Inform cognizant
officers.
-
40 and above to less than 70 Component (electrical)
failure almost certain
unless corrected.
t 1 1
1
See footnotesat end of table.
1 - 1 w [
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MIL-STD-2194(SH)
12 February 1988
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TABLE I. Severity code.1 s - Continued
Temperature above or below
Remarks
reference temperature (C)
--!
Severity
code
**
*
*
+
25 and above to less than 40
Above O
10 and above O to less than 25
Below O to ambient
___-
failure probable unless
corrected.
Component (electronic)
failure probable unless
corrected.
failure unlikely but
corrective measure
required at next scheduled
routine maintenance
period or as scheduling
permits.
Component has probably
failed or degraded or been
affected by an upstream
component or equipment.
1
2
Applies to electrical, electronic, or I.C. equipment.
Some components such as coils,
resistors and the-l overload heaters may
have high temperature readings which are no-l.
The above general criteria have
been determined by past field experience
for maintenance scheduling.
Final decision as to priorities and order of
maintenance shall be determined by the temperature above or below the reference
temperature,
the type of component
and the critical nature of the equipment
or system involved.
5.4.4 Potential hot or cold spot locations. When scanning the following
equipment>the accessible components
listed shall be specificallyobserved for
temperaturedifferencesabove
or below their normal operating temperatures.
(a) Switchboards:
(1) Bus bar connections.
(2) Bus disconnect connection.
(3) Circuit breaker connections.
(4) Control wire terminal board connections.
(5) Relay connections.
(6) Fuse holder connections.
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ML-STD-2194(SH)
12 February 1988
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(b)
(c)
(d)
(e)
(f)
Power lightingpanels and fuse distributionpanels:
(1) Line connections.
(2) Individualload connections.
(3) AQB circuit breaker contactsvia molded case signature,
fuse and fuse clip connectors.
Automaticbus transfer (ABT)switches:
(1) Normal source connections.
(2) Alternatesource connections(whenABT is placed in
manua1, and alternatesource is selected).
(3) Load connections.
(4) Control relay connections.
(5) Controlwire connections.
(6) Relay or contactorcontactsand electroniccomponents.
Ffotorcontrollers:
(1) Nain contactorconnections.
(2) Overload connections.
(3) Control relay and fuse connections.
(4) Controlwire terminalboard connections.
(5) Controlwire connections.
(6) Overloadheaters and contacts,
resistors,and contactor
relay coniac~s.
Motor generatorsets:
(1) Motor and generator line comections.
(2) Slip ring connections.
(3) Starter/regulator/staticexciter components,connectionsand
terminalboard connections,
internalheater wiring, field
and brush pigtail (if applicable)connections.
Static converters:
(1) Semiconductorheat transferdevices (heat sinks).
(2) Line and load connections.
(3) Control relay and controlwire connections.
(4) Electroniccomponents,
bus connections,transformers,
terminalboards.
5.4.5 Equipment not available for survey.
If an electrical system is
not surveyed because it is not operational, the reason for the non-operating
condition shall be written on sheet 2 of the IRTI survey data sheet as shown
on figure 2.
5.5 Infrared thermal imaging EEGL survey report. The IRTI electrical
survey report shall be as specified in 5.5.1 and 5.5.2.

MIL-STD-2194(SH)
12 February 1988
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5.5.1 Preliminaryreport.
At the conclusionof the infraredthermal
imagingsurvey, a report, as shown on figures 3 through 8, shall be provided to
the ships commandingofficer,
engineeringofficer and electricalofficer.
The
reportshall contain one completeset
of photographsand thermograms.
(Another
set of photographsand thermogramsshall be retainedby the surveyingactivity
for future reference.)
The preliminaryreport shall contain the following
information:
(a)
(b)
(c)
(d)
(e)
(f)
Cover page (see figure 3).
Abstract (see figure 4).
Summary of problemsand repair priorities (see figure 5).
Equipment guide list marked to indicateall electrical
equipmentsurveyed (see figure 6).
List of electricalequipmentnot availablefor survey
(see figure 7).
Descriptionof individualequipmentproblems
(see figure 8).
5.5.2 Final report.
A final report, as shown on figures 9 through 13,
shall be provided to NAVSEA,
the appropriatetype Command, the appropriate
Planningand Engineeringior Repairs and Alterations,and the ship which was
surveyed. This report s~lallcontainthe followinginformation:
(a) Cover page (see figure 9).
(h) Abstract (see figure 10).
(c) Summary of problemsand repair priorities (see figure 11).
(d) List of electricalequipmentnot availablefor survey
(see figure 12) and status.
(e) Summary matrix of electricalequipmentproblems
(see figure 13).
6. NOTES
6.1 Subject term (keyword) listing.
Background
Equipment,electronic
Gray scale
Hot spot
Thermograph
Preparing activity:
Navy - SH
(Project5855-N282)
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MIL-STD-2194(SH)
12 February 1988
Inspectiondate:
Ship class/name:
Inspectorname:
Activity:
Problem no.:
Thermographno.:
Equipmentunder survey:
Specificcomponentexperiencing
high temperature:
Temperatureabove ambient:
IRTI test equipmentnomenclatureand settings:
Prc)bablecause:
~~!~~mmcn~:l~ions :
Remarks:
~. .
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FTGURE 1. IRTI survey data sheet: descriptionof individualequipmentproblems.
8
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MIL-STD-2194(SH)
12 February 1968
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Equipment
nomenclature
2*
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3.
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5.
6.
Inspectiondate:
Ship class/name:
Inspectorname:
Activity:
Equipment
location
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Reason for non-availability
FIGURE 2. IRTI survey data sheet: list of electricalequipmentnot
availablefor survey.
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9
}IIL-STD-2194(SH)
12 February 1?58
Start date:
IRTI SURVEY - PRELIMINARYREPORT
Ship name and hull no.
Completiondate:
Performedby:
,
.
FIGURE 3. IRT1 survey-preliminaryreport.
}lIL-STD-2194(S}I)
12 February 19S6
The purpose of the infrared
thermal imaging (IRTI) electricalsurvey is
For each hot
to scan electricalequipment in order to find hot or cold spots:
or cold spot,
the probable cause
and recommendedcorrectiveactions are determined
by the survey team and provided
to the ships electricalofficer in this report.
1. Survey dates
2. Name and hull no. of ship
3. Ship location
4. Activity conductingsurvey
5. TuL~l IiJ n.tIeY
of electricalproblems fo~nd
6. Number of problems correctedduring survey
)
7. Number of remailingproblems
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FIGURE A. Abstract.
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MIL-STD-2194(Sli)
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12 Fcbruar)-1988
Inspectiondate:
Ship class/name:
Inspectorname:
Activity:
Component
experienciilg
Repair priority (check one)
Problem Equipment
Equipment
high
(see note below)
nomenclature
location
temperature
Immed. }land.
Import. Desir.
number
._ --- .
G
NOTE: Repair priority
is based on the temperature difference between the
electrical component and the equipment to which it is attached as
follows:
Immed:
Immediate - component is 70C or more above ambient,
Mand:
Nandatory -
component is 40 to 69C above ambient.
Import:
Important - component is 25 to 39C above ambient.
Desir:
Desirable - component
is 10 to 24C above ambient.
Summary sheet
of
FIGLIRE5.
Summary of problems and repair
priorities.
.
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NIL-STD-2194(SH)
12 February 1988
NOTE : The equipmentguide list should be marked up to indicateall
electricalequipmentsurveyed.
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FIGURE 6. Electricalequipmentguide list.
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NIL-STD-2194(SH)
12 February 19SS
Equipment Equipment
No. nomenclature location Reason for non-availability
1.
9
-.
3.
4.
5.
,
6.
7.
6.
9.
}
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FIGURE 7. List of electrical equipment not available for sllrve~.
. .
-----
--
. . . .. -_ ____ ~ ~
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MIL-STD-2194(SH)
12 February 1988
Inspection date:
Ship class/name:
Inspector name:
Activity:
Problem no.:
Thermogram no.:
Equipment nomenclature:
Equipment location:
Specific component experiencing
high temperature:
Equipment temperatureabove normal
operating temperature:
IRTI test equipmentsettings:
Probable cause:
Recommendations:
Remarks:
FIGURE 8. Description of individual equipment problems.
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Start date:
MIL-STD-2194(SH)
12 February 1988
.
IRTI SURVEY - FINAL REPORT
Ship name and hull no.
Completion date:
Performed by:
FIGURE 9.
IRTI survey-final report.
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ML-STD-2194(SH)
12 February 1988
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The purpose of the infraredthermal
imaging (IRTI)electricalsurvey is
to scan electricalequipment in order to find hot or cold spots.
For each hot
or cold spot,
the probable cause and recommendedcorrectiveactions are determined
by the survey team and provided to
the appropriateNaval activity in this report.
1.
2.
3.
4.
5.
6.
7.
Survey dates
Name and hull no. of ship
Ship location
Activityconductingsurvey
Total number of electrical problems
Number of probl(!n~~corrected ~luring~~rveY
....
Number of remaining problems
FIGURE 10. Abstract.
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NIL-STD-2194(SH)
12 Feb]-udr}19S8
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Prob1em Equipment
number nomenclature
I
Equipment
location
I
.. ___
Component
experiencing
high
temperature
Repair priority (check one)
(see note below)
Immed. Mand. Import. Desir.
NOTE : Repair priority is based or~the temperature difference between the
electrical component and the equipment to which it is attached as
follows:
Xmmed: Immediate - component is 70C or more above ambient.
~falld :
Mandatory - component is 40 to 69C above ambient.
Import: Important - component is 25 to 39C above ambient.
Desir: Desirable - component is 10 to 24C above ambient.
Summary sheet of
1IGURE11. Summary of problems and repair priorities .
...
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NIL-STD-2194(SH)
12 February 1988
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Equipment Equipment
No. nomenclature location Reason for non-availability
1.
2.
3*
4.
5.
6.
7.
8.
9.
10.
, {
11.
19
*-.
.
13.
14.
15.
16.
17.
18.
19.
20.
A
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FIGURE 12. List of electrical equipment not available for survey.
I
..- . .. . . .. ..-
.
19
... . # ..
..- .*-.--=. ..
..*
,
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MIL-STD-2194(SH)
12 February 19SS
.
Electrical equipment
Results of this survey b wiority code
Qty
I
Qty
Type abroad surveyed
ship
Generators
(60 hertz (Hz))
Switchboards
(60 Hz)
Load centers
Automatic/manualbus
transfer switches
Motor controllers
Power panels
(fuses/breakers)
400 Hz systems
I.C. systems
Motors
Miscellaneous & shore
power
I
Immed. land. Import.
1---
Totals
Desir. Total
FIGURE 13. Summary matrix of electrical equipment problems.
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Infrared Thermal Imaging Survey Procedure for Electrical Equipment

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Infrared Thermal Imaging Survey Procedure for Electrical Equipment

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NIL-STD-2194(SH)

identifyingpotentialproblem areas for future analysesas

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