IR Survey 6aug03

Preventive Maintenance Inspection
at
Cromptons Paper - Heywood
06/08/2003
General Information
Ambient Conditions
Wednesday, 6 Aug
18:00 Mostly Sunny
Temp C Dew Point Precip. Humid. Wind

28
17
Nil
50%
From the West at 7 mph
Contact information:
Diagnostic Solutions Ltd
Murlain Business Centre
Union Street
Chester CH1 1QP
T: 01244 357263 (Mon-Fri, 8.30-5.00) or 07768 582321/517206 (Outside office hours)
F: 01244 357264
E: office@diagnosticsolutions.co.uk
Ron Frend
IR Survey 6Aug03.REP
Page 1
06/08/2003
Table of Contents
Section
Equipment
PM2
Oven contactor panel
PM2
PM2
Main panel 214
PM2
Main panel 216
PM2
Main panel 223
PM2
Main panel 229
PM2
Main panel 235
PM2
Main panel 241
10
PM2
Main panel 244
11
Boiler room
Main cabinet
12
Boiler room
Main cabinet
13
Refiners
Manilla refiner #2
14
Refiners
HiLo Pulper HiSpeed Rotor
15
Refiners
HiLo Pulper LoSpeed Rotor
16
Page
Page 2
06/08/2003
Inspected Equipment:
Operator:
Ron Frend
Identification
Section
PM2
Equipment
Additional information
Fuses R2 & Y5
Date
06/08/2003
Time
09:12:53
Fault description
AR02: 108.8C
131.4C
120
100
AR01: 135.6C
80
60
51.2C
Fault
Poor termination
Object parameter Value

Emissivity
0.93
Object distance
1.0 m
Label
Value
AR01 : max
135.6C
AR02 : max
108.8C
Recommendation
Repair terminations
Clean and tighten the cable teminations on Red 2 and Yellow 5.
Page 3
06/08/2003
Operator:
Ron Frend
Identification
Section
PM2
Equipment
Contactor #3
Date
06/08/2003
Time
09:15:43
Fault description
112.1C
100
AR01: 119.0C
80
60
Fault
Bottom right termination

Emissivity
0.93
Object distance
1.0 m
Label
Value
AR01 : max
119.0C
40
39.3C
Recommendation
Repair termination
The overheated termination is caused by a poor electrical connection. The termination should be
cleaned and tightened.
Page 4
06/08/2003
Operator:
Ron Frend
Main panel 214

Identification
Section
PM2
Equipment
Main panel 214
Rear fuses
Date
06/08/2003
Time
10:26:07
Fault description
91.1C
Mid fuse top: 90.9C
80
Right fuse bottom: 93.0C

60
Fault
Poor terminations

Emissivity
0.93
Object distance
1.0 m
Label
Value
Mid fuse top : max 90.9C

47.3C
Right fuse bottom : m93.0C
Recommendation
Repair terminations
The middle top and right bottom cable terminations are overheating due to poor electrical
connection.
The terminations should be cleaned and retightened.
Page 5
06/08/2003
Operator:
Ron Frend
Main panel 216

Identification
Section
PM2
Equipment
Main panel 216
Contactor
Date
06/08/2003
Time
10:29:47
Fault description
93.5C
80
Bottom, mid, rear: 90.8C
60
Fault
Poor connection L2
Object parameter
Value
Emissivity
0.93
Object distance
1.0 m
Label
Value
Bottom, mid, rear : max 90.8C

46.8C
Recommendation
Repair termination
The bottom, middle, rear termination has a poor electrical connection.
Clean and tighten the termination.
Page 6
06/08/2003
Operator:
Ron Frend
Main panel 223

Identification
Section
PM2
Equipment
Main panel 223
Middle fuse
Date
06/08/2003
Time
10:34:51
Fault description
95.0C
AR01: 100.5C
Fault
Poor connection

80
60
Emissivity
0.93
Object distance
1.0 m
Label
Value
AR01 : max
100.5C
43.6C
Recommendation
Repair connection
The middle fuse top connection has a poor electrical connection.
Clean and tighten the fuse top connections.
Page 7
06/08/2003
Operator:
Ron Frend
Main panel 229

Identification
Section
PM2
Equipment
Main panel 229
Middle fuse
Date
06/08/2003
Time
10:38:11
Fault description
67.4C
60
Mid fuse bottom: 69.3C
50
Fault
Poor termination
Object parameter
Value
Emissivity
0.93
Object distance
1.0 m
Label
Value
Mid fuse bottom : max
69.3C
42.5C
Recommendation
Repair termination
The middle fuse has a bad electrical connection at the bottom of the fuse.
Clean and tighten the connnection.
Page 8
06/08/2003
Operator:
Ron Frend
Main panel 235

Identification
Section
PM2
Equipment
Main panel 235
Middle fuse
Date
06/08/2003
Time
10:46:29
Fault description
64.2C
60
Mid fuse top: 64.1C
50
Fault
Poor termination

Emissivity
0.93
Object distance
1.0 m
Label
Value
Mid fuse top : max 64.1C

40.6C
Recommendation
Repair termination
The middle fuse has a bad electrical connection at the top cable termination.
Page 9
06/08/2003
Operator:
Ron Frend
Main panel 241

Identification
Section
PM2
Equipment
Main panel 241
Righthand contactor
Date
06/08/2003
Time
10:50:34
Fault description
104.2C
Fault
Overheating coil
100
Coil: 104.8C
80
60
Emissivity
0.93
Object distance
1.0 m
Label
Value
Coil : max
104.8C
46.7C
Recommendation
Change coil
The coil is overheating and should be changed.
Page 10
06/08/2003
Operator:
Ron Frend
Main panel 244

Identification
Section
PM2
Equipment
Main panel 244
Main contactor
Date
06/08/2003
Time
10:56:37
Fault description
82.7C
Fault
Hot internal contacts
80
AR01: 83.4C
70
SP01
60
50
46.8C
Emissivity
0.93
Object distance
1.0 m
Label
Value
SP01
72.0C
AR01 : max
83.4C
Recommendation
Repair contactor
The coil internals are showing signs of overheating when compared to similar units.
Most probable cause is poor electrical contact at the internal contacts.
Overhaul the contactor.
Page 11
06/08/2003
Operator:
Ron Frend
Main cabinet
Identification
Section
Boiler room
Equipment
Main cabinet
#2 feed pump isolator
Date
06/08/2003
Time
13:08:24
Fault description
Top cables: 79.8C
81.1C
80
Fault
Hot cables

70
60
50
Bottom cables: 74.2C
43.3C
Emissivity
0.93
Object distance
1.0 m
Label
Value
Top cables : max
79.8C
Bottom cables : max 74.2C
Recommendation
Resize cables
The cables to the isolator are overheating without a point heat source. This indicates that
the cables are undersized for the application.
The cables should be replaced with a larger diameter cable.
Page 12
06/08/2003
Operator:
Ron Frend
Main cabinet
Identification
Section
Boiler room
Equipment
Main cabinet
Relay middle of block
Date
06/08/2003
Time
13:09:59
Fault description
89.8C
80
Middle relay: 90.5C
60
Fault
Relay overheating

Emissivity
0.93
Object distance
1.0 m
Label
Value
Middle relay : max 90.5C

40
38.2C
Recommendation
Change relay
The indicated relay is overheating and should be replaced.
Page 13
06/08/2003
Operator:
Ron Frend
Manilla refiner #2
Identification
Section
Refiners
Equipment
Manilla refiner #2
Overload
Date
06/08/2003
Time
13:33:27
Fault description
79.2C
Fault
Overheating

AR01: 79.8C
60
40
Emissivity
0.93
Object distance
1.0 m
Label
Value
AR01 : max
79.8C
34.4C
Recommendation
Clean and tighten
The overload top, middle connection is overheating due to a poor electrical connection.
Page 14
06/08/2003
Operator:
Ron Frend
Identification
Section
Refiners
Equipment
Additional information Left hand Fuse

Date
06/08/2003
Time
13:39:23
Fault description
Left fuse top: 90.6C
90.5C
80
60
40
Fault
Overheating

Emissivity
0.93
Object distance
1.0 m
Label
Value
Left fuse top : max 90.6C
30.0C
Recommendation
Clean & tighten
The left hand fuse top connection is hot due to a poor electrical connection.
Page 15
06/08/2003
Operator:
Ron Frend
Identification
Section
Refiners
Equipment
Additional information Left hand fuse

Date
06/08/2003
Time
13:41:32
Fault description
140.9C
100
LH fuse bottom: 141.7C
50
Fault
Overheating
Object parameter
Value
Emissivity
0.93
Object distance
1.0 m
Label
Value
LH fuse bottom : max
141.7C
29.6C
Recommendation
Clean & tighten
The connection at the left fuse bottom connection is very hot due to a poor electrical connection.
Clean and tighten the connection.
Page 16
06/08/2003
Summary of Inspection
at
Cromptons Paper - Heywood
List of Inspected Items
Section
Equipment
Fault
Recommendation
PM2
Poor termination
Repair terminations
PM2
Bottom right terminatioRepair termination
PM2
Main panel 214
Poor terminations
Repair terminations
PM2
Main panel 216
Poor connection L2
Repair termination
PM2
Main panel 223
Poor connection
Repair connection
PM2
Main panel 229
Poor termination
Repair termination
PM2
Main panel 235
Poor termination
Repair termination
PM2
Main panel 241
Overheating coil
Change coil
PM2
Main panel 244
Hot internal contacts
Repair contactor
Boiler room
Main cabinet
Hot cables
Resize cables
Boiler room
Main cabinet
Relay overheating
Change relay
Refiners
Manilla refiner #2
Overheating
Clean and tighten
Refiners
HiLo Pulper HiSpeed Rotor Overheating
Clean & tighten
Refiners
HiLo Pulper LoSpeed Rotor Overheating
Clean & tighten
Page 17
06/08/2003
Inspection
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Location
Description
PM2
PM1
PM1
PM1
PM1
PM1
PM1
PM1
PM1
PM1
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel
PM2 Main Panel

Reel drum drive
Float dryer entry roll
Calender bottom ( swimming) drive
Calender top drive
Cylinder 9 drive
Spooner control panel
Through dryer panel
High vac pump panel
Remote panel for through dryer
214
215
216
217
218
222
223
226
227
228
229
230
231
232
233
234
235
237
240
241
242
244
245
Fault
Fuses R2 & Y52:
Contactor #3
rear fuses
Contactor - L2
mid fuse top
mid fuse bottom
RH contactor - coil
Main contactor - internal
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Agitators - Raw materials

Beaters
Beaters MCC
Beaters MCC
Beaters MCC
Beaters MCC
Beaters MCC
Beaters MCC
Beaters MCC
Beaters MCC
Beaters MCC
Beaters MCC
Beaters MCC
Cutting floor
FR1 - 1st stage FLOC Refiner #1

FR2 - 1st stage FLOC Refiner #2
DEF - Deflaker
SBP - Supaseal broke pulper
BPP - Supaseal broke pulper pump
TR3 - Manilla refiner #1
#5 Beater
B2
B4
B5
C1
C3
D5
D6
E1
E2
E3
E4
Chemical panel (melamine) CP17-01
53
54
55
56
57
58
59
60
61
Boiler House
Main Panel
Poly Pulper HiSpeed Rotor
Poly Pulper LoSpeed Rotor
Manilla refiner #2
Hi-Lo Pulper HiSpeed Rotor
Hi-Lo Pulper LoSpeed Rotor
TR2 - Top wood refiner #2
TR1 - Top wood refiner #1
TRF - Top wood refiner feed pump
#2 Feed pump
Relay overheating
Overload
Fuse
Fuse

IR Survey 6aug03

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IR Survey 6aug03

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Preventive Maintenance Inspection

Temp C Dew Point Precip. Humid. Wind

Oven contactor panel

Oven contactor panel

Main panel 214

Main panel 216

Main panel 223

Main panel 229

Main panel 235

Main panel 241

Main panel 244

HiLo Pulper HiSpeed Rotor

HiLo Pulper LoSpeed Rotor

Oven contactor panel

Oven contactor panel

Object parameter Value

Oven contactor panel

Oven contactor panel

Bottom right termination

Object parameter Value

Main panel 214

Main panel 214

Mid fuse top: 90.9C

Right fuse bottom: 93.0C

Object parameter Value

Mid fuse top : max 90.9C

Right fuse bottom : m93.0C

Main panel 216

Main panel 216

Bottom, mid, rear : max 90.8C

Main panel 223

Main panel 223

Object parameter Value

Main panel 229

Main panel 229

Mid fuse bottom: 69.3C

Mid fuse bottom : max

Main panel 235

Main panel 235

Object parameter Value

Mid fuse top : max 64.1C

Main panel 241

Main panel 241

Object parameter Value

Main panel 244

Main panel 244

Hot internal contacts

Object parameter Value

#2 feed pump isolator

Object parameter Value

Bottom cables: 74.2C

Top cables : max

Bottom cables : max 74.2C

Relay middle of block

Object parameter Value

Middle relay : max 90.5C

Object parameter Value

HiLo Pulper HiSpeed Rotor

HiLo Pulper HiSpeed Rotor

Additional information Left hand Fuse

Object parameter Value

Left fuse top : max 90.6C

HiLo Pulper LoSpeed Rotor