MIL-STD-2194

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MILITARY STANDARD.

INFRAREDTHERMAL IMAGING SURVEY PROCEDURE

FOR

ELECTRICALEQUIPMENT

AMSC N/A

FSC 5855

DISTRIBUTIONSTATEMENTA Approved for public release;distributionunlimited

Downloaded from http://www.everyspec.com on 2011-12-01T17:07:39.

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DEPARTMENTOF DEFENSE

NAVAL SEA SYSTEMS COMMAND

Washington,

DC 20362-5101

InfraredThermal ImagingSurvey Procedurefor ElectricalEquipment

1.

This Military Standardis approvedfor 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-

tinentdata 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.

ii


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COhqENTS

Page

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

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 .......................................

Reference temperature.............................

Hot spot ........~.0.o..c0.00.co..O.o.o..o...o.o

Cold spot............-................

GENERAL REQUIMMENTS ..............................

Phase Iand II survey.. ..........................

DETAILED REQUIREMNTS .............................

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****w.

Preliminaryreport ...............................

Final report

...*..** *.*****.-*......

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

~

2

2

2

2

2

3

3

3

3

3

3

3

3

4

5

6

6

7

7

iii


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CONTENTS - Continued

paragraph6.

6.1

Figure 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Table

I.

NOTES ...........OOO--0--

Subjectterm (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

Severity code .....................................

iv

Page

7

7

8

9

10

11

12

13

14

15

16

17

18

19

20

4

rl

mnw mnVnll arrrmlnr rnr urmfirrlma

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1.

SCOPE

1.1 Scope.

This standardprovidesdetailedproceduresfor conductingan

infraredthermal imaging (IRT1)survey on electricalequipmentaboard ship.

An IRTI survey is recommendedfor new constructionships, pre-overhaultest and

inspection,post repair and overhaulchecks,and

ships electricalsystem occur.

2.

REFERENCEDDOCUMENT

2.1 Governmentpublication.

The following

whenevermajor changes to the

Governmentpublicationforms a

part of this standardto 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. Electricalequipment is equipment,other than

electronic,which is designedto generate,convert,distribute,control,or

utilize electricalenergy.

Examplesof electricalequipmentare generators,

switchboards,power panels,motor controllers,motor generators,and bus

transferswitches.

3.2 Electronicequipment. Electronicequipment is equipmentdesignedto

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 conductedat 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

docksideunder 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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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 infraredimage.

3.7 Gray scale.

The gray scale is a referencescale on the monitor

containingbars of differentshades from dark to light.

3.8 Referencetemperature.

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~edi~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 futureanalysesas

appropriate.

5. DETAILEDREQUIREMENTS

5.1 Electricalequipmentto be surveyedduring P

base 1.

Duringphase I

(dockside),

as much of the electricalequipmentas possibleshall 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 surveyedduringp

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-:

I

I

I

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(~)

(b)

(c)

Electricalequipmentassociatedwith the anchorwindlassmotor,

whale boat, catapult,and underwayreplenishmentsystem.

Power panels,

transformers,and load centersprovidingpower

service to electronicequipmentand motors.

Steeringgear 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,

millingmachines, 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

specifiedin 5.4.1.1 through 5.4.1.4.

5.4.1.1 Safety. Ship electricalsafetyproceduresshall 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 leadershall contact

the ships electricalofficer and request the assistanceof shipspersonnel

to gain-accessto all equipmentto be surveyed.

5.4.1.3 Equipment loading. Electricalequipmentto be surveyedshall 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 shipsEEGL, 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 equipmentis energized. Initiallyand when the IRTI test equipment is

operatedcontinuouslyfor 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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5.4.3 Proceduresfor checkinghot or cold spots on electricalequipment.

Proceduresfor checkingfor 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 problemsare due to loose electricalconnectionssuch

as fuse connections,switch connections,breaker connections,and

terminal lugs, corrosion,and improperscrew or lug materialor

size. Anothercommon 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)

TWCIthcrrxtogramshall be taken showingthe faulty

componentwith isotherm level shown.

Two color,

instant.photographsshall be taken showing

the faultycomponent.

A severity code shall be assignedto the equipment

as specified in table 1.

Data shall be taken listingall necessary IRTI test

equipmentsettingsto verify the actualtemperature

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 affixedto the thermogramsand

color photographsto identifythe faultycomponent.

A numberingsystem shall be devisedby the survey

team leaderto match the color photographswith the

appropriatethermogram.

TABLE I.

Severitycode.1 3

v

Severity

Temperatureabove or below

Remarks

code

referencetemperature(C)

**

70 and above

Component (electrical)

failure inuninent.ztop

survey.

Inform cognizant

officers.

-

40 and above to less than 70


failure almost certain

unless corrected.

t

1

1

1

See footnotesat end of table.

1 -

1

w

[

-

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I

TABLE I. Severity code.1 s - Continued

Temperature above or below

Remarks

reference temperature (C)

--

everity

code

**

*

*

+

25 and above to less than 40

Above

10

and above O to less than 25

Below O to ambient

___-


failureprobable unless

corrected.

Component (electronic)

failureprobable

unless

corrected.

Component electrical)

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 terminalboard connections.

(5) Relay connections.

(6) Fuse holder connections.

.

.


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I

(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) Overloadconnections.

(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/staticexcitercomponents,connectionsand

terminalboard connections,

internalheater wiring, field

and brush pigtail (if applicable)connections.

Static converters:

(1) Semiconductorheat transferdevices (heatsinks).

(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.


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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 (seefigure3).

Abstract (see figure4).

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 figures9 through 13,

shall be providedto NAVSEA,

the appropriatetype Command, the appropriate

Planningand Engineering

ior 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

Preparingactivity:

Navy - SH

(Project5855-N282)

7


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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:

~. .

FTGURE

1.

IRTI survey

data sheet:

descriptionof individualequipmentproblems.

8

.


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I

Equipment

nomenclature

2*

I

3.

I

5.

6.

Inspectiondate:

Ship class/name:

Inspectorname:

Activity:

Equipment

location

I

Reason for non-availability

FIGURE 2.

IRTI survey

data sheet: list of electricalequipmentnot

availablefor survey.

-

9


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Start date:

IRTI SURVEY -

PRELIMINARYREPORT

Ship name and hull no.

Completiondate:

Performedby:

FIGURE 3.

IRT1 survey-p

reliminaryreport.


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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 I iJ n tI eY

of electricalproblems fo~nd

6.

Number of problems correctedduring survey

7.

Number of remailingproblems

FIGURE A. Abstract.

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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

.

_ ---

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.

.

12


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NOTE :

The equipmentguide list should be marked up to indicateall

electricalequipmentsurveyed.

j

FIGURE 6. Electricalequipmentguide list.

13


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Equipment Equipment

No. nomenclature

location Reason for non-availability

1.

9

-.

3.

4.

5.

,

6.

7.

6.

9.

}

I

I

[

I

.

FIGURE 7. List of electrical equipment not available for sllrve~.

.

.

.

.

.

.

-

____ ~ ~


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Inspection date:

Ship class/name:

Inspector name:

Activity:

Problem no.:

Thermogram no.:

Equipment nomenclature:

Equipment location:

Specific component experiencing

high temperature:

Equipment temperatureabove normal

operatingtemperature:

IRTI test equipmentsettings:

Probable cause:

Recommendations:

Remarks:

FIGURE 8.

Description of individual equipment problems.

i

I

15


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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.

16


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\

The purpose of the infraredthermal

imaging (IRTI)electricalsurvey is

to scan electricalequipmentin 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.

Surveydates

Name and hull no. of ship

Ship location

Activityconducting

survey

Total number of electrical problems

Number of probl( n~~corrected ~luring~~rveY

....

Number of remaining problems

FIGURE 10. Abstract.

17


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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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I

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

FIGURE 12. List of electrical equipment not available for survey.

.

.. .

.

.. ..-

.

19

...

.

..

..- .*-.--=. ..

..*


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.

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/manual

u

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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