Calsta - IRT Sample Report · 2017. 6. 1. · Infrared Thermography Sample Report 1.1 Leibherr R996B Rear Engine Control Box A machine condition audit was completed on the large mining

Infrared Thermography Sample Report

Client Name Calsta Pty Ltd

Reference CPL_IRT_Sample

Revision Number Rev0

Prepared By Matt Taylor

Date 04 February 2015

Page 2 Infrared Thermography Sample Report

Table of Contents

1 Introduction .......................................................................................................................................... 3

1.1 Leibherr R996B Rear Engine Control Box .................................................................................. 4

1.2 Leibherr R996B Rear Engine Control Box Cable Protector ........................................................ 5

1.3 Komatsu 930E Low Voltage Cabinet Fuse Block Two ............................................................... 6

1.4 Unit Rig MT3700 Engine Turbocharger ...................................................................................... 7

1.5 Caterpillar 994 Radiator Internal Blockage.................................................................................. 8

1.6 Unit Rig MT3700 Payload Monitoring Cabinet .......................................................................... 9

1.7 Hitachi EX1200 Front Load Roller ............................................................................................ 10

1.8 Hitachi EX2500-5 Bucket H Link Pin ....................................................................................... 11

1.9 Caterpillar EMP 6040 Front Load Roller ................................................................................... 12

1.10 Hitachi EX3600 High Bucket Wear ........................................................................................... 13

1.11 Caterpillar EMP 6040 Main Bucket Pin..................................................................................... 14

1.12 Unit Rig MT3700 Air Conditioning Condenser......................................................................... 15

1.13 Hitachi EX2500 Hydraulic Boom Lift Cylinders....................................................................... 16

1.14 Komatsu 930E Low Voltage Electrical Cabinet ........................................................................ 17

1.15 Leibherr R996B Undercarriage Load Rollers ............................................................................ 18

1.16 Caterpillar 994K Control Relays ................................................................................................ 19

1.17 Drill Rig Exhaust Manifold ........................................................................................................ 20

1.18 Hitachi EX2500 Oil Coolers ...................................................................................................... 21

1.19 Hitachi EX2600 Hydraulic Boom Lift Cylinders....................................................................... 22

1.20 Caterpillar 988H Bucket Wear ................................................................................................... 23


1 INTRODUCTION

The aim of Calsta’s infrared thermal (IRT) imaging program is to detect equipment performance anomalies prior to any sign of visible failure. This proactive approach allows for adjustments or repairs to be conducted in a safe, effective and planned manner, negates consequential damage resulting from catastrophic failure and provides dynamic in service performance data which can assist in discussions with Original Equipment Manufacturers (OEM) around warranty and product improvement. All images contained in this document have been captured, analysed and reported on by ISO accredited Calsta thermographers. The thermal images in this report have been captured during multiple thermographic inspections at various mine sites in Australia. The majority of thermal images represent defects found although some of the thermal images show correct operating parameters or a base line condition which future IRT survey can be compared to. A FLIR T640 thermographic camera is used for all inspections. The FLIR T640 is the head of its class in professional and expert level cameras, providing the highest in class infrared resolution. Although this report is provided as a sample only, a client generated report will follow the same format consisting of a thermogram (infrared thermographic image), photographic image and description of conditions with a recommendation for follow up actions. However, the report can be tailored to a specific client needs on a case by case basis. Benefits of completing individual or regular thermographic inspections.

Increase Safety o A non-invasive test method; physical contact is not required with the test object.

o Unexpected equipment failure can create hazardous situations by forcing repairs to take place in high risk environments.

Reduce Diagnostic Time o Anomalies are identified more efficiently providing an opportunity to repair the problem

prior to failure of the component or system.

Reduce Operating Costs o More accurate diagnostics allow for only failed parts to be replaced rather than replacing

complete major components to repair a minor failure.

o Increased asset reliability can lower the number of assets required to complete the same task.

o Negate consequential damage such as contaminating hydraulic systems.

o Negate early change out of major components (lifecycle cost impact)

Increase Asset Reliability o Mean Time Between Failure (MTBF) will increase as defects are repaired during planned

events.

o Mean Time To Repair (MTTR) will decrease due to a greater level of job planning.

o Asset utilisation will increase as outages become more predictable

For further details on how a thermographic survey will benefit your asset reliability please contact me on the details below. Matt Taylor

Project Manager Mobile: +61 (0)439 993 457 Office: +61+(0)8 9271 9723 Email: [email protected] Web: www.calsta.com.au

http://www.calsta.com.au/


1.1 Leibherr R996B Rear Engine Control Box

A machine condition audit was completed on the large mining excavator covering component health, work order summary. Part of the audit was an inspection using thermography. A wire is showing excessive heat most likely caused by a high resistive connection. The wire should be removed and inspected for possible cause of failure and assessed if any damage has occurred. It is the 27th wire from the left at the top on the back row (numbering ferrules were illegible).

Date 6/08/2014

Image Time 12:29:46 PM

Emissivity 0.90

Image Camera Type FLIR T640

Image Range Max 150.0 °C

Image Range Min -40.0 °C

Repaired by:.............................................................. date:.............................. Comments:

30.7

37.6 °C

32

34

36


1.2 Leibherr R996B Rear Engine Control Box Cable Protector

One of the electrical circuit breakers is showing slightly higher than normal temperature. This may be due to excessive loading or a highly resistive connector within the breaker. Further testing will be required to determine what remedial action is required. The suspect protector is 15amp F126 – Rear engine control box.

31.2

37.3 °C

32

34

36

Date 6/08/2014


Emissivity 0.90




Repaired by:.............................................................. Date:.............................. Comments:


1.3 Komatsu 930E Low Voltage Cabinet Fuse Block Two

Fuse #9 in block #2 is showing a high temperature. This can be caused by overloading of the circuit or a high resistant connector. The heat appears to be coming from only one side of the fuse which would lead towards a high resistance connector therefore the fuse should be removed and the connection inspected.

26.4

33.6 °C

28

30

32

Date 7/08/2014

Image Time 11:23:25 AM

Emissivity 0.90






1.4 Unit Rig MT3700 Engine Turbocharger

The turbocharger on the right is showing a standard temperature (approx. 160 degrees Celsius) opposed to the turbocharger on the left that is cooler (approx. 40 degrees Celsius). The right turbocharger is operating correctly. It is possible the left turbocharger has failed severely reducing machine performance and increasing the chance of complete engine failure.

61.7

197.8 °C

80

100

120

140

160

180

Date 19/08/2014


Emissivity 0.90






1.5 Caterpillar 994 Radiator Internal Blockage

An inconsistent path of heat transfer through the engine cooling radiator indicates it could be blocked internally. The cooling system should be flushed with Cat Cooling System Cleaner (part number 6V-4511) and clean coolant added. A new IRT inspection will be required to ensure the corrective action has been successful.

32.5

65.0 °C

35

40

45

50

55

60

Date 20/08/2014


Emissivity 0.90






1.6 Unit Rig MT3700 Payload Monitoring Cabinet

An electrical connector in the payload monitoring cabinet is operating at a higher temperature compared to the other connectors in the same wiring harness. It is possible the connector has high electrical resistance and should be stripped then repaired.

32.4

44.7 °C

34

36

38

40

42

44

Date 23/10/2014


Emissivity 0.90






1.7 Hitachi EX1200 Front Load Roller

The first load roller on the left undercarriage is showing a higher temperature in comparison to the other load rollers. The roller should be inspected for leaks or damage and scheduled for replacement.

38.0

44.8 °C

40

42

44

Date 30/12/2014


Emissivity 0.90






1.8 Hitachi EX2500-5 Bucket H Link Pin

The left H link pin is operating at higher temperatures compared to the other bucket pins. This is most likely caused by a lack of grease lubrication or pin failure.

31.3

44.4 °C

32

34

36

38

40

42

44

Date 30/12/2014


Emissivity 0.90






1.9 Caterpillar EMP 6040 Front Load Roller

The front load roller on the right undercarriage is operating at a temperature higher than the other load rollers. In the photographic image below the roller can be seen leaking. This roller should be replaced at the next planned interval.

33.7

42.9 °C

34

36

38

40

42

Date 30/12/2014


Emissivity 0.90






1.10 Hitachi EX3600 High Bucket Wear

High wear spots can be seen on the left and right heels of the bucket. This is not a defect however shows a poor engineering design for the conditions the machine is currently working creating uneven load in certain areas.

36.8

48.2 °C

38

40

42

44

46

48

Date 30/12/2014


Emissivity 0.90






1.11 Caterpillar EMP 6040 Main Bucket Pin

The main bucket pin is operating at a higher temperature than the other bucket pins. Due to the higher load experienced on this bucket pin the increase in temperature is standard and does not represent a defect.

35.2

46.3 °C

36

38

40

42

44

46

Date 30/12/2014


Emissivity 0.90






1.12 Unit Rig MT3700 Air Conditioning Condenser

The high temperature at the top of the air conditioning condenser gradually decreases to a lower temperature at the bottom on the condenser. This is an indication of correct operation.

26.5

36.5 °C

28

30

32

34

36

Date 19/08/2014


Emissivity 0.90






1.13 Hitachi EX2500 Hydraulic Boom Lift Cylinders

All the hydraulic cylinders were inspected on the large mining excavator fleet as risk mitigation due to a recent unplanned cylinder failure. Both hydraulic boom lift cylinders show a consistent temperature which indicates correct operation. This is a base line condition and will be monitored for deviation on an ongoing basis. The right boom cylinder has an oil leak from the head seal.

66.9

90.6 °C

70

75

80

85

90

Date 30/12/2014


Emissivity 0.90





1.14 Komatsu 930E Low Voltage Electrical Cabinet

One of the diode connectors is showing a higher temperature that the other diodes in the circuit. This could be due to a higher electrical load or higher electrical resistance in the connection. Further testing will need to be carried out to confirm the status of this component and if repairs are required.

21.8

40.0 °C

25

30

35


Date 7/08/2014


Emissivity 0.90





1.15 Leibherr R996B Undercarriage Load Rollers

The load rollers for the right undercarriage show a consistent temperature. This is an indication there is currently no fault with the rollers.

17.9

30.1 °C

18

20

22

24

26

28

30


Date 6/08/2014


Emissivity 0.90





1.16 Caterpillar 994K Control Relays

The three relays for the machine control system are operating at a consistent temperature which indicates correct operation.

37.0

73.9 °C

40

50

60

70


Date 20/08/2014


Emissivity 0.90





1.17 Drill Rig Exhaust Manifold

The engine on DR3125 was creating high crankcase pressure so an inspection was carried out on the exhaust manifold to see if an individual cylinder was operating at a lower temperature in comparison to the other cylinder. A consistent temperature indicates the cylinders were all operating correctly.

350.0

440.3 °C

360

380

400

420

440


Date 8/01/2015


Emissivity 0.90



Image Range Min 100.0 °C


1.18 Hitachi EX2500 Oil Coolers

The oil cooler on the right does not appear to have a consistent cooling pattern. It is possible an internal or external blockage is causing the cooler to lose effectiveness. Note: a later visual inspection of the cooler revelled an external leakage causing the cooler to be blocked.

13.4

80.3 °C

20

40

60

80


Date 30/12/2014


Emissivity 0.90





1.19 Hitachi EX2600 Hydraulic Boom Lift Cylinders

All the hydraulic cylinders were inspected on the large mining excavator fleet as risk mitigation due to a recent unplanned cylinder failure. Both hydraulic boom lift cylinders show a consistent temperature which indicates correct operation. This is a base line condition and will be monitored for deviation on an ongoing basis.

55.8

82.4 °C

60

65

70

75

80


Date 30/12/2014


Emissivity 0.90





1.20 Caterpillar 988H Bucket Wear

A thermographic image was taken of the underside of the front end loader bucket to identify any uneven wear patterns. The left side of the bucket appears to be wearing higher than the right however is fairly consistent.

15.9

49.0 °C

20

30

40


Date 30/12/2014


Emissivity 0.90




Documents

Calsta - IRT Sample Report · 2017. 6. 1. · Infrared Thermography Sample Report 1.1 Leibherr R996B Rear Engine Control Box A machine condition audit was completed on the large mining