What is Infrared Testing of Electrical Equipment?

For over 30 years, Mid Atlantic Infrared has been conducting predictive testing of electrical equipment in commercial, industrial and other types of facilities. This widely accepted test procedure provides low cost, early identification of electrical problems with no interruption to facility operations. Our extensive experience, highly trained personnel, on-line verification tests and immediate repairs when possible combine to ensure you the highest quality survey at the lowest possible total cost.

This might be judged to be a loose feeder connection. Without interrupting equipment operation, our verification test revealed that the problem was caused by a loose connection inside the contractor.

What types of problems may be identified by Infrared Testing?

An infrared survey of operating electrical equipment will reveal loose connections, overloaded circuits, unbalanced loads, sludged transformers, poor contact inside breakers, contactors and switches and much more. A typical infrared survey will test switch gear, panels, motor control centers, transformers and more. Often, testing of a commercial or industrial facility can be completed in a single day.

How do we save money and provide superior service?

The total cost of an infrared survey is the cost of the survey plus the cost of repairs. Our objective is to minimize both of these costs. Our experience and verification tests assure that 1) problems are real and 2) the problem causes are properly identified. These goals are often unmet by competitors who inaccurately assess problem causes and include hot spots that are actually part of normal operation. These types of errors can dramatically increase the total cost of testing. Of critical importance: We fix problems during the survey. Every problem we fix reduces the total cost of the infrared survey.

Years of experience
With over 30 years of experience, we know the equipment we’re testing and instantly recognize the problems.

State of the Art Instruments
If you can’t see it, you can’t find it. Our instruments provide the best images available, permitting fast, accurate surveys.

Problem verification
Different types of problems produce similar infrared images. Many problems cannot be diagnosed by simply viewing the infrared image. We have developed on line verification techniques that pinpoint the problem cause.

Remember, faulty problem diagnosis will cost you money. Repairs will either be unnecessary or simply wrong. The cost of incorrect repairs can easily exceed the cost of a day of infrared testing!

This loose connection was immediately repaired during the inspection process. Repairs are completed whenever possible at no extra cost. This will dramatically reduce the total survey cost.

Custom reporting software
We developed custom software for creating inspection inventories and problem reports. This software speeds the inspection process.

Fast surveys
We often complete inspections in half the time of our competitors. Fast survey speed is a direct result of experience, high quality instruments and efficient reporting software. Our high speed saves you money and frees your staff for other projects.

User friendly reports
Our reports are attractive, simple and easy to understand. These features insure that problems will be corrected properly. Most important, our reports are timely-most reports are submitted the day of the survey via PDF documents, with hard copy sent out within 24 hours of completion.

Not Just Hot Spots: Any code viola- tions or safety concerns are reported as problems. Here, we have a dust filled transformer with trash lying on the bottom.	Instrumentation provides true RMS readings. We can also investigate current and voltage harmonic distortion where needed.	This may appear to be a loose feeder connection, but it is actually poor contact between the lug and breaker bus. This can only be correctly diagnosed with our verification tests.

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Overview

Vibration Testing

Ultrasound Testing

What is Vibration Testing?

A bearing failure in a motor can bring production to a grinding halt. An unbalanced cooling tower on the roof can shake a tenant’s conference room table on the first floor. A failed coupling in a chill water pump can mean early dismissal from an overheated building.

Two plane balance of fan results in smooth operation.

Your plant or office building’s operations depend upon continuous operation of numerous pieces of rotating equipment. One failure in a critical item can result in a chain reaction of severely damaged equipment, lost production and lost revenue. Such failures need not happen. Vibration testing will provide early detection of developing failures in rotating equipment so that repairs can be planned and conducted at your convenience.

How does vibration testing work?

As mechanical or electrical problems develop in rotating equipment, vibration levels increase. These increases occur at specific frequencies that relate to the type of developing fault. A vibration analyzer measures both vibration severity and frequency. By combining these measurements, we can determine the cause and severity of problems developing in your rotating equipment. We use the latest generation of vibration analyzers. All analyzers are multichannel, with the latest analytical features. These instruments greatly reduce the time required to acquire and analyze vibration data. Large numbers of machines may be analyzed rapidly and at dramatically reduced costs. Vibration analysis of your rotating equipment is just as cost effective as infrared testing of your electrical equipment!

What types of problems may be identified by vibration testing?

Our vibration test will identify most of the problems that will make your machines fail. This includes bearing faults, misalignment, imbalance, motor stator or rotor faults, worn belts or sheaves, mechanical looseness or rubs, flow deficiencies in pumps and fans, and more. Vibration analysis can be used to identify sources of objectionable mechanical or HVAC noise and vibration.

How is vibration testing conducted?

For many clients, vibration testing of rotating equipment is conducted in conjunction with infrared and ultrasonic surveys of the entire facility. All data is retained in a computer data base for trending future inspection results. Where large numbers of machines are to be tested (typically between 25-100 machines per day), we develop a customized computer data base of all machines. This facilitates rapid testing and analysis. Many clients opt for periodic monitoring. Test intervals range from monthly to annually. Periodic monitoring permits changes in critical machines to be detected before a failure condition can develop. Finally, indepth studies of specific machines may be conducted to resolve recurring problems, verify proper operation or obtain baseline data for acceptance of new installations. Where required, we utilize advanced techniques such as modal and operating deflection shape analysis. We can correct problems by performing inplace balancing, precision alignment and assist in developing structural modifications.

Examples

		Extreme vibration in new 500 HP compressor. The vibration resulted from a resonance in the male high speed impellor. This resulted from improper support of the discharge air line. The upper plot shows reduced vibration when pipe supports were tightened.	Bearing fault in a water pump. The fault is demonstrated by peak view and ultrasound spectra.
		A roof top air handler was causing loud vibration in the ceiling of a conference room. We balanced the fan. This eliminated the noise from the ceiling grid.	The lower plot shows very high vibration in a chill water pump. We predicted a damaged coupling. The upper plot shows vibration after the coupling was replaced.

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Overview

Infrared Electrical Surveys

Ultrasound Testing

What is Ultrasonic Testing?

Ultrasound spectral analysis of compressor bearing. Here, ultrasound output is fed into the vibration analyzer to provide a quantitative evaluation of the ultrasound source.

Many electrical and mechanical problems produce sound and vibration at ultra-sonic frequencies (greater than 20kHz). Unfortunately, these sounds cannot be detected by the human ear. These sounds can be detected by ultrasonic listening instruments. These instruments have been integrated into our Predictive Testing Service.

Ultrasonic testing is used in two ways in our Predictive Testing Service. First, it permits us to identify faults that cannot be detected by either infrared or vibration tests. Second, it permits an independent verification of problems that can be detected by the infrared or vibration tests.

What problems may be identified by ultrasonic testing?

Any type of impacting mechanical fault will generate ultrasound. Such faults in clude bearing and gear defects as well as mechanical looseness. Ultrasonic testing generally provides earlier warning of these types of faults than vibration or infrared tests.

Other mechanical faults that are found by ultrasound include: defective steam traps; leaks in pipes or vessels due to faulty welds, holes, gasket failures, etc.;leaky valves in liquid or gas lines and leaks in compressed air systems. Compressed air leak surveys can be a particularly valuable process that can easily reduce compressed air demand and electrical usage.

Ultrasonic survey of high voltage power lines. The sensitivity of the instrument is greatly enhanced for this application by using a parabolic signal concentrator.

Ultrasound is extremely valuable for inspections of high voltage electrical systems (above 2,000V). These systems require properly functioning insulation systems. Failure of high voltage insulation systems can result in catastrophic faults. Deterioration of high voltage insulation produces an electrical leakage known as corona, tracking or partial discharge. This condition causes ionization of the surrounding air. The ionization process produces ultrasound which is readily detected by the ultrasound instrument.

Pushing the Ultrasound Envelope

Mid Atlantic Infrared has innovated and expanded the use of ultrasound by developing spectral analysis of ultrasound signatures. This technique permits quantified analysis of both electrical and mechanical ultrasound sources. Analysis of the resulting spectral patterns reveals the source of high ultrasound. For example, ultrasound signatures readily reveal specific bearing fault frequencies. Also, ultrasound signatures can distinguish faulty high voltage insulation and arcing from other background ultrasound sources.

Mid Atlantic Infrared has pioneered the use of ultrasound for the evaluation of packing line equipment. This equipment consists of motors, gearboxes and numerous bearings, operating at a wide variety of speeds, often with limited access. Ultrasound has been proved to be an excellent tool for rapid and dependable identification of problems with this type of equipment.

Examples

		This plot compares an ultrasound reading and a vibration reading of a failing bearing. The vibration analysis revealed nothing about the condition. The ultrasound analysis readily shows the problem.	Ultrasound plots show once per revolution impact on a shaftturning at 66 RPM. Ultrasound is excellent for evaluation of slow speed machinery.
		High broad band ultrasound results from arcing in high voltage switchgear.The 60hz components to the left are from magnetically induced vibration in the switchgear. Spectral analysis of ultrasound permits dangerous insulation failures to be distinguished from normal ultrasound noise. Mid Atlantic Infrared pioneered these spectral analysis techniques.

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Overview

Infrared Electrical Surveys

Vibration Testing

Your building walls keep out the wind, rain, cold and heat.

Design errors, construction defects or aging of materials will defeat these goals. 

Unless these problems are discovered, they will waste energy, money and raise tenant complaints for the life of the building. An infrared envelope survey will find these problems fast. Developed over 25 years, our unique survey procedures and test instruments will identify infiltration, exfiltration and insulation deficiencies that would otherwise remain hidden. Often, of greatest importance are operational imbalances created by the building’s HVAC system. Such problems can lead to uncontrolled infiltration. We will find these problems as well.		Building has single glazed glass panels above ceiling line. Insulation was missing or improperly installed at numerous panels! Many uninsulated masonry wall sections were also found. Uninsulated glass panels and masonry are seen in center photo.
With our extensive knowledge of testing techniques, building construction details and building heat loss mechanisms, we not only identify problems, but suggest solutions. Air barrier systems often fail due to installation errors. When an infrared building envelope survey is required for building acceptance, the contractors know that any deficiencies will be found. Infrared envelope surveys of new construction are cheap quality assurance. The infrared envelope survey will provide points for LEEDS certification Applications. Every building should be tested at least once. New is best, but the benefits of an infrared survey can be realized at any time in the building’s life. Test Every Building Once!		Cold ceiling temperatures result from air infiltration. Investigation revealed that soffit areas beneath balconies were unsealed to exterior air flows. This results in substantial energy loss and, during cooling season, mold growth potential. Last photo shows open soffit.

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NOW, SEE THE AIR! Our Patent Pending DAMM cart provides a revolutionary view of data center air flows! At a fraction of the cost of CFD, we produce 3D maps of actual air flow in the data center. These maps combine air flow velocity, direction, temperature and humidity. We can quickly and accurately demonstrate air flows in the data center. Short cycling, mixing, ineffective CRAC placement and more can be easily seen. In the example above, air flows out of the center hot aisle and is drawn into the adjacent cold aisle. Inadequate tile air flow forces servers to draw exhaust air from the adjacent hot aisle back to the cold aisle. Arrow length shows velocity, color indicates temperature. Click on image above to enlarge.

• You lose a single CRAC, you cannot maintain local rack inlet temperatures
• You can no longer grow your data center due to insufficient cooling capacity
• You are sub-cooling your data center to avoid local hot spots
• You are getting constant hot spot alarms
• Your energy costs are out of control

These problems develop as data centers evolve from their original design. Data Center Cooling Optimization re-enables efficient cooling by delivering cooling just where it is needed and eliminating inefficiencies resulting from leaks, short cycling, recycling and improper cooling set points. Substantial improvements can typically be realized in legacy data centers with minimal investment.

New Measurement Technologies Yields Big Savings:

We can reduce your cooling costs by 20% or more by optimizing the operation of your existing infrastructure. We enable greener, more reliable data centers that deliver the right cooling just where it is needed.

The Benefits:

The data center will achieve Reduced Operating Costs, Increased Cooling Capacity, Greater CRAC Redundancy, Improved Equipment Reliability.

In order to optimize cooling in the data center, you need to know where the cooling loads are located and you have to know where cooling capacity is delivered. If cooling capacity location and delivery is not matched to cooling loads, than optimization cannot be achieved.

We don’t speculate about energy use in your data center—
We measure it with revolutionary tools!

In order to optimize cooling in the data center, you need to know where the cooling loads are located and you have to know where cooling capacity is delivered. If cooling capacity location and delivery is not matched to cooling loads, than optimization cannot be achieved.

You must also know when inefficient air flow patterns and operational practices are reducing available cooling capacity. These data center characteristics must be acquired through comprehensive measurements.

Once acquired, the measured data may be used to produce engineered and modeled solutions. Without the data, any solution approach is merely a guess.

Revolutionary Thermal Imaging-Rack inlet temperatures are the critical indicator of cooling air effectiveness. With our pioneering mosaic thermal images, we measure, quantify and index every square inch of rack inlet. We can determine cooling performance referenced to ASHRAE or any other standard. In the bottom image, all orange surfaces exceed recommended ASHRAE rack inlet limits.

Our Measurement Process

Rack Metrics:
We have developed innovative Infrared temperature mapping techniques that produce temperature readings of every square inch of server inlets. Computer analysis of infrared mosaic images allow us to readily measure the effectiveness of cooling air delivery and produce quantitative performance metrics.

Air Distribution Metrics:
How much air is moved and where does it go? We measure energy performance and efficiency of CRAC units. Measurements include air flow, humidity, temperature and power. We use these data to calculate heat transfer and COP for every unit. We measure air flows at every perforated tile that serves a rack.

Rack Energy Requirements:
We measure power requirements for racks.

Air Flow Mapping:
We use our patent pending DAMM Cart to find efficiency robbing air flow patterns throughout the data center. Our unique data display permits visualization of leak-age, short cycling, recycling and flow obstructions. Our visualization is crucial to convincing decision makers that problems exist and must be corrected!

Solutions

Using this data, we develop improved CRAC and perforated tile layouts, recommend leak remediation steps, design air barrier schemes and more. This is the low cost, low hanging fruit of improved operation.   The greatest improvements in cooling efficiency are realized by achieving the highest possible rack inlet temperatures and the lowest humidity levels.  We will simulate both air flow and CRAC operation to calculate optimal  set points for both temperature and humidity.   Importantly, we calculate the impact of our recommendations on operating costs and capacity availability using our sophisticated, proprietary CRACSYM  model.

The Final Step

Upon implementation of recommended actions, we can obtain new benchmark data to document the level of achieved savings and improved cooling efficiency.

Read Our Latest White Paper On Energy Efficiency Through Environmental Optimization!

What is the most cost effective investment you can make to reduce energy use?

An Ultrasonic Steam Trap Survey by Mid Atlantic Infrared Services!

A single blowing trap can cost you $1,000 per month.

The cost of finding and repairing that trap can be repaid in less than 1 month!

Failed steam traps waste dollars! A single blowing trap can waste many thousands of dollars per year.

Within a typical steam system, 15% of the traps may be bad at any time. This can translate into hundreds of thousands of dollars of wasted steam each year!

The solution is simple. An ultrasonic trap survey by Mid Atlantic Infrared will find all your failed traps.

Our techniques, representing over 25 years of testing experience, are fast and efficient, so our surveys are economical. Survey costs can often be repaid a few weeks after repairs are made. This is typically the best energy conservation investment available to the facilities manager.

We have pioneered the use of digital ultrasound to optimize survey effectiveness, speed and accuracy. Our unique statistical analytical approach ensures high accuracy.

We have developed innovative tools to estimate steam losses. These losses and all other operational issues are reported in detailed yet easy to use reports. These reports can be easily incorporated into you management systems.

Just how much can you save? The table below presents steam savings for six projects completed in 2005. Savings will vary with energy costs. Energy savings for these projects pay back survey and repairs costs in a few months! Where can you find a better return for your energy conservation investment?

Mid Atlantic Infrared is an independent testing organization. We do not sell or install steam traps. Our goal is to provide our customers the greatest energy efficiency.

Let Mid Atlantic Infrared make sure your steam dollars are well spent!

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Call us before you cut or core concrete walls or slabs.

We provide 3 dimensional, computer generated images to accurately identify:

Rebar Post-tension cables Structural components Electrical conduit PVC or metal pipes Voids With over 25 years experience applying cutting edge test procedures, Mid Atlantic Infrared brings the expertise to properly acquire and accurately interpret complex radar data. From state of the art instruments to expert image processing skills, we deliver unsurpassed accuracy to our clients. Radar testing is fast and convenient. Unlike X-ray, radar has no radiation hazard and requires access to only one side of the concrete. The inspection can be conducted at any convenient time and provides real time results. When we leave, your concrete is marked and your project can begin immediately. We bring a new level of safety and accuracy to your construction projects.

Before pouring concrete, note rebar. Radar image through poured concrete. 6” reinforcement mat in 10’ by 10’ slab area. Note overlapping grids.

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Images show PVC pipe  over rebar.
Images show electrical conduit above rebar.
	
	

		

	
	

		
3D cube cross section shows  characteristic arc of PT  cable over a 15 foot length
	
	

		

	
	

		

	
	

		

	

Predictive Testing for Your Roof!

Your Roof Is A Substantial Asset

Like other major components of your facilities, your roof, with its replacement cost of $6 to $18 per square foot, must be properly managed at each stage of its life. Proper roof management will ensure maximum roof life, maximum return on your roof investment, and a safe, dry working environment under your roof.

Our sophisticated tests and experienced personnel work together to find the least cost roofing solution.

Your Maintenance Priorities

Proper maintenance requires that roof problems be accurately identified as they develop. Mid Atlantic Infrared’s array of tests will find all roof deficiencies—those that are visible and those that are below the surface. With this information, we will design a roof maintenance program to ensure the lowest roofing costs and longest roof life.

Reroof or Repair?

Often, our surveys of older roofs will determine that minor repairs, combined with on-going, low cost maintenance, will add years of satisfactory roof performance. Where a roof has reached the end of its dependable life, timely reroofing will save substantial costs. Whether reroofing or simple repairs are required, we will design the least cost approach, consistent with your budget and facility use goals.

Getting What You Bargained For

Conducted prior to the purchase of a new or existing facility, our surveys will avoid buying a roof full of hidden problems that will require expensive solutions down the road. Mid Atlantic Infrared’s surveys of new roofs will identify the construction or design defects that might otherwise go undetected for years.

What Our Service Provides

Our roof evaluation is truly comprehensive. We conduct a variety of tests and inspections to determine the condition of every roof component. We communicate this information, along with complete repair specifications and cost estimates in a comprehensive, yet easily understood report.

Our service provides you with the following:

• The extent to which water has penetrated the roof system
• The nature and seriousness of all roof deficiencies
• Recommended maintenance/repair procedures including estimated costs

Moisture Testing

Visual Inspection

The Final Package

Underground water leaks waste money, cause service interruptions and result in property damage.

We find leaks in city water, domestic hot and cold water, closed loop heating and cooling, steam and fire systems. We’ve been doing it for over 20 years! We use acoustical correlation, ground microphones, ultrasound, infrared and ground penetrating radar. In short, if the leak can be found, we have the technology to succeed. Why waste thousands of dollars digging when we can pinpoint the leak location? If you have complex underground piping systems, a leak survey will reveal unknown leaks that are draining your budget.

Ground mics and vibration sensors identify leak locations. Ground penetrating radar identify leak locations. Radio frequency detectors & ground penetrating radar locate pipes & other underground utilities.

Acoustical Correlation identifies leaks in many types of systems by measuring leak sounds on the pipes. It is the primary leak location tool.Infrared imaging can identify hot water, condensate and steam leaks.

When leaks occur, we provide fast response.

Underground steam line leaks can wreck your facility’s bottom line. Steam leaks waste money and energy. They can ultimately lead to line failure, system interruptions, property damage and angry customers.

Since 1981, Mid Atlantic Infrared has provided aerial infrared surveys of underground steam and hot water distribution systems. Deteriorated insulation and steam or condensate leaks result in increased ground surface temperatures.   Our surveys provide early warning of developing steam system failures so repairs can be planned, not forced.

Our unique process provides problem analysis that combines ground surface temperature measurements, the highest resolution digital infrared, along with knowledge of steam system construction and operation. We inspect and analyze every foot of pipe in your system.

As in all of our applications, we provide ANALYSIS, not just hot spot identification!

Survey Benefits Early detection of developing faults permits scheduled repairs rather than emergency responses to catastrophic failures. Capital improvement projects may be planned and budgeted based on problem severity. System performance may be trended. Stable vs. deteriorating line sections can be identified. We will document improvement or deterioration. Enhanced steam system reliability translates to high customer confidence. Inspection Features Exceptional image quality provides easy problem identification and location. Accurate temperature measurement enables problem prioritization and trending. Our verification techniques can distinguish between deteriorated insulation and steam leaks. User friendly reports ensure that information is readily incorporated into system planning procedures.

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