The Hartford Steam Boiler Insurance and Inspection Company

HSB Thermography Services

One State Street
Hartford, CT 06102-5024

INFRARED THERMOGRAPHIC SURVEY

For

ABC Company, Inc.

123 Any Street
Any Town, US 12345

Survey Performed

March 24, 2020

By
JR Smith
AVP / Level III Thermographer
HSB Thermography Services
[email protected]
(216) 588-1381

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor 1
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any of
its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 The Hartford Steam Boiler Insurance and Inspection Company

HSB Thermography Services

One State Street
Hartford, CT 06102-5024

ABC Company, Inc.

123 Any Street
Any Town, US 12345

Dear Mr. Johnson,

Thank you for allowing HSB Thermography Services to provide this service. We trust that this report
proves helpful and is of assistance to you.

The scope of work included the following areas:

Outside Substation, Load Centers, Motor Control Centers, Control Panels, Breaker Panels, and
Disconnects.

Equipment not surveyed during this visit includes de-energized, lightly loaded, inaccessible and/or
deemed by facility personnel to be non-critical.

As a result of this service the following Findings are presented for your review:

1 CRITICAL
1 SEVERE
2 ALERT
0 ADVISORY

Should you have any questions or comments concerning this report or our services, we are here to
assist you. Please feel free to call me at (216) 588-1381 or email [email protected]

Sincerely,

JR Smith
AVP / Level III Thermographer
HSB Thermography Services

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor 2
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any of
its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 The Hartford Steam Boiler Insurance and Inspection Company

HSB Thermography Services

One State Street
Hartford, CT 06102-5024

COMMENTS

The criteria used to categorize findings in this report are based on the potential effect that a failure will
have on operations and/or production.

ADVISORY - The following is helpful information based on HSB’s experience and engineering
judgement.

ALERT - The noted condition is routine in nature and is easily repairable. Cost is often limited to
labor and a few minor parts.

SEVERE - The noted condition presents a risk of personnel injury, contained property damage and
fire may be possible, and/or localized equipment damage and business interruption may
result.

CRITICAL - The noted condition presents a significant risk of personnel injury, property or fire
damage, exhibits signs of advanced degradation and imminent failure, and/or may
subject the facility to an extended business interruption.

Infrared thermographic surveys are non-contact, non-destructive examinations used to find abnormal
or unexpected thermal patterns or temperature differentials. These thermal patterns may indicate such
conditions as loose connections, overloaded circuits or phases, deteriorated or damaged insulation or
refractory, or excessive or unwanted friction, among others.

To perform the thermographic survey of your facility, HSB Thermography Services used the FLIR
Thermacam infrared imaging system. This system utilizes the latest developments in un-cooled
technology to generate the most accurate data available.

The calibration for this system is certified traceable to The National Institute of Standards and
Technology, NIST, USA and the Swedish National Testing and Research Institute, SP. This
calibration is based on the International Temperature Scale (ITS-90).

The Findings of this survey are in the following pages. These conditions warrant your attention.

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor 3
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any of
its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 The Hartford Steam Boiler Insurance and Inspection Company

HSB Thermography Services

One State Street
Hartford, CT 06102-5024

Inspection Summary

Finding CATEGORY Location Area Equipment Location Equipment ID Est. Repair Est. Repair
No. Cost Before Cost After
Failure Failure
1 CRITICAL Outside Main Transformer East Secondary $5,000 $78,000
Substation Bushing
2 SEVERE Raw Materials Pellet Feeder Main Breaker $100 $4,000
3 ALERT Packaging Dept. Palletizer No.3 Fuse No.1673 $25 $40
4 ALERT Press Dept. Press No.22 Disconnect $50 $475

Total Estimated Repair Costs Before Failure $5,175

Total Estimated Repair Costs After Failure $82,515
Cost Avoidance = $77,340

*Before and After costs- This estimate is based only on direct damage to the equipment and does not include the costs of
business interruption, extra expenses, spoilage, etc.

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor 4
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any of
its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 The Hartford Steam Boiler Insurance and Inspection Company

HSB Thermography Services

One State Street
Hartford, CT 06102-5024

Finding No. 1 Category CRITICAL

 
 

Location Area Outside Substation

Equipment Location Main Transformer
Equipment ID East Secondary Bushing
Est. Repair Cost $5,000
Before Failure
Est. Repair Cost $78,000
After Failure
Est. % of Production 90%
Est. Down Time 10-14 Days

 
 
154.2 °F

140 Ref. Temperature 76.2 °F

Area 1 Max. Temperature 176.0 °F
120

Area 1

100 Area 1: Rise 99.8 °F

Ref. 80

59.1

 
Recommendation/Comments:

The thermal pattern indicates the transformer has an internal problem conducting heat out to the surface of
the bushing. This should be investigated and repaired by a qualified HV electrical contractor.

*This is rated as “CRITICAL” due to the high replacement cost of the transformer and potential business
interruption should a failure occur.
 

Repair notes: Signature:….………..………………………………….Date:

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor 5
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any of
its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 The Hartford Steam Boiler Insurance and Inspection Company

HSB Thermography Services

One State Street
Hartford, CT 06102-5024

Finding No. 2 Category SEVERE

Location Area Raw Materials

Equipment Location Pellet Feeder
Equipment ID Main Breaker
Est. Repair Cost $100
Before Failure
Est. Repair Cost $4,000
After Failure
Est. % of Production 50%
Est. Down Time 2 Days

264.2 °F

250
Ref. Temperature 140.1 °F
Area 1 Max. Temperature 262.5 °F

200
Area 1

Area 1: Rise 122.4 °F

Ref.
150

105.9

Recommendation/Comments:

The lug connection should be disassembled, cleaned, inspected for damage and repaired as necessary.
Replace any discolored or damaged hardware and cut back the wire to sound conductor. Reassemble and
torque the fastener according to the manufacturer’s specifications.

*This is rated as “SEVERE” due to the very high temperature and potential business interruption.

Repair notes: Signature:….………..………………………………….Date:

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor 6
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any of
its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 The Hartford Steam Boiler Insurance and Inspection Company

HSB Thermography Services

One State Street
Hartford, CT 06102-5024

Finding No. 3 Category ALERT

Location Area Packaging Dept.

Equipment Location Palletizer No.3
Equipment ID Fuse No.1673
Est. Repair Cost $25
Before Failure
Est. Repair Cost $40
After Failure
Est. % of Production 0%
Est. Down Time 0

113.2 °F

110
Area 1
Ref. Temperature 78.9 °F
Area 1 Max. Temperature 121.0 °F
100

Ref.
90 Area 1: Rise 42.1 °F

80

72.2

Recommendation/Comments:

Remove the fuse and clean the fuse and fuse clip. Reinsert the fuse ensuring the fuse clip is providing
adequate tension and making good contact with the fuse. Also, all three fuses (yellow arrow) should be
the same size, style, and type from the same manufacturer.

Repair notes: Signature:….………..………………………………….Date:

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor 7
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any of
its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 The Hartford Steam Boiler Insurance and Inspection Company

HSB Thermography Services

One State Street
Hartford, CT 06102-5024

Finding No. 4 Category ALERT

Location Area Press Dept.

Equipment Location Press No.22
Equipment ID Disconnect
Est. Repair Cost $50
Before Failure
Est. Repair Cost $475
After Failure
Est. % of Production 10%
Est. Down Time 1 Day

131.0 °F

Ref. Temperature 91.4 °F

120 Area 1 Max. Temperature 132.3 °F
Area 1 Area 2 Area 2 Max. Temperature 139.1 °F

100 Area 1: Rise 40.9 °F

Ref.

Area 2: Rise 47.7 °F

80

74.9

Recommendation/Comments:

The connections should be disassembled, cleaned, inspected for damage and repaired as necessary.
Reassemble and torque fasteners according to the manufacturer's specifications using new hardware as
required.

Repair notes: Signature:….………..………………………………….Date:

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor 8
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any of
its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 The Hartford Steam Boiler Insurance and Inspection Company

HSB Thermography Services

One State Street
Hartford, CT 06102-5024

For more information or comments contact:

JR Smith- AVP/ HSB Thermography Services

Cleveland, OH
216-588-1381
[email protected]

Western Region Eastern Region

Dennis DeGerald LVL II Thermographer Bill Viot LVL II Thermographer

Madison, WI Hartford, CT
904-214-5201 860-281-2541
[email protected] [email protected]

Steve Woods LVL II Thermographer Charles Johnson LVL II Thermographer

St. Louis, MO Richmond, VA
618-973-7835 804-691-3082
[email protected] [email protected]

Jim Nelson LVL II Thermographer Norm Gaver LVL II Thermographer

Dallas, TX Charlotte, NC
903-217-7016 704-892-33947
[email protected] [email protected]

Richard Toth LVL III Thermographer Ron Griggs LVL II Thermographer

Yuma, AZ Lakeland, FL
916-995-2267 863-413-6251
[email protected] [email protected]

Rick Stafford LVL II Thermographer

Los Angeles, CA
951-457-1229
[email protected]

If you would like to learn more about electrical risk management, please click on the following link:

http://www.hsb.com/hsbext/Electrical_Risk_Management/

This report does not purport to set forth all hazards nor to indicate that other hazards do not exist. By issuing this report, neither the Company nor 9
any of its employees makes any warranty, expressed or implied, concerning the contents of this report. Furthermore, neither the Company nor any of
its employees shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by the
Company) for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
 The Hartford Steam Boiler Insurance and Inspection Company

HSB Thermography Services

One State Street
Hartford, CT 06102-5024

VIBRATION ANALYSIS SURVEY

For

ABC Company, Inc.

123 Any Street
Any Town, US 12345

Survey Performed

March 24, 2020

By
JR Smith
AVP / Level III Thermographer
HSB Thermography Services
[email protected]
(216) 588-1381

HSB IIC Pilot Program Branch

Vibration Analysis * Ultrasound Analysis

This report is provided for informational purposes only and does not purport to set forth all hazards nor to indicate that other hazards do
not exist. By issuing this report, neither HSB, Munich RE, nor any of their a liates, employees or suppliers makes any warranty, express or
implied, concerning the accuracy and contents of this report. Furthermore, neither HSB, Munich RE, nor any of their a liates, employees or
suppliers shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by HSB) for
personal injury or property damage or loss of any kind arising from or connected with this report, the inspection or any failure to inspect. All
recommendations are general guidelines and are not intended to be exhaustive or complete, nor are they designed to replace information or
instructions from the manufacturer of your equipment. Contact your equipment service representative or manufacturer with speci c
questions. (c) Copyright HSB
 I. ANALYSIS BACKGROUND

The vibration measurements were collected on the machine casing at bearing locations in a vertical, horizontal, and axial
direction using an accelerometer and vibration data collector. The vibration levels were compared to a database of vibration
severity levels. The vibration severity levels are based on the vibration characteristics of machines with similar mechanical
configurations and on ISO Standard 10816. The vibration levels were compared to previous measurements to establish the
trend and determine the final severity.

CONDITION DEFINITIONS

Condition Level Vibration Analysis Indicates Action

Little or no deterioration in
Acceptable There is no cause for concern. Note for future analysis.
equipment condition.

Monitor the vibration levels more frequently to establish a trend and to

Monitor Developing Problems.
determine if repairs should be made during next shutdown.

The machine is running Plan for a repair outage at the nearest opportunity. Until repaired,
Alarm
rough. monitor closely.

Correct problems immediately or at the first opportunity to avoid

Danger A severe problem.
machine failure, unscheduled downtime, and secondary damage.

This report is provided for informational purposes only and does not purport to set forth all hazards nor to indicate that other hazards do
not exist. By issuing this report, neither HSB, Munich RE, nor any of their a liates, employees or suppliers makes any warranty, express or
implied, concerning the accuracy and contents of this report. Furthermore, neither HSB, Munich RE, nor any of their a liates, employees or
suppliers shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by HSB) for
personal injury or property damage or loss of any kind arising from or connected with this report, the inspection or any failure to inspect. All
recommendations are general guidelines and are not intended to be exhaustive or complete, nor are they designed to replace information or
instructions from the manufacturer of your equipment. Contact your equipment service representative or manufacturer with speci c
questions. (c) Copyright HSB
 II. EQUIPMENT SUMMARY

The overall condition of equipment can have a large impact on the operation of any facility. As the condition of the
equipment improves, there are several factors that are affected:
Operating Costs will decrease.
Reliablility will increase.
Building Environment quality will increase.

ABC Company
1234 Any Street, Any Town, US

Machines Health

no health level 0 machines

danger 0 machines
alarm 1 machine
5 monitor 1 machine
acceptable 3 machines

Health Machine Last Faults Type

Recorded

1 Alarm 84-Fan Mold -10 Nov 12, 2019 GMT Radial unbalance - Driven Fan
Scope

2 Monitor Shop 31 Mold Cooling Fan Nov 12, 2019 GMT Misalignment - Motor
Scope

3 Acceptable 84-Fan Mold-12 Nov 12, 2019 GMT

Scope

4 Acceptable 84-Fan Mold-7 Nov 12, 2019 GMT

Scope

5 Acceptable Shop 32 Mold Cooling Fan Nov 12, 2019 GMT

Scope

This report is provided for informational purposes only and does not purport to set forth all hazards nor to indicate that other hazards do
not exist. By issuing this report, neither HSB, Munich RE, nor any of their a liates, employees or suppliers makes any warranty, express or
implied, concerning the accuracy and contents of this report. Furthermore, neither HSB, Munich RE, nor any of their a liates, employees or
suppliers shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by HSB) for
personal injury or property damage or loss of any kind arising from or connected with this report, the inspection or any failure to inspect. All
recommendations are general guidelines and are not intended to be exhaustive or complete, nor are they designed to replace information or
instructions from the manufacturer of your equipment. Contact your equipment service representative or manufacturer with speci c
questions. (c) Copyright HSB
III. DETAILED ANALYSIS AND DATA
84-Fan Mold -10 - Fan
Nov 12, 2019 4:05:45 PM GMT by Charlie Johnson
Last Recorded
Critical

Scope

Overview
Schedule the recommended activities in the next quarter and monitor the machine frequently until repaired.

alarm Radial unbalance - Driven Fan

The vibration levels at the fan running speed indicate a possible fan imbalance.

Possible Cause Maintenance Practices

- Heavy spot. - Wash and clean as access permits.
- Dirt build-up. - Balance the fan.
- Erosion of fan blades.

Bearing2 - 2H

RMS | Measurement: vibration | Domain: frequency | Vector: velocity

mm/sec

CPM

This report is provided for informational purposes only and does not purport to set forth all hazards nor to indicate that other hazards do
not exist. By issuing this report, neither HSB, Munich RE, nor any of their a liates, employees or suppliers makes any warranty, express or
implied, concerning the accuracy and contents of this report. Furthermore, neither HSB, Munich RE, nor any of their a liates, employees or
suppliers shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by HSB) for
personal injury or property damage or loss of any kind arising from or connected with this report, the inspection or any failure to inspect. All
recommendations are general guidelines and are not intended to be exhaustive or complete, nor are they designed to replace information or
instructions from the manufacturer of your equipment. Contact your equipment service representative or manufacturer with speci c
questions. (c) Copyright HSB
 Shop 31 Mold Cooling Fan
- Fan
Last Recorded Nov 12, 2019 3:54:10 PM GMT by Charlie Johnson
Critical

Scope

Overview
Monitor the machine more frequently.

monitor Misalignment - Motor

Misalignment between the motor and the machine.

Possible Cause Maintenance Practices

- Damaged or worn shaft or coupling. - Inspect coupling for wear.
- Pipe strain - Consider performing a precision shaft alignment.
- Soft foot - Continue to monitor.
- Incorrect thermal growth offset
- Imprecise installation / maintenance practices

Bearing1 - 1H

RMS | Measurement: vibration | Domain: frequency | Vector: velocity

mm/sec

CPM

This report is provided for informational purposes only and does not purport to set forth all hazards nor to indicate that other hazards do
not exist. By issuing this report, neither HSB, Munich RE, nor any of their a liates, employees or suppliers makes any warranty, express or
implied, concerning the accuracy and contents of this report. Furthermore, neither HSB, Munich RE, nor any of their a liates, employees or
suppliers shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by HSB) for
personal injury or property damage or loss of any kind arising from or connected with this report, the inspection or any failure to inspect. All
recommendations are general guidelines and are not intended to be exhaustive or complete, nor are they designed to replace information or
instructions from the manufacturer of your equipment. Contact your equipment service representative or manufacturer with speci c
questions. (c) Copyright HSB
 84-Fan Mold-12 - Fan
Last Recorded Nov 12, 2019 4:08:29 PM GMT by Charlie Johnson
Critical

Scope

Overview
Continue with usual maintenance activities and monitoring on a regular basis.

This report is provided for informational purposes only and does not purport to set forth all hazards nor to indicate that other hazards do
not exist. By issuing this report, neither HSB, Munich RE, nor any of their a liates, employees or suppliers makes any warranty, express or
implied, concerning the accuracy and contents of this report. Furthermore, neither HSB, Munich RE, nor any of their a liates, employees or
suppliers shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by HSB) for
personal injury or property damage or loss of any kind arising from or connected with this report, the inspection or any failure to inspect. All
recommendations are general guidelines and are not intended to be exhaustive or complete, nor are they designed to replace information or
instructions from the manufacturer of your equipment. Contact your equipment service representative or manufacturer with speci c
questions. (c) Copyright HSB
 84-Fan Mold-7 - Fan
Last Recorded Nov 12, 2019 4:11:46 PM GMT by Charlie Johnson
Critical

Scope

Overview
Continue with usual maintenance activities and monitoring on a regular basis.

Bearing1 - 1H

RMS | Measurement: vibration | Domain: frequency | Vector: velocity

inch/sec

Hz

This report is provided for informational purposes only and does not purport to set forth all hazards nor to indicate that other hazards do
not exist. By issuing this report, neither HSB, Munich RE, nor any of their a liates, employees or suppliers makes any warranty, express or
implied, concerning the accuracy and contents of this report. Furthermore, neither HSB, Munich RE, nor any of their a liates, employees or
suppliers shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by HSB) for
personal injury or property damage or loss of any kind arising from or connected with this report, the inspection or any failure to inspect. All
recommendations are general guidelines and are not intended to be exhaustive or complete, nor are they designed to replace information or
instructions from the manufacturer of your equipment. Contact your equipment service representative or manufacturer with speci c
questions. (c) Copyright HSB
 Shop 32 Mold Cooling Fan
- Fan
Last Recorded Nov 12, 2019 3:50:18 PM GMT by Charlie Johnson
Critical

Scope

Overview
Continue with usual maintenance activities and monitoring on a regular basis.

This report is provided for informational purposes only and does not purport to set forth all hazards nor to indicate that other hazards do
not exist. By issuing this report, neither HSB, Munich RE, nor any of their a liates, employees or suppliers makes any warranty, express or
implied, concerning the accuracy and contents of this report. Furthermore, neither HSB, Munich RE, nor any of their a liates, employees or
suppliers shall be liable in any manner (other than liability that may be expressed in any policy of insurance that may be issued by HSB) for
personal injury or property damage or loss of any kind arising from or connected with this report, the inspection or any failure to inspect. All
recommendations are general guidelines and are not intended to be exhaustive or complete, nor are they designed to replace information or
instructions from the manufacturer of your equipment. Contact your equipment service representative or manufacturer with speci c
questions. (c) Copyright HSB