Thermal Energy Survey
Manufacturing Operations

Thermo Guard provides accurate, thorough and efficient inspections of manufacturing processes and buildings for opportunities to reduce energy waste.  Our Thermal Energy Survey programs provide significant pay back in energy savings.  Additionally our inspections are completed more efficiently, safely and thoroughly then can be done by conventional means. 

After the inspection clients receive comprehensive reports covering suspect equipment that include

• Equipment Database
• Equipment identification and location
• Equipment descriptions and nomenclature
• Date of inspection for historical record keeping
• Description of each anomaly
• Estimated energy losses for failed steam traps
• Comprehensive Color Report
• Side-by-side thermal and visible images for accurate identification of damage/defects
• Visible images aid equipment identification on shop floor
• Infrared images isolate problem location on equipment to aid future repairs
• Repair Guidance
• We established repair priorities, note probable causes, and provide recommendations for corrective action

Following are detailed descriptions of Thermo Guard’s Thermal Energy Survey program’s various energy related inspections.  An energy inspection survey for one or more of the following areas can identify significant opportunities to reduce your company’s energy consumption.

Energy Equipment Inspections

Processes dependent on steam heating of equipment have many opportunities to lose energy due to hidden equipment failures.  A Thermo Guard inspection makes these hidden problems visible.  The inspection includes the following energy generating and consuming equipment.

• Boilers for temperature anomalies
• Jackets
• Exhaust piping
• Refractory linings
• Steam distribution system to identify
• Failed open steam traps
• Wet or damaged insulation
• Process oven shells: for temperature anomalies to indicate failed refractory and uneven heating.
• Process insulation: on tank jackets, presses, and piping for failure, leaks or moisture
• HVAC units: and accessible distribution ductwork for wet or damage insulation.

Building Envelope Inspections

A thermal survey of the building envelope detects and records anomalies of the wall, door and window assemblies, showing inward and outward losses of energy.  Inspection items include:

• Interior and exterior wall surfaces to detect
• Heating and cooling leaks
• Water damaged or missing insulation
• Warm electrical wiring inside wall that could lead to fire hazards
• Windows - Discover leaks around window frames
• Doors – Identify crimped insulation and seal failures
• Exterior electrical junction boxes and fuse panels for loose or corroded connections

Roof Inspections

Roof inspections, performed at night, provide information about roof condition in addition to energy loss areas.  Thermo Guard’s thorough roof inspection will locate wet and missing insulation, wet roofing membrane and flashing problems.  This inspection includes:

• Visual field inspection of roofing components documented with 35mm photographs of damaged areas or items of concern
• IR scan of entire roof surface
• Summary of present condition, along with recommended repair considerations
• Marking moisture damaged areas with high visibility paint
• Day time panoramic photographs of the roof area
  

Basic Survey Procedure

We have found it highly effective to have one (1) company representative (usually a member of engineering, maintenance, or management at the site) to be a contact person for the survey team.  This person serves as a coordinator and interface between the plant and the survey team.

Pre-Survey Meeting :

Our procedure for conducting a survey begins with a pre-survey meeting at the site, where possible.  This meeting serves several functions.

• It allows us to establish a relationship with the plant personnel.
• Enables us to gather information about the plant processes to determine the specific expertise needed and time required on-site.
• Allows us to review survey details, such as safety protocols, plant policies, and plant personnel that will be working with the survey team.
• Discuss logistics, such as lodging, lunches, etc.

Once the pre-survey meeting has been completed the survey team members are selected, a budget prepared and submitted, and schedules finalized.

Plant Survey:

Depending upon the size of the facility, site surveys typically require from one (1) to three (3) days.

For the survey, at least one person from the plant is required for each team member.  That person should be familiar with the particular processes or systems under review.  Participation by others is encouraged and in some past surveys personnel from sister plants or neighboring industries have attended.  It is not uncommon for team members to have a group as large as 4-5 people accompanying them.  These surveys are used as vehicles for educating people in energy management and predictive maintenance principals, along with developing a better understanding of equipment operations. 

Survey Report:

Producing a final survey report involves several steps.  Once the site survey is completed it typically takes two to three weeks to generate the report.  A copy of the report is provided to the plant along with a Project Profile.  The Project Profile is a one page executive summary that highlights such critical features as anomalies found, and potential savings by identifying the problems early.