When reliability is non-negotiable, sometimes the smallest tools can make the biggest difference. At CIPCO’s Summit Lake Generating Plant, a pocket-sized thermal camera attachment changes a smartphone into a heat-detecting powerhouse - spotting equipment issues long before they lead to unplanned shutdowns.

Operator mechanic Klint Craft connects a Teledyne FLIR One thermal camera attachment to a smartphone and links it to the FLIR One app. Teledyne FLIR designs and develops professional technologies to bring sensing solutions like thermal imaging.

This real-time data enables CIPCO to monitor the exact temperature of components on their phone screen, such as turbines, charge air coolers, generators, oil supply lines, and exhaust systems, all without the need for bulky equipment or planned maintenance outages.

Plant Superintendent Dustin Stark explains, “The thermal imaging helps detect hot spots that are abnormally warm when compared to other areas that have the same moving parts, like an engine that varies in temperature compared to other engines.”

When equipment overheats, the risks vary.  “If it’s an exhaust leak, hot gases could burn wiring. If it’s mechanical, you risk engine damage,” Stark added.

On a thermal camera, overheating can look different depending on the intended temperature of that piece of equipment. Brighter colors like orange, yellow or white indicate higher temperatures, while colors like blue, purple and black indicate cooler temperatures.

The causes of overheating can range from bearing failures to worn seals or blocked cooling systems, making early detection key to keeping the plant running efficiently.

Once excessive heat is detected, the Summit Lake crew must shut down the engine and investigate further.

“We look through trends on the Wärtsilä Operator interface system for changes in temperature, pressure, and value changes,” Stark said. Additionally, crew uses a tool called UNITOOL to measure real-time system control, allowing for detailed engine diagnostics. “We review manuals and determine the parts, outage length and manpower needed to fix the issue.”

Maintaining the reliability of our natural gas operations is a top priority. By identifying problems early, CIPCO can prevent unplanned outages and extend the life of equipment, ensuring reliable energy for our Member-owners.