See the Invisible: Detect Problems Before They Cause Failures
Over 65% of electrical equipment failures are preceded by detectable temperature increases. Loose connections, overloaded circuits, and failing components generate excess heat weeks or months before catastrophic failure. Infrared thermography detects these thermal signatures invisible to the human eye.
Regular thermographic surveys identify problems enabling planned repairs costing $500-$5K versus emergency failures costing $50K-$5M+ in equipment damage, fire, and downtime. NFPA 70B recommends annual IR surveys as cornerstone of preventative maintenance programs.
Infrared thermography uses thermal imaging cameras to detect and measure temperature differences in electrical equipment. Services include:
Electrical System Surveys
Complete facility scanning of all energized equipment
Problem Identification
Detection of overheating connections and components
Trending Analysis
Track temperature changes over time
Priority Assessment
Risk-based categorization of findings
IR surveys cover: switchgear, panelboards, transformers, motors, cables, busway, fuses, circuit breakers, disconnect switches, contactors—all energized electrical equipment. Performed during normal operation without disruption to facility operations.
Electrical fires cause $1.3 billion annual property damage in the U.S. Most originate from overheating connections, overloaded circuits, or failing components. These conditions develop gradually, generating detectable heat before ignition. Thermography identifies fire hazards enabling correction before disasters occur. Insurance carriers often require IR surveys as policy conditions for good reason—documented programs prevent losses.
Real Example:
Manufacturing facility conducted annual thermographic survey. Survey identified main breaker connection showing 45°C temperature rise above ambient. Load analysis showed breaker operating at only 60% rating—connection resistance, not overload. Electricians tightened connection during next scheduled maintenance ($500 repair). Three months later, adjacent identical breaker without high temperature failed catastrophically causing arc flash fire. Main distribution panel destroyed, two workers injured requiring hospitalization, facility without power 8 days during reconstruction. Total costs: $2.8M (equipment $850K, medical/legal $450K, lost production $1.5M). Cost of annual thermography: $3K. Repair cost of identified problem: $500. ROI: 5,600:1.
Overheating dramatically accelerates equipment aging. Every 10°C temperature increase halves insulation life. Chronic overheating from poor connections or overloads degrades equipment that should last 30+ years in 5-10 years. Thermography identifies these conditions enabling load redistribution or repairs that restore normal operating temperatures.
Unlike many electrical tests requiring de-energization, thermography scans energized equipment during normal operation. No arc flash risk to personnel. No disruption to facility operations. No exposure of energized parts. Thermographers scan from outside panels using viewport windows or doors removed with equipment energized at safe standoff distances.
NFPA 70B recommends annual thermographic surveys. OSHA requires equipment be maintained in safe operating condition. Many insurance carriers mandate IR surveys as policy conditions. Documentation from professional surveys satisfies these requirements while demonstrating due diligence in asset management.
Loose bolted connections from improper torque, vibration, or thermal cycling create high resistance generating heat. Oxidation and corrosion increase resistance further. These connections fail suddenly causing arc flash or fire. Thermography detects elevated temperatures at connections. Tightening connections or replacing degraded hardware costs $100-$2K; connection failures cause $50K-$5M+ damage including fires and arc flash events.
Circuits loaded beyond nameplate ratings or severely imbalanced three-phase systems generate excessive heat. Conductors, terminations, and breakers operate above design temperature accelerating aging. Thermography identifies overload conditions. Load redistribution or circuit upgrades prevent premature equipment failure and fire hazards. Identifying overloads before failure enables planned corrections versus emergency repairs after failures.
Circuit breakers with failing mechanisms, fuses with high resistance, contactors with pitted contacts—all generate excess heat before complete failure. Thermography identifies these degrading components enabling planned replacement during scheduled maintenance. Component replacement costs $50-$5K; emergency failures after complete loss costs 10-100x more including downtime and damage to connected equipment.
Transformers with cooling system problems, internal faults, or overload show elevated temperatures detectable through tank walls. Motors with bearing problems, winding faults, or ventilation blockage exhibit thermal patterns characteristic of specific problems. Early detection enables targeted repairs versus complete equipment replacement after catastrophic failure.
Busway joints, cable terminations behind panels, and connections inside gear show no external signs of problems. Thermography detects temperature increases through panel covers and enclosures. Problems in inaccessible locations identified before failure enables planned access and repair versus emergency troubleshooting and extensive disassembly under time pressure.
Best Practice: Schedule surveys during normal operating loads. Peak load surveys reveal problems masked at light loads. Trending analysis requires consistent survey timing annually.
Typical Duration: Small facility (1-2 distribution boards): 2-4 hours. Medium facility (multiple substations): 4-8 hours. Large facility or campus: 1-3 days. All surveys performed during normal operations without service interruption.
$50K-$5M+
Electrical fire and equipment failure costs
$2K-$15K
Typical facility thermographic survey cost
50-500x
ROI from preventing ONE major incident
Recommends annual thermographic surveys as fundamental component of electrical maintenance programs with specific survey procedures.
Defines thermographic survey procedures, temperature rise limits, and reporting requirements for electrical maintenance.
Qualification and certification requirements for thermographers ensuring competency in equipment operation and results interpretation.
Requires electrical equipment be maintained in safe condition; thermography provides documentation of maintenance diligence.
Professional thermographic surveys detect fire hazards and equipment problems before disasters occur.