Thermographic Inspection: A Must-Have for Electrical Preventive Maintenance

Electrical systems and equipment are critical to the operations of many businesses. However, they are also subject to wear and tear, and degradation over time, which can lead to electrical faults and failures that can cause downtime, safety hazards, and loss of revenue. To prevent these problems, businesses need to implement a proactive maintenance program that includes testing or inspecting electrical assets’ conditions. One of the most effective and efficient testing methods for detecting electrical faults is thermographic inspection. In this article, we will explore what electrical thermographic inspection is, why it is essential for businesses to conduct routine infrared inspections as part of a preventive maintenance program.

What is Infrared Thermographic Inspection?

Electrical thermographic inspection is a non-destructive testing method that uses thermal imaging technology to identify potential faults and issues in electrical equipment. Electrical components generate heat as they operate, and any malfunction or fault will increase the temperature of the component. A thermographic camera can detect the temperature differences and provide an image that displays the thermal patterns of the equipment. By analyzing these patterns, a qualified thermographer can identify potential faults and issues that may not be visible to the naked eye.

Thermographic inspection is an efficient testing method because it provides a non-invasive means of detecting faults on energized electrical systems. Traditional inspection methods that require equipment shutdown, can cause significant downtime and disruption to business operations. On the other hand, electrical thermographic inspection can be conducted while the equipment is in operation, reducing downtime and the need for expensive shutdowns. Also, the technology used in the camera makes it possible to detect temperature differences as small as 0.1°C, allowing for early and accurate detection of potential problems before they become critical.

When to Conduct an Infrared Inspection Program?

According to the NFPA 70B, routine infrared inspections of energized electrical systems should be performed annually prior to shut down, and more frequent inspections for example, quarterly or semi-annually, should be performed where warranted by loss experience, installation of new electrical equipment, or changes in environmental, operational, or load conditions. The NFPA 70B details preventive maintenance for electrical, electronic, and communication systems and equipment to prevent equipment failures and worker injuries. In the latest 2023 revision of NFPA 70B, electrical thermographic inspection is now mandatory and enforceable by OSHA. Facilities with aging electrical assets are particularly vulnerable to problems caused by wear and tear, so it is essential to conduct more frequent routine inspections. While OSHA's adoption of these NFPA Standards applies only in the US, many countries have adopted some form of the NFPA standards into their own regulations.

Common Faults Detectable by Infrared Thermographic Inspection

Electrical distribution systems comprise various assets, including transformers, switchgear, circuit breakers, fuses, motors, and generators, among others. Each component is susceptible to specific types of faults, which can be detected through thermographic inspection. During an infrared inspection, these assets can be checked for various faults, including:

• Loose connections: these are caused by thermal cycling, which can cause expansion and contraction of components. Loose connections can lead to arcing, overheating, and fire hazards.
  
  

  Hotspot detected at Sp2 caused by loose connection

• Imbalanced loads: these are caused by electrical appliances draw an uneven amount of power. If left unattended, imbalanced load can lead to various problems such as overheating, unexpected trip, damage to electrical appliances, and increased energy costs.
  
  

  Hotspot caused by load imbalances (red indicator)

• Defective components: these include faulty circuit breakers, fuses, and transformers, among others. Defective components can lead to electrical faults, equipment failure, and safety hazards.
   

  Cold spot indicating defective radiator

  Cold spot indicating defective circuit breaker

• Overloaded circuits: these are caused by excessive current flow in the circuit, which can lead to overheating and component failure.

Benefits of Including Thermographic Inspection in Preventive Maintenance Programs

An excerpt from the NPFA 70B document declares, "a well-administered Electrical Preventative Maintenance program will reduce accidents, save lives, and minimize costly break downs and unplanned shutdowns of production equipment.”

Implementing a thermographic inspection program as part of a preventive maintenance program has several benefits for businesses, including:

• Early detection of potential problems: Regular inspections can identify issues before they become critical, reducing the risk of unscheduled downtime and safety hazards.

• Cost-effective solution: Thermographic inspection is a cost-effective solution compared to the cost of equipment failure and downtime.

• Prolonged equipment life: Early detection of faults and timely repairs can extend the life of electrical assets, reducing the need for costly replacements.

• Improved safety: Inspections can identify potential safety hazards, reducing the risk of accidents and injuries.

• Compliance with regulations: Some industries are required by regulations to conduct regular electrical inspections, and thermographic inspection is an effective testing method for compliance

In addition, a study by the Federal Energy Management Program (FEMP) estimated that an annual thermographic inspection program could yield a savings of 30-40% over reactive maintenance, demonstrates the value of including thermographic inspection in a preventive maintenance program.

Conclusion

Electrical thermographic inspection is a powerful tool that businesses can use to improve safety and reduce downtime. By detecting faults early, businesses can extend the life of their electrical assets, prevent costly downtime, and reduce the risk of equipment failure and personnel injuries. Adopting electrical thermographic inspection as part of a preventive maintenance program can provide businesses with a competitive advantage, improve their bottom line, and ensure compliance with industry regulations. Thus, investing in electrical thermographic inspections is a smart decision for any business looking to improve safety and reduce downtime, and our team is here to help you achieve your maintenance goals. Contact us today to request a free quotation and consultation and visit our website at www.amkatech.solutions to learn more about our services.