Why Malaysia Must Mandate Thermography for Electrical Safety

Electrical failures are a persistent and growing threat to Malaysia’s industrial and commercial sectors. According to the Fire and Rescue Department of Malaysia (Bomba), 20–25% of building fires in recent years have been linked to electrical causes, resulting in millions of ringgit in damages, operational downtime, and, tragically, loss of life. These failures disrupt operations, endanger workers, and threaten the long-term sustainability of businesses, making robust preventive measures more critical than ever.

Industry studies from IEEE, NFPA, and EPRI consistently reveal that over two-thirds of electrical failures are caused by just two primary factors:

• Loose/Corroded Connections (35–50%).
• Insulation Breakdown (including Partial Discharge) (20–30%).

Mandating infrared thermography as an essential first step will provide a strong foundation for electrical safety and reliability across Malaysia. Alongside this, online partial discharge (PD) testing should be strongly recommended to complement thermography, with future consideration for making PD testing mandatory based on its proven effectiveness and industry readiness. This approach allows Malaysia to address critical electrical risks, safeguard businesses and infrastructure, and promote public safety while supporting long-term industrial growth.

1. The Root of the Problem: What’s Causing Electrical Failures?

According to data from Hartford Steam Boiler Insurance Co., electrical failures stem from a range of identifiable causes:

• Loose Connections/Parts (30.3%):
  These are the most common cause of electrical failures and are effectively detected and addressed through infrared thermography.
• Partial Discharge Related Causes (29.5%):
  This includes moisture (17.4%), defective or inadequate insulation (9.9%), and accumulation of dust, dirt, and oil (2.2%). These factors contribute significantly to insulation degradation and partial discharge activity, which online PD testing is specifically designed to detect and mitigate.
• Other Electrical Disturbances (18.6%):
  Includes line disturbances not related to lightning (10.4%) and lightning strikes (8.1%), both of which cause voltage fluctuations and surges that can stress and damage equipment.
• Foreign Objects/Short Circuiting (7.3%):
  Caused by external objects or animals interfering with electrical systems, leading to shorts and potential system failures.
• Physical Damage & Overloading (6.3%):
  Collision (3.9%) and overloading/inadequate capacity (2.4%) contribute to structural failures and overheating, leading to breakdowns.
• All Other Causes (8.1%):
  Encompasses miscellaneous causes such as design flaws, accidental damage, and lack of maintenance.

Key Insight: By targeting loose connections through thermography and insulation-related issues through online PD testing, facilities can address nearly 60% or almost two-thirds of all electrical failure risks. This combined approach ensures a robust, proactive maintenance strategy that directly tackles the leading causes of electrical breakdowns.

2. The Two-Pronged Solution

To build a strong foundation for electrical safety, infrared thermography should be mandated and conducted at least once a year to detect and address emerging issues such as loose or corroded connections before they become hazardous. This proactive approach ensures that critical faults are identified early, reducing the risk of costly failures. In support of thermography, online partial discharge (PD) testing is strongly recommended to be carried out annually as well. PD testing complements thermography by monitoring insulation health and detecting subtle degradation over time. Conducting these inspections together every year provides a complete, reliable picture of the system's condition, helping facilities prevent failures, avoid downtime, and maintain compliance with industry best practices and future regulatory standards.

Infrared Thermography (IR)

Infrared thermography identifies heat anomalies in real time, helping facilities detect early signs of loose connections, overloaded circuits, and failing components. This non-invasive method allows inspections under normal operating conditions, minimizing disruption.

• Detects heat anomalies in real time that signify resistance-related faults.
• Benefits: Live system checks without shutdowns, visual and quantifiable results, high ROI through early intervention, and compliance with safety standards.

Online Partial Discharge (PD) Testing

Partial discharge testing focuses on insulation health in high-voltage equipment. PD testing identifies microscopic electrical discharges that gradually erode insulation, potentially leading to arcing and system failure.

• Focuses on insulation health, detecting subtle electrical deterioration.
• Benefits: No shutdowns required, real-time monitoring, early detection of insulation degradation, and mitigation of catastrophic failure risks in vital assets like switchgear and transformers.

3. The ROI Case: Why It Pays to Prevent Failures

When considering the costs of thermography and PD testing, it's important to prioritize long-term savings over short-term expenses. While upfront investment may seem significant, the avoided costs of unexpected failures, emergency repairs, production downtime, and safety incidents are far greater. Predictive maintenance not only reduces the likelihood of catastrophic failures but also extends the lifespan of critical assets and minimizes operational disruptions. Facilities that invest in these technologies benefit from long-term financial stability, lower insurance premiums, and enhanced safety records.

Many insurers also offer premium discounts of 10–20% for facilities with proactive IR and PD programs. These technologies not only help in reducing insurance costs but also lower operational expenses, protect valuable infrastructure, and preserve reputational integrity.

4. Implementation Challenges & Solutions

Successfully adopting thermography and PD testing across industries in Malaysia requires addressing several practical challenges. Below are the key obstacles and strategies to overcome them:

5. Call to Action: What Should Happen Next?

Addressing electrical failures requires a united effort from all key stakeholders. Each has a critical role to play in creating a safer, more resilient electrical infrastructure for Malaysia.

For Regulators (Suruhanjaya Tenaga, DOSH):

Regulatory bodies must take the lead by establishing mandatory frameworks and enforcing compliance across industries.

• Mandate annual infrared thermography for all commercial/industrial installations above a certain capacity to establish a national baseline for electrical safety.
• Strongly recommend online PD testing for high-voltage equipment, with a view to evaluating its performance and potentially mandating it in the future based on industry outcomes and feedback.
• Develop enforcement mechanisms to ensure compliance, regular audits, and centralized reporting of inspection outcomes.

For Facility Owners:

Owners and operators of facilities must commit to incorporating these preventive measures as a permanent part of their maintenance strategy.

• Schedule a baseline IR scan to assess current system health.
• Identify and assess critical HV assets for PD monitoring, focusing on high-risk areas.
• Train staff internally or partner with certified thermographers and PD specialists to establish a sustainable maintenance routine.
• Integrate inspection results into ongoing maintenance plans to prioritize repairs and upgrades.

For Industry Bodies (IEM, MEF):

Industry groups should mobilize to raise awareness, provide training, and build collective momentum for nationwide adoption.

• Advocate for regulatory updates to encourage best practices.
• Publish success stories and case studies demonstrating tangible benefits.
• Host educational forums and workshops to disseminate knowledge and promote widespread adoption.

6. Future Innovations

The future of electrical maintenance is evolving rapidly with cutting-edge technologies designed to complement traditional practices and elevate system reliability.

• Drones equipped with advanced thermal cameras will revolutionize inspections of overhead lines, transformers, and other hard-to-reach infrastructure, reducing the need for manual labor and enhancing safety.
• Permanent PD monitoring systems embedded into critical assets will provide 24/7, real-time data, allowing facilities to detect and address insulation issues before they progress, eliminating guesswork and reducing unplanned outages.
• AI-driven predictive analytics will harness data from thermographic and PD tests, identifying patterns and predicting failures with increasing accuracy, allowing maintenance teams to plan interventions before issues arise.
• Integration with smart grid technologies will facilitate centralized diagnostics, enabling real-time visibility into the health of electrical networks and allowing automatic responses to detected anomalies, minimizing disruption.
• Remote monitoring platforms will enable off-site experts to analyze diagnostics, collaborate with on-site teams, and guide decision-making, helping facilities optimize resources and maximize uptime.
• Augmented reality (AR) tools may soon assist maintenance teams by overlaying diagnostic data directly onto equipment during inspections, making problem areas easy to identify and resolve.

These innovations represent the next phase of electrical maintenance—offering safer, faster, and more precise management of electrical assets to secure the future of industrial operations in Malaysia.

Conclusion

With 20–25% of Malaysian building fires linked to electrical issues, and over two-thirds preventable through thermography and PD testing, regulatory action is not just advisable—it is crucial. By implementing mandatory annual thermographic inspections and strongly encouraging online PD testing, Malaysia can dramatically reduce the risk of electrical failures, safeguard public safety, and protect economic stability.

The long-term advantages of these practices far outweigh the initial costs. Beyond preventing catastrophic failures and avoiding costly downtime, these proactive measures ensure operational continuity, enhance workplace safety, and protect valuable infrastructure. They also foster a culture of responsibility and foresight within industries, driving improvements in maintenance standards nationwide.

It is essential for regulators, facility owners, and industry bodies to collaborate and lead this transformation. By prioritizing preventive strategies today, Malaysia can build a future where electrical systems are not only reliable and efficient but also serve as a foundation for sustainable industrial growth and national resilience. The time to act is now—before the next avoidable failure occurs.

References

• Fire and Rescue Department of Malaysia (Bomba). "Annual Report 2013." https://www.bomba.gov.my/wp-content/uploads/2021/11/LAPORAN_TAHUN_2013.pdf
• Suruhanjaya Tenaga (Energy Commission). "Electricity Supply Act 1990." https://faolex.fao.org/docs/pdf/mal130375.pdf
• Electricity Regulations 1994. https://policy.asiapacificenergy.org/sites/default/files/Electricity%20Regulations%201994.pdf
• IEEE 493-2007 - IEEE Recommended Practice for the Design of Reliable Industrial and Commercial Power Systems (Gold Book). https://ieeexplore.ieee.org/document/4264700
• Electric Power Research Institute (EPRI). "Power Equipment Failure Modes and Maintenance Practices." https://www.epri.com/search#q=power%20equipment%20failure%20modes
• The Institution of Engineers Malaysia (IEM). https://www.myiem.org.my/
• NFPA 70B: Recommended Practice for Electrical Equipment Maintenance. https://www.nfpa.org/codes-and-standards/all-codes-and-standards/list-of-codes-and-standards/detail?code=70B
• NFPA 70E: Standard for Electrical Safety in the Workplace. https://www.nfpa.org/codes-and-standards/all-codes-and-standards/list-of-codes-and-standards/detail?code=70E
• Tenaga Nasional Berhad (TNB). https://www.tnb.com.my/