Infrared Thermography
See the Invisible: Detect Problems Before They Cause Failures
Electrical Failures Announce Themselves with Heat
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.
Thermal imaging inspection experts (and a quick note on cameras)
ClarkTE’s thermography team holds Level II and Level III certifications under the ASNT and ITC frameworks — meaning every survey is run by someone who can interpret what the camera shows, not just point it. We use FLIR T-series and equivalent professional cameras (320×240 or higher resolution, sub-50 mK NETD), which is the minimum sensitivity for finding the kind of subtle, low-delta-T defects that actually matter in industrial gear.
About thermal imaging camera price: a research-grade IR camera lives in the $5,000-$25,000 range; a smartphone IR adapter is fine for a homeowner spotting a drafty window but is not the right tool for a substation. ClarkTE doesn’t sell cameras — we run surveys with our own gear and deliver a report. If you want camera buying guidance for an in-house program, we’ll happily share what we use and why.
What is Infrared Thermography?
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.
Why This Service is Critical
Fire Prevention and Life Safety
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.
Equipment Protection and Reliability
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.
Non-Intrusive and Safe
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.
Compliance and Insurance Requirements
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.
Common Problems This Service Solves
1. Loose or Degraded Connections
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.
2. Overloaded Circuits and Imbalanced Phases
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.
3. Failing Components Before Complete Failure
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.
4. Transformer and Motor Overheating
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.
5. Hidden Problems in Inaccessible Equipment
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.
When Should You Schedule This Service?
Immediate Survey Needed
- • New facility acquisition or management
- • No previous thermographic surveys documented
- • Recent electrical problems or failures
- • After major electrical work or modifications
- • Insurance carrier requirements
- • Prior to seasonal peak loads
- • Before facility sale or major refinancing
- • Electrical smells or unusual equipment sounds
Scheduled Survey Programs
- • Critical facilities: Quarterly thermographic surveys
- • Standard facilities: Annual surveys per NFPA 70B
- • Best timing: Under normal or peak load conditions
- • Temperature: Avoid extreme cold affecting results
- • Follow-up: Re-scan repaired items to verify correction
Best Practice: Schedule surveys during normal operating loads. Peak load surveys reveal problems masked at light loads. Trending analysis requires consistent survey timing annually.
What to Expect During the Service
Phase 1: Pre-Survey Planning (1 week before)
- • Review single-line diagrams and equipment locations
- • Coordinate facility access and escort requirements
- • Verify survey will occur under normal operating loads
- • Arrange panel access keys and building passes
- • Review previous survey results for trending
Phase 2: Field Survey (4-12 hours depending on facility size)
- • Systematic scanning of all electrical equipment
- • Thermal imaging through viewport windows (energized)
- • Panel doors removed as safety permits for detailed scans
- • Documentation of all thermal anomalies with photos
- • Load measurements and ambient temperature recording
- • Real-time identification of critical problems requiring immediate attention
Phase 3: Analysis and Severity Assessment (2-3 days)
- • Temperature rise calculations for all anomalies
- • Comparison to NETA and manufacturer acceptance criteria
- • Priority categorization (critical/serious/monitor)
- • Root cause determination for identified problems
- • Recommended corrective actions with timing
Phase 4: Reporting and Follow-up (3-5 days after survey)
- • Comprehensive report with thermal images and analysis
- • Prioritized action list with repair recommendations
- • Estimated costs and timeframes for corrections
- • Trending analysis with previous surveys
- • Follow-up survey scheduling for repaired items
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.
ROI & Business Value
Cost Avoidance
$50K-$5M+
Electrical fire and equipment failure costs
$2K-$15K
Typical facility thermographic survey cost
50-500x
ROI from preventing ONE major incident
Operational Benefits
- • Fire prevention and life safety protection
- • Non-intrusive testing (no service interruption)
- • Early problem detection before failures
- • Planned repairs vs. emergency response
- • Equipment life extension through proper loading
- • Insurance and regulatory compliance
- • Documentation of due diligence
- • Energy efficiency identification opportunities
Industry Standards & Compliance
NFPA 70B: Recommended Practice for Electrical Equipment Maintenance
Recommends annual thermographic surveys as fundamental component of electrical maintenance programs with specific survey procedures.
NETA MTS: Maintenance Testing Specifications
Defines thermographic survey procedures, temperature rise limits, and reporting requirements for electrical maintenance.
ASNT/ISO 9712: Thermographer Certification Standards
Qualification and certification requirements for thermographers ensuring competency in equipment operation and results interpretation.
OSHA 1910.333: Electrical Maintenance Requirements
Requires electrical equipment be maintained in safe condition; thermography provides documentation of maintenance diligence.
See Problems Before They Become Catastrophic Failures
Professional thermographic surveys detect fire hazards and equipment problems before disasters occur.