Thermography Testing and
Training
Trainer Name: Ravichandran R
Designation: Trainer and Technical Manager
Contents
➢ Introduction
➢ Infrared Thermography
➢ Infrared Radiation
➢ Infrared Thermography
➢ Benefits of Periodic
Electrical Infrared Inspections
➢ Qualitative
Infrared Electrical Inspection
➢ Qualitative
Infrared Electrical Inspection
➢ Electrical Inspection Items
➢ Benefit of Electrical Infrared Inspections
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Introduction
Thermography test is to use infrared imaging to detect and measure the
temperature variations on the surface of an object or a system. This non-invasive
testing method allows for the identification of potential issues that may not be
visible to the naked eye. The primary objectives of thermography include:
1. Detecting Heat Patterns and Anomalies
2. Preventive Maintenance
3. Building Inspections
4. Electrical and Mechanical Inspections:
5. Fire Safety etc.,
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INFRARED THERMOGRAPHY
ELECTRICAL INSPECTIONS
.
Recent technical manuals published by National Fire Protection
Association (NFPA) and the Inter-National Electrical Testing
Association (NETA) prominently recommend the use of infrared
inspection in the testing and maintenance of electrical systems
Thermographer Level II
Infrared Radiation
Infrared waves are not visible by the eye
. Wavelength is longer than visible light.
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Infrared Thermography
An Infrared Camera Senses Infrared Radiation
A Processor In The Camera Assigns Color To The Infrared
Radiation-Different Color Equals Different Temperature
Enabling Us To Visualize The Thermal World
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Infrared Image
Color Palette Range Is Chosen For Clarity
Palette 2 Is Better Suited For This Image
Color Palette 1 Color Palette 2
White = T>85F White = T>95F
Black = T<72F 1 Black = T<72F 2
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Some Uses Of Infrared Thermography
Electrical Inspections Hot Medical
Connections
Severe Acute Respiratory Syndrome
Failing Components (SARS)
Overloaded Circuits Manufacturing Processes Plastics
Carpet
Mechanical Inspections Motors,
Bearings, Drives, Steam Systems, Boilers Heat/Chilling Processes
Fire Hot Spots Mill Operations Slag
People Rescue Detection
Building Police Work Fugitive
Search Drug Enforcement
Thermal Envelope Missing Persons Search
Roof Leaks Animal
Military Equine Hot Joints Ligaments
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Benefits of Periodic
Electrical Infrared Inspections
Predictive Maintenance...Allows Scheduling Of
Repairs, Forward Buying
Reduces Downtime… Find It, Repair It, Before It Blows Up
and Stops Production
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Qualitative
Infrared Electrical Inspection
Qualitative Inspection: The practice of gathering information
about an electrical system by observing infrared radiation,
recording findings, analyzing findings, and presenting that
information.
Exceptions: are abnormally warm components that may be
a potential problem. Exceptions are usually identified by
comparing the thermal patterns of like components.
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Electrical Inspection Items
Transformer Bus Duct
Pad Mount Distribution
Dry Panels
Overhead Control Panels
Service Entrance Rectifiers
Main Switchgear Drives
Motor Control Capacitor Banks
Centers Any Electrical
Disconnects Connection
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Exception Analysis
Below is an exception. One of the conductor terminals is hot.
Hot Terminal Temperature…..203F
Left Terminal Temperature….156F
Temperature difference is …… 47F
179.5°F
AR01
SP01 160
140
120
119.7°F
When should you repair this exception?
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Exception
Repair Priority Criteria
Priority 0
Temperature Difference 10F or Less
Priority 1
No Corrective Measures Required Temperature Difference 10F to 20F
At This Time. Corrective Measures Required
At Next Maintenance Period
Priority 2 Priority 3
Temperature Difference 20F to 30F
Corrective Measures Required Temperature Difference 30F to 100F
Corrective Measures Required
As Scheduling Permits
As Soon As Possible
Priority 4
Temperature Difference Over 100F
Corrective Measures Required Immediately
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Exception Example #1
Breaker Connections
179.5°F
AR01
SP01 160
140
120
119.7°F
Hot Spot Temperature…...203F Repair Priority 3
Reference Temperature….156F Corrective Measures Required
Temperature Difference….47F As Soon As Possible
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Exception Example #2
Fuse Block
232.4°F
SP01 200
AR01
150
100
87.8°F
Hot Spot Temperature…...303F
Repair Priority 4
Reference Temperature….170F
Corrective Measures Required
Temperature Difference….133F
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Immediately
Exception Example #3
Breaker Connections
144.6°F
140
AR01 130
120
110
100
SP01 93.0°F
Hot Spot Temperature…...459F Repair Priority 4
Reference Temperature…..101F Corrective Measures Required
Temperature Difference….358F Immediately
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Exception Example #4
Main Switchboard Fused Switch
245.4°F
AR01 240
220
200
180
160
140
SP01
120
118.9°F
Hot Spot Temperature...311F
Reference Temperature..151F Repair Priority 4
Temperature Difference...160F Corrective Measures Required
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Immediately
Exception Example #5
Breaker Load
119.1°F
115
110
105
100
95
92.6°F
Hot Spot Temperature….71F
Reference Temperature…55F
Repair Priority 0
Temperature Difference..16F
No Corrective Measures Required
Breaker Load A-105 amps At This Time
B-150 amps
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C-167 amps
Exception Example #6
Building Service Drop
Hot Spot Temperature...301F
Reference Temperature…77F Repair Priority 4
Temperature Difference..224F Corrective Measures Required
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Ambient Temp………….45 F Immediately
Exception Example #7
Arrestor Pad Mount Transformer
Hot Spot Temperature….92F
Repair Priority 3
Reference Temperature...58F
Corrective Measures Required
Temperature Difference..32F
As Soon As Possible
Ambient Temperature….45F
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Exception Example #9
Pad Mount Transformer High Side
124.2°F
120
110
100
90
80
71.9°F
Hot Spot Temperature….159F
Reference Temperature…98F Repair Priority 3
Temperature Difference..61F Corrective Measures Required
Ambient Temperature….71F As Soon As Possible
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Exception Example #10
Motor Drive End Bearing Hot
Hot Spot Temperature….127F
Repair Priority ?
Reference Temperature…99F
Mechanical System
Temperature Difference..28F
Ambient Temperature….74F
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Thermal Picture
Pad-Mount Cooling Fins
120.7°F
120
110
100
90
84.1°F
In this case the exception is cold
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Thermal Picture
480 Volt Capacitor Bank
141.3°F
140
120
100
80
67.8°F
Again the exception is cool
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Infrared Tips
Use a Certified Thermographer
–Proper Training is vital to understand thermography
–Cost Effective - Quality Camera is $20,000 to $50,000
Scan should cost from $800 to $1500 per day
Inspect When System Load Is High
–Useless To Scan Under Light or No Load
–Keep in mind that an infrared electrical inspection is only a
report of the electrical system at the time of the inspection.
Equipment that was off or unloaded because of cycling or
scheduling may have problems that were not evident at the
time of the inspection.
Do Inspections On A Periodic Basis
--Annually Good - Semi-Annually Better (at least first couple of
times)
Insures that over period of time all equipment is inspected
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Benefit of Electrical Infrared
Inspections
"...From a return on investment perspective, infrared inspection
programs have proven that on average for every $1 spent on
infrared electrical inspections, there is a $4 return on investment
for materials and labor from fixing the problems before it fails..."
"Cost/Benefits Analysis of Infrared Programs." Maintenance
Technology Magazine June 2001
$1.00 $4.00
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Reference
1. BS EN 13187:1999 Thermal Performance of Building. Quality
Detection of Thermal Irregularities In Building Envelopes.
Infrared Method
2. ASTM E 1934-99a (2024) Standard Guide for Examining
Electrical And Mechanical Equipment With Infrared
Thermography
3. ASTM C 1060-11a (2015) Standard Practice for Thermographic
Inspection Of Insulation Installations In Envelop Cavities of
Frame Buildings
4. ASTM C-1153-10 (2015) Standard Practice for Location of Wet
Insulation In Roofing Systems Using Infrared Imaging
5. ANSI/NETA ATS-2023 Standard for Acceptance Testing
Specification for Electrical Power Equipment and Systems
6. ADOSH-SF- Abu Dhabi Occupational Safety and Health System
Framework
