Thermal Imaging Inspection For Electrical Fault

CHAPTER 1

INTRODUCTION

Human eye can see visible light or s mall part of electromagnetic spectrum. Human eye
cannot see ultraviolet light and infrared light. Infrared energy is just one part of the electromagnetic
spectrum that encompasses radiation from x-rays, gamma rays, ultra violet, and a thin region of
visible light, radio waves infrared, and microwaves. To remotely determine the temperature of an
object, infrared radiation is used[1]. Thermogaphic camera detects infrared radiation in the range of
electromagnetic spectrum roughly 0.9-14 micrometer and produce the picture of that radiation that
we can see. Thermal energy is part of electromagnetic spectrum and makes upper part of infrared of
light spectrum. The primary source of infrared radiation is heat or thermal radiation. Any object that
has a temperature above absolute zero ( 0 Kelvin) emits radiation in the infrared region. Every
objects that are very cold, such as ice cubes, emit infrared radiation. Although our eyes cannot see
it, the nerves in our skin can feel it as heat. The warmer the object, the more infrared radiation it
emits.

Electrical inspection find hots spot caused by defects in connections and components. Infrared
Thermography is used to find areas excess heat. So that problem can be detected and corrected
before a component fails,causing damage to component,creating safety hazards.[1]

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CHAPTER 2

REVIEW

Thermal imaging goes all the way back to 1800 when infrared was discovered as a form of
radiation beyond red light. While infrared technology has many uses it’s most notable for thermal
imaging cameras. A standard camera captures the light we can see with our eyes, but a thermal
camera captures “invisible” infrared light, making technology such as night vision goggles
possible.[2]

The first thermal camera is almost 100 years old, and it spent much of its early days used
in the wars of the 20th century .Also known as “Thermography,” the process of using heat and
infrared light to create an image goes back as far as early cameras. Hungarian physicist Kalman
Tithanyi first invented thermal imaging or “night vision” for British anti-aircraft defense” 1World
War I. The new camera technology was so useful that it didn’t take long to cross the Atlantic where
it grew rapidly in the United States throughout the rest of the 20th century.[2]

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CHAPTER 3

CONSTRUCTION OF THERMAL CAMERA

A thermal imaging camera consist of five system[3]

3.1 Optic system

3. 2 Detector amplifier

Detector amplifier uses the IR sensor .IR sensor is a simple electronic device which emits and
detects the IR radiation in order to find out certain objects in range.

The key element of infrared detection system is as follows:

3.2.1 IR TRANSMITTER :

IR transmitter act as source for IR radiation. According to planks radiation law at temp
above 0 kelvin posses thermal energy and are use as infrared radiation. Tungsten lamps, silicon
carbide, infrared lasers are used as sourced

3.2.2 TRANSMISSON MEDIUM :

Transmission medium provides passage for radiation to reach from IR transmitter to IR

receiver. Vacuum atmosphere are used as medium.

3.2.3 IR RECEIVER :

Generally IR receives are photo diode and photo transistor .They are capable for
detecting infrared radiation . hence IR receiver is also called as IR detector.

IR source is used to emit radiation of required radiation of required wavelength .This

radiation reaches the object and is reflected back . This reflected radiation is detected by IR
receiver. This detected radiation is given to the amplifier to amplify the signal and covert it into the
large electrical signal .

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3.4 Signal conditioning

3.5 Display

Cameras may be handled or helmet mounted. A handled camera requires one hand
to position camera requires one hand to position and operate ,leaving only one free hand for other
task.

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CHAPTER 4

WORKING OF THERMAL CAMERA

All objects emit some kind of infrared radiation, and it’s one of the ways that heat is
transferred. If you hold your hand over some hot coals on the grill, those coals are emitting a ton of
infrared radiation, and the heat is transferring to your hand. Furthermore, only about half of the
sun’s energy is given off as visible light the rest is a mix of ultravoilet and infrared light.[3]

Fig 4.1 Wavelength

From fig 4.1 the hotter an object is, the more infrared radiation it produces. Thermal
cameras can see this radiation and convert it to an image that we can then see with our eyes, much
like how a night vision camera can capture invisible infrared light and convert it to an image that
our eyes can see.

Inside of a thermal camera, there are a bunch of tiny measuring devices that capture
infrared radiation, called microbolometers, and each pixel has one. From there, the microbolometer
records the temperature and then assigns that pixel to an appropriate color.

A special lens camera is employed to focus the infrared emission by objects . The focused
light is scanned by the infrared detector element. The detector element create a very detailed
temperature pattern called as Thermogram. This Thermogram created by detector element is

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Thermal Imaging Inspection For Electrical Fault

translated into electrical impulses. This impulses are send to signal processing unit. This signal
processing unit send the information to display.

An infrared camera contains an optical system that focuses infrared energy onto a special
detector chip (sensor array) that contains thousands of detector pixels arranged in a grid.

Each pixel in the sensor array reacts to the infrared energy focused on it and produces an
electronic signal. The camera processor takes the signal from each pixel and applies a mathematical
calculation to it to create a color map of the apparent temperature of the object. Each temperature
value is assigned a different color. The resulting matrix of colors is sent to memory and to the
camera’s display as a temperature picture (thermal image) of that object.

Fig 4.2 constructional view of camera

Above fig 4.2 shows constructional diagram of camera. Many infrared cameras also include a
visible light camera that automatically captures a standard digital image with each pull of the
trigger. By blending these images it is easier to correlate problem areas in your infrared image with
the actual equipment or area you are inspecting.

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CHAPTER 5

WORKING OF IR SENSOR

Fig 5.1 Circuit digram of IR sensor

In this above fig 5.1 the transmitter section includes an IR sensor, which transmits
continuous IR rays to be received by an IR receiver module. An IR output terminal of the receiver
varies depending upon its receiving of IR rays. Since this variation cannot be analyzed as such,
therefore this output can be fed to a comparator circuit. Here an operational amplifier (op-amp) of
LM 339 is used as comparator circut.[1]

IR sensor consist of LED , photodiode as receiver. Photodide is connected in reversed

biased of inverting end of amplifier is connected to variable resistor to adjust the sensitivity of
sensor.

When we turn on the circuit their is no IR radiation towards photodiode then the potential at
the inverting input goes higher than that non-inverting input of the comparator IC (LM339). Thus
the output of the comparator goes low, but the LED does not glow.

Now when we take some object in front of IR emitted by IR LED is reflected by object and
absorbed by photodiode. Not at that time, voltage drops across photodiode drops and voltage across
R2 increases. When voltage gets higher at resistor R2 than voltage at inverting end , then output
becomes high and LED turns on.

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CHAPTER 6

ELECTRICAL INSPECTION BY USING THERMAL IMAGING CAMERA

Main cause of many problems in electrical systems. Infrared Thermography allows us to

see these invisible thermal signatures of impending damage before the damage occurs. When
current flows through an electric circuit, part of the electrical energy is converted into heat.
Abnormal heating associated with high resistance or excessive current flow is the energy. This is
normal. But, if there is an abnormally high resistance in the circuit or abnormally high current flow,
abnormally high heat is generated which is wasteful, potentially damaging and not normal.[2]

Ohm's law (P=I2R) describes the relationship between current, electrical resistance, and
the power or heat energy generated. We use high electrical resistance for positive results like heat in
a toaster or light in a light bulb. However sometimes unwanted heat is generated that result in costly
damage. Under-sized conductors, loose connections or excessive current flow may cause
abnormally high unwanted heating that result in dangerously hot electrical circuits. Components
can literally become hot enough to melt.[1]

Thermal image enable us to see the heat signatures associated with high electrical resistance
long before the circuit becomes hot enough to cause an outage or explosion. Be aware of two basic
thermal patterns associated with electrical failure: 1) a high resistance caused by poor surface
contact and 2) an over loaded circuit imbalance problem.

6.1 CONTACT PROBLEM

Heat is produced by current flow through a contact with high electrical resistance. This
type of problem is typically associated with switch contacts and connectors. Contact problem is
done at busbars connection, insulator connection. Heat is generated when their is any loose contact.
Heat is produced by current flow through contact with high electric resistance. This produce a heat
at this junction. When their is loose contact at connector then arc is produced which produce large
amount if heat

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Fig 6.1 800 amp switch problem

In above fig 6.1 of an 800-amp switch with an internal connection problem overheating the bottom
right wires..

Fig 6.2 Problem of loose connection

Above fig 6.2 shows heat generated from a loose connection on the top wire

Fig 6.3 Heat generated due to loose connection

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In fig 6.3 The lower portion of the center vertical buss bar appears hot because it is
wrapped in electrical tape which increases the emissivity of the bare copper making it possible to
see the heat generated by the loose connections. Infrared Thermography can quickly identify
potential problems with breakers, inter connections, wire crimps, and loose or corroded
connections. You can reduce unscheduled down time and catastrophic failures with an Infrared
electrical survey.

Fig 6.4 Fuse problem

Fig 6.4 is a 3-phase fuse installation where one end of one fuse has poor electrical contact
with the circuit. The increased contact resistance caused a 45C (81F) hotter temperature at that
connection than at the other fuse connection.[2][

Fig 6.5 Two phase wall plug

Fig 6.5 is a two-phase wall plug-in where the wire connections were loose causing the
terminals to heat 55C (100F) hotter than the ambient..

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All of these examples were serious and needed immediate attention. Thermogram B)
shows an interesting principal used in interpreting thermal patterns of electrical circuit. The fuse is
hot at one end only. If the fuse were hot at both ends, the problem would be interpreted differently.
An overloaded circuit, phase imbalance, or an undersized fuse would cause both ends of the fuse to
overheat. Being hot at one end only suggests that the problem is high contact resistance at the
heated end.

The wall plug in Thermogram D) was seriously damaged as seen in the visual picture below,
however, it continued to operate until it was replaced.

6.2 OVERLOAD CIRCUIT PROBLEM

In current transformer the temp of one transformer is 14 degree celcius warmer than other two
transformer in 3 phase service installation. This indicates that their is serious problem of voltage
imbalance and caused problem to utility. Due to this their is less voltage at consumer end .[1]

6.3 ELECTRIC DISTRIBUTION

They start with the utility electricity production, high voltage distribution, switchboards and
substations, and end with service transformers, switchgear, breakers, meters, local distribution, and
appliance panels.[4]

A service transformer that had leaked some cooling oil, resulting in dangerously over heated
coils near the top. One connection was 160C (288F) above ambient. This transformer needed
immediate replacement but the company wanted to delay the repair one month so it could be done
during a scheduled total plant shutdown. They used the IR Snap Shot camera to monitor the state of
the transformer and successfully delayed the repair. Thermogram N) is for a pole mounted service
transformer that has a connection 30C (54F) hotter than ambient. Such a condition required
maintenance at the next convenient opportunity.

6.4 UNBALNCED VOLTAGE

Unbalance voltage occurs when their is load on one or more of the phase is different than
others.

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In three phase transformer if there is more load connected on one phase than rated capacity
then there is voltage fluctuation occurs in this phase.This produces large amount of heat. By
capturing the image we can save the transformer form overheating

In motor operate continuous with unbalance voltage. However its efficiency is reduced.
This reduction of efficiency is caused by both increase in currents or resistance. This contribute to
ensure in heat hence we use the camera and remove the voltage unbalanced problem and save the
stator and rotor winding of motor.

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CHAPTER 7

LOAD REQUIREMENENT FOR THIS CAMERA

When making an inspection it is important that the system is under load. Wait with the
inspection for "worst case" or peak loads, or when the load is at least 40% (according to NFPA
70B). Heat generated by a loose connection rises as the square of the load; the higher the load, the
easier it is to find problems.[4]

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Thermal Imaging Inspection For Electrical Fault

CHAPTER 8

ADVANTAGES

8.1 Reduce unscheduled down time

8.2 Increase equipment life

8.3 No service interruption during inspection

8.4 Lower risks

8.5 Lower repair costs

8.6 Increase profits

8.7 Prevent catastrophic failures

8.8 Lower insurance premiums due to reduced losses

8.9 Improved insurability

8.10 Reduces risk of equipment failure

8.11 No disturbance to power system while inspection with camera

8.12 Saves money

DISADVANTAGES

8.1 Thermal imaging products require high initial investment cost

8.2 Images are difficult to interpret in specific objects having errtic temp

8.3 This equipment are used by anybody other than large company

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Thermal Imaging Inspection For Electrical Fault

CHAPTER 9

CONDITION DTECTED BY THERMAL CAMERA

9.1 Finding loose/deteriorated connections

9.2 Overloads

9.3 Open circuits

9.4 Unbalanced loads

9.5 Inductive heating

9.6 Harmonics

9.7 Defective equipment

9.8 Phase load imbalanced

9.8 Thermal loss

9.9 Overheting in distribution equipment

9.10 Overloaded fuses or breakers

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CHAPTER 10

CONCLUSION

It deals with helping individual see what the naked eye cannot.With the use of special lenses
and cameras,this technology offers benefits ranging from industrial advantage, down to low
enforcement.[4]

By using thermal camera we can reduce the losses in electrical system and increases the
efficiency of electrical equipment.In electrical appliances such as motors, transformer etc are use in
transmission distribution and generation hence by using camera we can reduce the losses in power
system and increase the efficiency.

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CHAPTER 11

REFERENCE

1 www.thermal review.com

2 www.wikipidia.com

3 www.fluke.com

4 Thermal imaging cameras (Bromley, kent,UK)

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