Infrared Thermography in Electrical Systems: A 30-Page Journal
Author: Jayakrishna Thiruvarangam
Level 2 Certified Thermographer
📧 Email:
[email protected]🌐 Website: www.teknospaces.com
📞 Contact: +91 7204247216 / +91 9945210759
🔹 Page 1: Introduction
Infrared Thermography (IRT) is one of the most effective predictive maintenance tools in
electrical systems. It provides real-time thermal imaging to identify invisible temperature
anomalies that could lead to equipment failure, fire hazards, or power outages.
🔹 Page 2: Principle of Electrical Thermography
All electrical components generate heat due to resistance. Excessive heat often indicates a
defect. IRT detects these patterns using infrared cameras, enabling non-contact, non-
invasive monitoring of live electrical systems.
🔹 Page 3: Benefits of Electrical Thermography
Early fault detection
Reduced downtime
Fire risk mitigation
Energy savings
Compliance with safety norms (e.g., NFPA 70B)
🔹 Page 4: Types of Electrical Systems Inspected
Low-voltage panels
Medium-voltage switchgear
High-voltage substations
Motors and drives
Transformers
Control panels
UPS and battery systems
🔹 Page 5: Common Faults Detected
Loose or corroded connections
Phase imbalances
Overloaded circuits
Faulty breakers or fuses
Hot spots in relays or terminals
Oxidation in contacts
Harmonics in cables
🔹 Page 6: Tools and Equipment
Handheld thermal cameras (Fluke, FLIR, etc.)
Drone-mounted cameras for substations
Software for image processing and reporting
Thermography apps and AI-based platforms
🔹 Page 7: Thermographic Survey Planning
Define scope of inspection
Ensure access to all panels
Schedule during peak load operation
Use appropriate safety gear
Follow standard procedures (ISO 18434)
🔹 Page 8: Safety in Electrical Thermography
Work under live conditions (use PPE)
Maintain safe distance
Never remove covers without proper shutdown
Work with qualified personnel
Follow lockout/tagout (LOTO) guidelines
🔹 Page 9: Load Considerations
For accurate readings:
Equipment must run at ≥40% load
Idle equipment may give misleading results
Compare components under identical conditions
🔹 Page 10: Case Study – MCC Panel Overheating
Issue: One cable showed 35°C more than others.
Cause: Loose connection at terminal.
Fix: Tightened joint and re-inspected.
Result: Temperature normalized. Prevented possible arc flash.
🔹 Page 11: Temperature Thresholds & Alarm Criteria
Different components have different safe operating temperatures. Common thresholds:
Component Warning Threshold (°C) Alarm Threshold (°C)
Circuit Breakers 40–50°C above ambient >70°C
Busbars 35–45°C >65°C
Transformers (oil-cooled) 50–70°C >90°C
Cable Lugs & Terminals 40–55°C >75°C
Setting alarm levels in monitoring software helps in automating responses and timely
maintenance.
🔹 Page 12: Emissivity and Surface Considerations
Accurate temperature readings depend on emissivity—the surface's ability to emit infrared
radiation.
Painted metal: 0.9
Oxidized metal: 0.7–0.85
Bare shiny copper: 0.2–0.3
Electrical tape (reference point): ~0.95
Low emissivity surfaces can lead to underestimation. Always adjust the camera's emissivity
settings or use tape/paint to increase accuracy.
🔹 Page 13: Image Interpretation Guidelines
Hot spot vs. ambient or neighboring phases
Evaluate thermal gradient
Look for symmetry between identical components
Consider load variations
Confirm with multi-meter (for voltage/load balance)
🔹 Page 14: Reporting and Documentation
A good electrical thermography report includes:
Image (IR + Visual)
Temperature scale
Emissivity used
Fault severity
Recommendation (Urgent/Monitor/Safe)
Asset ID and location
Reporting software often helps create automated, professional outputs.
🔹 Page 15: Case Study – Transformer Inspection
Observation: HV bushing showed 25°C excess.
Action: Oil tested – dielectric strength low.
Outcome: Transformer was decommissioned before failure, avoiding ₹5 lakh+ damage.
🔹 Page 16: Use in Predictive Maintenance Programs
Thermography is a pillar of Condition-Based Maintenance (CBM). When combined with:
Ultrasound (for arcing/corona)
Vibration (for rotating parts)
Insulation testing
…it forms a complete reliability strategy.
🔹 Page 17: Thermography for UPS and Battery Rooms
Monitors:
Battery cell temperatures
Terminal/cable hotspots
Ventilation issues
Charger performance
Essential in data centers and hospitals for uninterrupted backup.
🔹 Page 18: Substation and HV System Applications
Applications in:
Switchyards (CT, PT, Isolators)
SF6 breakers
Busbar joints
Lightning arrestors
Drones now allow safe scanning of live 11 kV–400 kV lines.
🔹 Page 19: COVID-Era Relevance & Contactless Inspections
During pandemic restrictions, thermography enabled:
Remote inspections
Fewer people on site
Thermal mapping of electrical assets
It highlighted the value of automation and safety.
🔹 Page 20: NFPA 70B and International Standards
Key references:
NFPA 70B: Recommends annual thermographic inspection for electrical systems
ISO 18434: Thermography for condition monitoring
IEC 61443: Electrical safety & thermal testing
Adhering to these ensures legal and safety compliance.
🔹 Page 21: Advanced Diagnostics – Delta T Analysis
Delta T (ΔT) = Difference in temperature between components (e.g., between three
phases).
ΔT > 10°C between phases → Imbalance
ΔT > 15–20°C between same type components → Fault or overloading
Trending ΔT over time helps forecast failure
Used in thermal condition scoring models to predict remaining equipment life.
🔹 Page 22: Integration with AI and IoT
Modern thermography now integrates with:
AI-based image recognition
IoT sensors transmitting data to cloud
Predictive maintenance platforms
Benefits include:
Real-time alerts
Remote access and trending
Integration with Building Management Systems (BMS)
Automation of thermal anomaly detection
🔹 Page 23: Industry Applications – Data Centers
Data centers rely heavily on thermography to:
Monitor PDUs, rack UPS, and cooling systems
Ensure optimal thermal distribution
Detect overloaded breakers
Comply with Tier 3/Tier 4 uptime regulations
Even a 1°C increase in cabinet temperature can impact performance.
🔹 Page 24: Industry Applications – Manufacturing Plants
In industries like:
Textiles: Motor panels, variable frequency drives
Pharma: HVAC systems, panel boards
Automotive: Robotic welding lines, control cabinets
Steel plants: Transformers, furnaces, substations
Thermography reduces unplanned downtime and supports lean maintenance practices.
🔹 Page 25: Industry Applications – Airports & Hospitals
Airports: Thermography on runway lighting systems, radars, ATC rooms
Hospitals: Backup generators, UPS banks, MRI & CT equipment
Retail Malls: HVAC, escalator panels, signage lighting panels
Helps ensure public safety and continuous power delivery in critical infrastructure.
