Quick Answer: Infrared thermography for industrial electrical equipment is provided by electrical testing and maintenance firms that scan energized gear under load and document every hot spot with a priority rating. Bowtie Engineering performs infrared surveys for facilities across the United States and Canada without a shutdown, delivers thermal and visible-light photos for each finding, and includes a code violation report and documentation control in BowVue at no extra charge. Call 866-730-6620 to schedule a scan.
A loose lug or an overloaded breaker gives off heat long before it fails. Infrared thermography finds that heat while your plant keeps running, which is why maintenance managers and NFPA 70B insist on it. This article explains who performs industrial infrared surveys, how to tell which hot spots are urgent, what a good report should contain, how often to scan, and what to ask before you hire a provider.
What Is Infrared Thermography for Electrical Equipment?
Infrared thermography is a non-contact inspection that uses a thermal imaging camera to find heat that should not be there. Electrical problems usually show up as heat first, for example:
- A connection that has loosened over time
- A phase carrying more than its share of the load
- Insulation that is starting to break down
Because the camera reads surface temperature from a distance, the technician does not touch live parts. That makes infrared one of the safest and fastest ways to check a large amount of equipment in a single visit.
What Problems Can an Infrared Scan Find?
An infrared scan finds heat-related faults that a visual check misses. Common findings include:
- Loose or corroded connections and lugs
- Overloaded or imbalanced circuits and phases
- Failing circuit breakers and disconnects
- Deteriorating insulation and hot terminations
- Overheating transformers, motors, and bus connections
- Undersized or damaged conductors
- Failed elements in a fuse bank
Many of these issues can cause an unplanned outage or an electrical fire if they are left alone. Finding them on a scheduled survey turns an emergency into a planned repair.
How Do You Know Which Hot Spots Are Urgent?
A hot spot is urgent when it runs much hotter than similar components carrying a similar load. Industry testing guidance gives a clear benchmark:
- The ANSI/NETA Maintenance Testing Specifications treat a temperature difference of more than 15°C between similar components under similar load as a major discrepancy that calls for immediate repair.
- Comparing similar components is more reliable than comparing to room temperature, because ambient conditions can swing widely through the day.
- Smaller differences still deserve investigation, since a connection that is warm today can get worse as load rises.
This is why a good report gives every finding a priority rating. Your team should never have to guess which problem to fix first.
Who Performs Industrial Infrared Thermography?
Industrial infrared thermography is performed by three main types of providers:
- Electrical testing and engineering firms that combine scanning with repairs, testing, and arc flash work
- Maintenance contractors that add infrared to routine service visits
- Thermography-only companies that scan and report but do not repair or test
- All of them require energized work, thus the technicians shall be qualified as outlined in NFPA 70E
The strongest providers understand electrical systems well enough to explain what each hot spot means. Bowtie Engineering’s infrared thermography service is led by people who work on electrical systems every day, including Jeff Lunsford, an engineer, master electrician, and ITC Level III certified thermographer.
Does the Facility Need to Shut Down for an Infrared Scan?
No, the facility does not need to shut down. Infrared thermography only works when equipment is energized and carrying load, so the scan happens during normal operation. During a typical survey:
- Equipment stays in service and production continues
- Panel covers are removed so the camera can see components inside
- The thermographer follows NFPA 70E practices and wears PPE suited to the exposure
- Lightly loaded equipment is noted, since a weak connection may not heat up until load climbs
What Should an Infrared Thermography Report Include?
A useful infrared report tells you what is wrong, where it is, and what to fix first. Each finding in a Bowtie Engineering report includes:
- A thermal image and a matching visible-light photo
- The equipment identification and location
- The recorded temperature difference
- A priority rating, so your team knows what needs attention now
Bowtie Engineering also documents code violations it sees while panel covers are open and includes them in the report at no extra charge on every infrared job. For service-contract clients, findings load into the BowVue platform alongside the rest of the electrical record.
How Often Should Electrical Equipment Get an Infrared Scan?
Most facilities scan electrical equipment at least once a year, and annual surveys are the common baseline. Bowtie Engineering notes that many insurers require an annual survey as a condition of coverage, so it is worth checking your policy. More frequent scans make sense for equipment that:
- Serves critical loads
- Runs around the clock
- Sits in a hot, dusty, damp, or corrosive environment
- Was recently repaired or modified
The NFPA 70B standard makes condition assessment part of a documented maintenance program, and infrared is one of its main tools. Bowtie Engineering sets scan intervals as part of an NFPA 70B program, based on equipment condition and how critical each piece is.
How Does Infrared Thermography Fit Into a Maintenance Program?
Infrared thermography is the first basic step in an electrical maintenance program, not the whole program. A scan shows where heat is building, but it cannot confirm:
- Whether a circuit breaker will trip in the time the arc flash study assumes
- Whether protective relay settings match the coordination study
- The internal condition of transformers and their oil
Those answers come from hands-on testing during planned outages. Bowtie Engineering pairs infrared surveys with switchgear maintenance, breaker injection testing, relay testing, and transformer testing through its electrical maintenance services.
What Should You Ask Before Hiring an Infrared Thermography Provider?
Ask questions that show whether the provider understands electrical systems and will give you a report you can act on:
- Who will perform the scan, and what thermography and electrical credentials do they hold?
- Will findings include both thermal and visible-light images?
- How are findings ranked by urgency?
- Will you note code violations you see while covers are open?
- Can your company also repair or test what the scan finds?
- How will results be stored so we can compare them next year?
Frequently Asked Questions
How long does an infrared scan take?
It depends on the amount of equipment, how many panels must be opened, and site access. A provider should give you a schedule with the quote. Because scanning happens during normal operation, it rarely disrupts production.
Is infrared thermography required by NFPA 70B?
NFPA 70B requires a documented electrical maintenance program that includes condition assessment, and infrared thermography is one of the methods that program relies on. Bowtie Engineering documents each scan so it can serve as part of your compliance record.
What certifications should a thermographer have?
Look for formal thermography certification, such as a Level I, II, or III credential, along with real electrical experience. Bowtie Engineering’s team includes an ITC Level III certified thermographer who is also an engineer and master electrician.
What temperature difference is considered serious?
The ANSI/NETA Maintenance Testing Specifications treat a difference of more than 15°C between similar components under similar load as a major discrepancy needing immediate repair. Any abnormal heating should still be investigated.
What happens after hot spots are found?
Each finding gets a priority rating, so your team can fix the most urgent items first. Bowtie Engineering can then carry out repairs or deeper testing through its electrical maintenance services. A follow-up scan is the simplest way to confirm a repair worked.
Need help now? Call Bowtie Engineering at 866-730-6620 or request a quote online.
Key Takeaways
- Infrared thermography finds electrical problems by detecting heat that should not be there.
- Scans are done while equipment is energized and under load, so no shutdown is needed.
- NETA guidance treats a difference of more than 15°C between similar components as a major discrepancy needing immediate repair.
- Annual scanning is the common baseline, with more frequent scans for critical or harsh-environment equipment.
- Bowtie Engineering includes a code violation report at no extra charge on every infrared job and serves facilities across the US and Canada.