Thermal or infrared (IR) imaging in industry, commonly referred to as an infrared survey—is a non-destructive inspection method that uses thermal cameras to detect heat variations and uncover hidden problems in electrical and mechanical systems. Since components in electrical systems almost always overheat before they fail, problem areas are more easily and safely found when viewed through an IR camera. Since components in electrical systems almost always overheat before they fail, problem areas are more easily and safely found when viewed through an IR camera. Have you been experiencing electrical failures or overheating? Loose connections and overloading circuits are the most common cause of electrical fires. Other issues, such as transformer cooling problems, induced currents, arcing, and motor-winding faults, are also dangerous to your equipment, and can be found through thermal imaging.
What is an infrared survey in industrial maintenance?
An infrared (IR) survey uses thermal imaging cameras to detect heat variations in electrical and mechanical systems. Since most components overheat before failing, an IR survey helps identify hidden problems such as loose connections, overloaded circuits, or cooling issues before they cause breakdowns or fires.
Why are infrared surveys important for plant reliability?
Infrared surveys allow technicians to find faults early, without shutting down equipment. Detecting overheating components in advance reduces the risk of electrical fires, prevents unplanned downtime, and lowers repair costs.
What types of problems can infrared surveys detect?
Infrared surveys can identify:
- Loose or corroded electrical connections
- Overloaded circuits
- Transformer cooling problems
- Motor-winding faults
- Induced currents and arcing
- Overheating in mechanical systems such as bearings or gearboxes
What equipment can be inspected with infrared imaging?
Thermal imaging can be used on a wide range of electrical equipment, including:
- Distribution panels
- Switchboards and contacts
- Transformers
- Service and control panels
It can also be applied to certain mechanical systems to detect heat-related issues.
Do infrared surveys require shutting down equipment?
No. One of the biggest advantages of infrared surveys is that they are non-contact and non-intrusive. Equipment remains running during inspection, allowing large areas to be evaluated quickly and safely.
How do infrared surveys support predictive maintenance?
By establishing a baseline and monitoring temperature changes over time, infrared surveys help predict failures before they occur. This makes them an essential tool in any predictive maintenance program, complementing other methods such as vibration analysis or ultrasonic testing.
Are infrared surveys cost-effective?
Yes. Infrared surveys are quick to perform, cover large areas efficiently, and prevent costly emergencies. They reduce unplanned downtime, lower fire risk, and help extend the lifespan of critical equipment all at a fraction of the cost of reactive repairs.
How often should infrared surveys be performed?
Most facilities schedule infrared surveys annually, though high-risk environments or critical electrical systems may benefit from semi-annual or quarterly inspections. Reliability Solutions can recommend a schedule tailored to your operations.
How do I schedule an infrared survey with Reliability Solutions?
Contact our service team at [email protected] or call (251) 490-2999. Our technicians will work with you to plan a safe, efficient, and thorough infrared inspection for your facility.
HOW WE DO IT
During an inspection, electrical equipment, such as distribution panels, switch boards, contacts, transformers, and service and control panels can be examined through an IR camera. By viewing apparent temperature differences, inspectors can identify and document problems. Because viewing apparent temperature differences through an IR camera requires no physical contact and can cover a lot of space in one sweep, no other technology allows electrical faults to be found as safely and as quickly as thermal imaging.
Benefits of Infrared Surveys:
- Safe and non-contact: No need to shut down equipment during inspections
- Detects issues invisible to the naked eye
- Prevents unplanned downtime and reduces fire risk
- Supports predictive maintenance and energy savings
- Fast and cost-effective for inspecting large areas