What is Thermographic Testing, and why is it important?

Thermographic testing, also known as infrared inspection, is a contact-free predictive maintenance approach for electrical components that detects connection faults, system overloads, degraded insulation, and other possible problems. Infrared thermography is used to locate locations of excessive heat so that issues may be addressed before they result in higher power consumption, increased maintenance costs, service disruptions, catastrophic equipment failure, and equipment damage.

What are the steps involved in thermographic testing?

Using highly sophisticated infrared optical scanning equipment, thermography detects the surface temperatures of electrical components. A thermal ‘camera’ is utilized during a scan to pick up traces of heat that would be invisible to the human eye, allowing inspectors to quickly identify heat anomalies based on the color of the thermal image.

Thermographic Inspection Devices Come in a Variety of Shapes and Sizes

During an on-site assessment, the energy assessor can employ a variety of infrared detecting instruments.

• The most basic radiometer is a spot radiometer (also known as a point radiometer). It takes one spot at a time to measure radiation, with a simple meter readout indicating the temperature of each area. With the instrument, the auditor pans the size and records temperature variations.

• A thermal line scanner displays the radiant temperature along a straight line. The line scan is placed on a photo of the panned region in the thermogram. Temperature changes can be seen down the line using this technique.

• A thermal imaging camera generates a 2-dimensional thermal picture of an area indicating heat leaking, which is the most accurate thermographic inspection instrument. Spot radiometers and thermal line scanners are insufficient for a thorough home energy evaluation. In addition, heat loss cannot be detected with infrared film used in a typical camera.

Early Identification of Errors with Thermographic Imaging

• Temperature variations are a warning indicator that something is wrong inside the machine. A maintenance company might take a proactive approach by implementing an infrared inspection program for predictive maintenance. By decreasing unexpected downtime, planning repairs rather than responding to breakdowns improves overall equipment efficacy.

• Thermographic imaging comprises obtaining a picture of electrical housings and components of operational equipment using a thermal imaging camera. The heat moves through the electrical components of the equipment in this illustration. Electrical resistance and heat rise when the condition of electric components deteriorates. As a result, infrared electrical testing can quickly show hot spots. Thermographic examination of electrical equipment also collects data that can identify long-term patterns, which can help with predictive maintenance.

• There are several advantages to infrared electrical testing. First, it detects real-time problems as part of an always-on predictive maintenance strategy. This improves safety by detecting possible electrical issues sooner and addressing them before they become dangerous. (Thermographic Testing)

• Furthermore, gathering data from infrared thermographic testing for later analysis aids in the optimization of maintenance and replacement schedules. This reduces the expense of maintenance while increasing the availability of the equipment. As a result, unplanned downtime is reduced, the mean time between failures is enhanced, and equipment life is extended. (Thermographic Testing)

Thermographic testing is commonly used in the following scenarios:

• Inspecting bearings
• Controlling the electric cabinet
• Locating and repairing leaks
• Checking the insulation
• Temperature measurements in the process

What can I do if I’m not sure whether or not my facility needs to be tested? 

Predictive maintenance services are beneficial to all properties with powered electrical systems. The bigger the demand, the more equipment you have. Commercial facilities with high power consumption, heavy equipment, and various branch circuits and distribution systems are at a far higher risk of costly failures. They can benefit substantially from yearly thermographic scans of their essential systems.(thermographic testing)

Here are a few more indicators that a thermographic scan is necessary:

• You’ve seen a rise in energy usage without increasing equipment usage.
• You’ve observed a slowness in your equipment.
• You’ve had power outages that you can’t explain.
• When your apparatus is turned on, the lights darken. 
• The temperature of your equipment is higher than normal.
• You’ve raised electricity consumption by adding equipment or making repairs.

Thermometric Testing can be done in Three Methods. 

A thermal camera, also known as a thermal imager, cannot provide a general solution for all infrared investigations. Your strategy should be tailored to the sort of equipment you’re evaluating and the amount of information you demand. However, three common approaches will handle the majority of scenarios: 

• Thermal Baselines

• Pattern Thermography  

• Correlations Thermography 

Thermal Baselines 

For almost every application, baseline thermography is an excellent place to start. When it’s first commissioned or later in its lifespan when it’s operating well, you scan the equipment and then utilize that as a baseline for future inspections.

This baseline technique opens the path to letting you discover abnormalities down the road, whether you compare thermal photos on your camera in the field or on your computer using software tools. (thermographic testing)

Pattern Thermography 

Thermal trending inspections can examine how temperature is distributed in the same components over time once you’ve established your baseline. This can help you notice diminishing performance over time, allowing you to arrange repair before the equipment does. (Thermographic Testing)

Correlations Thermography 

As you might assume, scanning identical components with your thermal camera under similar conditions and comparing the findings is what this entails. Similar or identical components, under comparable loads, should have similar temperature profiles, according to this technique. It’s relatively straightforward to detect an abnormality if you have three or more components. Isn’t that easy? Primarily, yes. There’s one additional complication to think about: The temperature difference that can be termed an anomaly varies depending on the components being compared.

Thermographic Testing is one of the predictive maintenance solutions offered by STOPLEAKLOSS.

Performing an infrared electrical examination or any other thermographic imaging requires more than just purchasing and using a high-end camera. Setting up a successful thermographic testing program necessitates a solid understanding of the technology and a thorough comprehension of the process equipment. This is when STOPLEAKLOSS enters the picture.

Our highly trained predictive maintenance specialists have the knowledge and experience to acquire and evaluate the data-driven metrics given by this technology to enhance asset availability.