Thermography — Mechanical & Electrical Inspections
Mechanical Inspections*
Thermal Imaging is often used for long term monitoring of mechanical and electrical equipment to avoid sudden failure. Baseline images are taken while the equipment is in working order. Equipment is then regularly monitored. During these monitoring sections, the baseline images are compared to real time images to locate areas of increased heat, which is often a precursor to component failure. Early identification can mean the difference between repairing and replacing a problem component.
Other benefits include:
- Increased safety
- Improved reliability
- Reduced unscheduled outages
- Reduced maintenance and repair costs
- Improved production rate and quality
- Better assurance of effectiveness of repairs and new installations
Thermal Imaging can also be used to ensure that HVAC duct systems have been adequately sealed.
Electrical Inspections*
ZWS uses Thermal Imaging to perform electrical inspections to prevent electrical fires and failures. The two main causes of electrical problems come from high resistance, and excessive current flow. If resistance or current are abnormally high, excessive heat can be generated.
Common reasons for unwanted electrical heat include:
- Poor surface connections
- Circuits, or wiring, carrying current greater than it is designed to carry
- ‘Pigtailing’ aluminum and copper wires
- Loose pigtails
Table 1.0 outlines ZWS’s guidelines for the Urgency of Electrical Repairs. The urgency of a repair is directly correlated to the difference in temperature (∆T) between a properly operating component, and a faulty component.
| Table 1.0 |
Urgency of Electrical Repairs in Relation to Temperature |
Temperature Difference (∆T) |
Potential Danger |
Urgency |
1 ○F to 18 ○F |
Minimal |
Routine repair during regular maintenance |
19 ○F to 36 ○F |
Moderate |
Repair within thirty (30) days |
37 ○F to 54 ○F |
Serious |
Repair/replace ASAP, inspect surround component for damage |
>55 ○F |
Severe |
Immediate repair/replace, danger exists |
Restoration Consultants ® – Thermography Training Manual
 Digital Picture |
 Thermographic Picture |
Combination of the two pictures |
*ZWS does not claim to be an expert in the field of mechanical and electrical maintenance, or in the field of mechanical and electrical diagnostics. All mechanical and electrical inspections must be performed with a member of the client’s maintenance staff, or with a qualified electrician (supplied by client).
ZWS makes no guarantees against unexpected mechanical/electrical failures or fires.
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