We recently completed a thermographic scan for one of our commercial customers, and the results are a perfect example of why these scans should be part of every facility’s preventive maintenance program.
Reading the Heat Map: Real Examples
Instead of visible light, thermographic cameras detect infrared radiation – basically, heat energy. The warmer something is, the more infrared energy it gives off, and the camera translates these heat signatures into a colour-coded image that shows cooler areas in blues and purples, medium temperatures in oranges and yellows, and hotter areas in white.
When current flows through a connection it should flow smoothly with minimal resistance, but when connections get loose, corroded, or components start to fail, they create resistance, and resistance creates heat. A connection that’s running even 10°C hotter than it should be is an indication of a problem.
These images from our recent scan really tell a story. What caught our attention right away was that we had hot spots showing up on one phase, even though the amperage readings were similar across all three phases. When you see this pattern, it’s time to ask “why?” – because balanced loads should mean balanced temperatures.
This image shows a hot spot in a factory connection of a fused disconnect switch. This is typically a torque issue – connections loosen over time due to thermal cycling, vibration, and old age. Left unchecked, this connection will continue to deteriorate, generating more heat, creating more resistance, and potentially lead to complete failure. A simple torque check and tightening will likely solve this one before it becomes a bigger problem.
Here we see heat buildup in a fuse inside the main disconnect. This tells us the fuse isn’t dissipating heat properly, which usually indicates the fuse is getting weak or has developed internal resistance issues. The risk here is that a failing fuse like this one might not blow at all, which defeats its entire purpose as a safety device. In cases like this we would replace all three fuses as a preventive measure, because they are all the same age and have seen the same service conditions. Just as with car headlight bulbs, if one is dead, the other won’t be far behind.
This image is particularly interesting, showing heat on the top side of a contactor inside a refrigeration condenser. An important point about thermographic scans is that the “white-hot” areas you see are relative to the surrounding temperature, and not necessarily a dangerously high temperature. What is concerning here is that the incoming connection is running hotter than the outgoing side, even though they are carrying the same load. This temperature difference usually points to a loose connection or corrosion on the wire or lug. The refrigeration system depends on that contactor, and failure here could mean thousands of dollars in spoiled inventory.
The Business Case
Electrical failures don’t care about convenient timing – they have a way of happening at 2 AM on a long weekend when your facility is running unmanned, or during your busiest production period when downtime costs you the most.
Preventing Catastrophic Failures: That hot connection we found, if left alone, could progress from a minor heat issue to complete failure, potentially taking out an entire production line or even causing a facility-wide power outage. Lost revenue, overtime costs to get back online, and expedited parts and service far exceed the cost of the preventive maintenance that would have caught the issue before it became a problem.
Insurance Benefits: Many commercial insurance policies now require regular electrical maintenance or offer significant discounts for facilities that conduct it. Insurance companies know the statistics – facilities with proactive maintenance programs file fewer claims and have less severe incidents when problems do occur. A maintenance program may even pay for itself in reduced insurance premiums.
Energy Efficiency: Those hot connections aren’t just potential failure points – they’re energy wasters. A connection running 20°C above normal can increase energy consumption for that circuit by 5-10%. Multiply that across multiple issues in a facility, and you’re looking at hundreds or even thousands of dollars annually in wasted electricity costs.
Beyond the Pretty Pictures
Thermographic scanning isn’t just about taking infrared photos – it’s a comprehensive electrical health check. During these scans, we do a complete visual assessment of your equipment and document deficiencies like double-tapped breakers (two wires under one breaker), dirt and debris in panels, missing knockouts, improper installations, and grounding issues. We also check for code compliance issues that might have been overlooked during previous work, proper labeling of circuits and panels, and general housekeeping issues that could impact safety or performance. Think of it as a detailed inspection that goes far beyond what you’d get during a routine service call.
Safety First, Always
During these scans we’re working with live equipment, which means arc flash protection is non-negotiable. Our team wears proper arc flash gear rated for the fault current levels in your facility and is trained in arc flash safety protocols. We also coordinate with your facility management to ensure any necessary safety procedures are followed, including lockout/tagout protocols for areas where we need to remove panel covers. We carry insurance for this type of work and can provide certificates of insurance for your facility management requirements.
Making It Work for Your Business
The key to a successful thermographic scanning program is regularity. One-time scans are valuable, but annual scans allow us to track the progression of issues and identify patterns in your electrical system’s aging. We maintain detailed records and can show you year-over-year comparisons that help prioritize maintenance budgets and planning. For larger facilities, we can coordinate scans during scheduled maintenance windows or low-production periods to minimize any operational impact.
If you haven’t had a thermographic scan done on your facility lately, or if you’re dealing with unexplained electrical issues, give us a call. Sometimes the best way to see what’s really going on is to look at it through a different lens – literally. Your electrical system is trying to show you something: we just need to look with the right equipment.
