What’s Included in a Thermography Inspection?

Facilities that rely on continuous operations must identify electrical and mechanical faults before they lead to downtime or failure. Thermography inspections give plant managers and engineers a noninvasive way to evaluate surface temperatures under real load conditions. By identifying abnormal patterns early, teams can schedule targeted repairs without disrupting operations.

Visual and Infrared Imaging Setup

Technicians begin with camera selection based on the equipment distance, expected temperature ranges, and surface emissivity. Thermal imaging highlights active heat anomalies, while visible-spectrum images allow engineers to identify the exact physical locations tied to each reading. Teams adjust emissive values and focus settings to match material properties and eliminate false readings under real load conditions.

Consistent positioning during scanning allows direct comparison over time without introducing spatial variance. Thermal and visual imaging are always included in a thermography inspection because both are required to diagnose faults with precision and trace them to exact components.

Electrical Component Evaluation

Electrical systems often show thermal patterns that signal underlying risks when evaluated under live load. Thermographers scan transformers, switchgear, breakers, and control panels for overheating, phase imbalance, and irregular current draw. They interpret elevated temperatures at contact points as signs of deterioration or loose connections.

Inspection teams also document each hotspot with temperature deltas to prioritize severity and determine urgency. Electrical fault detection is a core function included in a thermography inspection, especially in facilities running high-voltage distribution equipment.

Mechanical Equipment Analysis

Technicians apply thermal scanning to motors, gearboxes, bearings, and rotating equipment to detect friction, misalignment, and lubrication issues. Surface heat often builds gradually in damaged components, making infrared imaging ideal for early detection.

As the temperature increases beyond baseline levels, engineers can isolate worn parts before they fail. Ongoing inspection prevents unexpected shutdowns and supports predictive maintenance schedules in process-critical plants. At Illinois Electric Works, we provide Midwestern electric motor rebuild services that businesses can rely on for asset longevity and performance consistency backed by thermographic evaluation.

Load and Operating Condition Documentation

Thermographers only scan equipment under normal load to avoid misrepresenting surface temperatures tied to active current or mechanical movement. They confirm equipment remains energized and under expected operational demand during inspection to ensure data validity.

Technicians also note ambient conditions, start-up cycles, and recent usage to create context for thermal readings. Without load documentation, teams cannot reliably compare data across future inspections or assess trending degradation. Documenting load conditions supports actionable insights when interpreting results from high-value machinery.

Reporting and Interpretation of Results

After capturing thermal data, specialists develop a structured report using calibrated images, timestamped readings, and reference visuals. They categorize issues by severity, identify suspected root causes, and recommend corrective actions for each flagged area.

Reports may include comparisons against baseline data or past inspections to identify developing trends. Engineers use these findings to assign maintenance priorities and support compliance reporting across multiple departments. Final documentation produced from infrared evaluations drives capital planning and improves decision-making at every level of facility operations.

Teams that implement infrared inspection strategies gain early warnings tied to both electrical and mechanical health. Contact Illinois Electric Works today to discuss custom inspections, expert analysis, and rebuild solutions that support continuous performance in your most important equipment.