1. What do I need to do to prepare for a survey?
2. Do we need to be shut down to do this inspection?
3. We can't open the motor starters while they are running.
4. We don't have "electricians"; we have maintenance technicians.
5. I thought you were just going to look at the boiler.
6. You don't open the panels yourself?
7. Aren't all electrical connections hot?
8. Why is it hot?
9. So, what does this mean: Phase A line side fuse clip? What am I supposed to do with it?
10. That panel has been there for 25 years. I don't think it's going to fail.
11. That equipment is new, there is no reason to check it.
12. Is a hot spot bad?

There are a few things you can do to ensure a successful infrared survey.

1. Determine what you want surveyed. Major categories can be:
1. Electrical:  incoming power service down to control cabinets
2. Mechanical:  bearings on fans, motors and line shafts
3. Energy losses: steam traps, degraded insulation of boilers and kilns

2. Choose a professional infrared thermographer who has a minimum of the following:
1. Written Practice program that meets the recommended practices section, SNT-TC-1A, of The American Society of Nondestructive Testing, Inc.
2. Program that is audited by a third party.
3. Ability to provide reports in hard copy, as well as electronically.
4. References on request.

3. Establish what the report content will consist of and when you should expect a report to be produced and delivered

4. The electrical load should be as near as possible the normal level when surveying electrical breakers, relays, controllers, etc. Low loads may not show problems.

5. Most infrared thermographers require the customer provide a qualified person to open and close electrical panels and cabinets. Make sure your personnel can perform this task safely.

6. Time is money, so proper support in opening and closing panels can assist in using the thermographer to the fullest.

7. When the thermographer arrives at your facility, hold a short meeting to clarify the importance of safety and the route that will be taken to conduct the survey.

8. Talk to the thermographer before he/she leaves your site to be certain that you are clear about what was found.

9. Consider having the thermographer return after repairs and conduct another survey to ensure repairs were properly completed.

The plant needs to be operational during the inspection. Fully loaded is optimum for an infrared scan. Poor electrical connections generate heat that can cause power loss at the connection. The higher the current flow, the easier it is to see faulty connections using the infrared equipment.

Most electrical equipment, rated 480 volt and below, has an electrical interlock that allows for in-service testing.

A qualified electrical technician, who is familiar with facility equipment and has a thorough understanding of safety requirements, is an important part of any infrared scan.

The scope of work expected to be done should be understood by both client and thermographer. Most inspections will focus on electrical systems; however, the infrared camera can be used on any equipment where a heat profile, however slight, would provide significant data. These include:

1. Electrical
2. Boilers
3. Bearings
4. Structures

Due to liability constraints, thermographers are not allowed to open or physically touch your equipment. In addition, if the thermographer opens and closes panels, delay and cost increase can result. 

The optimum situation is to have one or two technicians opening panels in lead of the thermographer with another technician closing the panels after the scan. Infrared scans are very swift since the image can reveal almost immediately if a problem area exists.

Any electrical system is normally operating at a temperature slightly above and, in some cases, well above ambient. Problem connections are in excess of these temperatures.

All electrical connections and even straight runs of cable offer resistance to current flow. This resistance is a system power loss that is dissipated as heat. This is normal. An electrical connection that is as little as 0.5 degrees F hotter than the others can be detected.

Detection and analysis of the problem is only half of the job. Once a problem has been identified, it is the facility's responsibility to take action. Qualified technicians should make all repairs.

Failure of an over heating condition cannot be accurately predicted. When an electrical connection starts to form high resistance and generate heat there is no method to determine when it will fail. A connection could very well be hot for 25 years and fail in the 26th year. And, theoretically, the connection may never fail.

Unfortunately, age has no relationship to hot connections. Poor initial installation has been the cause of many failures.

A hot terminal connection affects your system in a couple of ways:

1. It is a power loss. You are paying extra in your electrical bill for all hot connections. The electrical meter does not care whether the power is going to turn a motor or heat the air. Therefore, a hot connection reduces plant efficiency.
2. Failure. Most damage occurs when the electrical connection actually fails. The arc that is caused when the connections separate will melt most metals. A connection that would have cost $200 in parts and labor to repair could cost the owner in excess of $500,000 in damage.
3. The fire caused by the failure could destroy an entire complex.