Top 10 Problems Infrared Thermography Detects Before They Cause Downtime

Unplanned downtime is one of the most expensive risks facing commercial and industrial facilities. Electrical failures, mechanical breakdowns, and hidden system defects often develop silently — until they escalate into outages, safety incidents, or costly emergency repairs.

This is why infrared thermography has become a cornerstone of predictive and condition-based maintenance programs. By identifying temperature anomalies early, facilities can address issues before they disrupt operations.

At Assured NDT, we perform professional infrared inspections nationwide to help facilities detect critical problems early, improve reliability, and meet NFPA 70B compliance requirements. Below are the top 10 infrared thermography problems we routinely detect before they cause downtime.

1. Loose or Deteriorating Electrical Connections

Loose connections are one of the most common — and dangerous — issues identified during infrared inspections.

Why It Matters

• Increased resistance causes excessive heat

• Leads to arcing, fires, and equipment failure

• Often invisible during visual inspections

Infrared thermography identifies overheating terminations long before failure occurs.

2. Overloaded Circuits and Panels

As facilities add equipment, EV chargers, or new processes, electrical loads increase.

Why It Matters

• Overloaded circuits overheat

• Can trip breakers or damage insulation

• Increase arc flash risk

Thermal imaging highlights uneven or excessive heating that signals overload conditions.

3. Failing Circuit Breakers and Fuses

Breakers are designed to protect equipment — but they can fail silently over time.

Why It Matters

• Breakers may not trip when required

• Creates significant fire and arc flash risk

• Leads to cascading failures

Infrared thermography detects abnormal heat signatures that indicate internal breaker failure.

4. Phase Imbalance

Electrical phase imbalance occurs when loads are unevenly distributed.

Why It Matters

• Causes overheating of conductors and motors

• Reduces efficiency

• Shortens equipment lifespan

Infrared inspections quickly reveal phase temperature differences that indicate imbalance.

5. Transformer Overheating

Transformers are critical — and expensive — assets.

Why It Matters

• Overheating accelerates insulation breakdown

• Can result in catastrophic failure

• Leads to extended downtime

Thermal imaging identifies hotspots caused by overloads, cooling issues, or internal defects.

6. Motor and Bearing Failure

Motors drive production, HVAC, and critical processes.

Why It Matters

• Bearing friction creates abnormal heat

• Leads to sudden motor failure

• Often missed until breakdown

Infrared thermography identifies early-stage bearing and winding issues.

7. HVAC Electrical and Mechanical Issues

HVAC systems operate continuously, especially in hot and humid climates.

Why It Matters

• Electrical faults impact occupant comfort

• HVAC downtime can halt operations

• Failures increase energy costs

Thermal inspections detect overheating contactors, motors, and electrical components.

8. Insulation Breakdown

Electrical insulation degrades over time due to heat, moisture, and age.

Why It Matters

• Leads to short circuits

• Increases fire risk

• Reduces system reliability

Infrared thermography detects heat patterns associated with insulation failure.

9. Moisture Intrusion in Electrical Equipment

Water and electricity are a dangerous combination.

Why It Matters

• Causes corrosion and shorts

• Accelerates electrical degradation

• Can result from roof or conduit leaks

Infrared inspections reveal cooling effects and thermal anomalies caused by moisture.

10. Failing Connections in Switchgear and MCCs

Switchgear and motor control centers distribute power throughout facilities.

Why It Matters

• Single failure can impact multiple systems

• Creates widespread downtime

• Increases arc flash exposure

Infrared thermography helps prioritize repairs before system-wide disruptions occur.

Why Infrared Thermography Prevents Downtime

Each of these infrared thermography problems develops gradually — and silently. Thermal imaging provides an early warning system that allows facilities to:

• Schedule repairs during planned outages

• Reduce emergency maintenance costs

• Improve worker safety

• Extend equipment lifespan

• Support NFPA 70B compliance

• Strengthen insurance risk profiles

Many facilities see a 5–10x return on investment from annual infrared inspections.

NFPA 70B and Annual Infrared Inspections

With the 2023 update to NFPA 70B, infrared thermography is now required at least annually for energized electrical equipment as part of a condition-based maintenance program.

Facilities must:

• Perform inspections

• Document findings

• Track corrective actions

• Use qualified thermographers

Assured NDT provides audit-ready reports aligned with NFPA 70B, OSHA, and insurance expectations.

Why Facilities Choose Assured NDT

Assured NDT delivers professional infrared thermography services nationwide, offering:

• Certified thermographers

• NFPA 70B-compliant inspection protocols

• Clear severity rankings and repair priorities

• Minimal operational disruption

• Commercial, industrial, and critical facility expertise

We don’t just show heat — we deliver insight.

Detect Infrared Thermography Problems Before Downtime Occurs

If your facility relies on electrical reliability, infrared thermography should be a core part of your maintenance strategy.

📞 Contact Assured NDT to schedule an infrared inspection or consultation👉 www.assuredndt.com/contact

FAQs: Infrared Thermography Problems

1. What types of problems does infrared thermography detect?

Infrared thermography detects overheating electrical connections, overloaded circuits, failing breakers, motors, transformers, insulation breakdown, moisture intrusion, and phase imbalance.

2. Can infrared thermography prevent downtime?

Yes. By identifying problems early, facilities can schedule repairs before failures cause outages or operational disruption.

3. Is infrared thermography required by NFPA 70B?

Yes. NFPA 70B requires annual infrared inspections for energized electrical equipment as part of a condition-based maintenance program.

4. Can inspections be performed without shutting down equipment?

Yes. Infrared thermography is non-contact and performed while equipment remains energized.

5. Who is qualified to perform infrared thermography inspections?

Certified thermographers using calibrated equipment, as required by NFPA 70B.