Electrical failures rarely happen without warning. Loose connections, overloaded circuits, failing breakers, and deteriorating components often generate heat long before they trigger a shutdown. Infrared electrical inspections (also called thermographic inspections) help facilities detect these hidden problems early reducing unplanned outages, preventing equipment damage, and improving safety.
At Bunney’s Inc., we support industrial electrical reliability programs by helping facilities execute the repair, upgrade, and outage work that commonly follows inspection findings especially when corrective actions involve heavy equipment handling, construction support, and schedule-critical shutdown windows.
What Are Infrared Electrical Inspections?
Infrared electrical inspections use thermal imaging cameras to identify abnormal heat patterns in electrical equipment while it is operating. Because many electrical issues create resistance, they show up as hot spots on infrared scans.
Infrared inspections are commonly performed on:
-
Service entrance and main distribution equipment
-
Switchgear and panelboards
-
Bus ducts and cable terminations
-
Transformers (as accessible and safe to scan)
-
Motor control centers (MCCs)
-
Disconnects, breakers, and fused switches
-
Critical connections feeding high-load equipment
These inspections help identify issues before they become failures.
Why Infrared Electrical Inspections Matter
Prevent unplanned outages
A single overheated connection can shut down a whole line. Infrared inspections can catch early-stage problems before they escalate.
Improve safety
Hot spots can signal conditions that increase arc flash or fire risk. Identifying them early reduces hazards to personnel and equipment.
Reduce maintenance costs
Thermal inspections support predictive maintenance fixing problems before they require emergency response or major replacement.
Support compliance and documentation
Inspection reports can support internal audits, insurance requirements, and reliability programs especially when paired with corrective action documentation.
Common Problems Infrared Inspections Detect
Infrared inspections can reveal a wide range of issues, including:
-
Loose or deteriorating connections causing resistance heating
-
Overloaded circuits and undersized components
-
Phase imbalance causing uneven heating across conductors
-
Failing breakers or contactors with abnormal thermal patterns
-
Damaged cable terminations or corroded components
-
Poor ventilation or blocked airflow in electrical rooms
-
Transformer or bus duct hot spots indicating internal stress (where accessible)
Thermal imaging doesn’t replace electrical testing but it’s a powerful early-warning tool for risk reduction.
When Should Facilities Schedule Infrared Electrical Inspection
Many facilities perform infrared inspections:
-
On a routine schedule (often annually or semi-annually for critical areas)
-
Before peak production seasons to reduce shutdown risk
-
After major electrical modifications or expansions
-
When experiencing nuisance trips, overheating, or unexplained shutdowns
-
Prior to planned outages, to prioritize repairs during shutdown windows
What Happens After an Infrared Inspection?
The inspection report typically ranks findings by severity and recommends corrective actions. Many corrective actions require skilled installation support, equipment changeouts, and careful outage planning.
Common follow-up work includes:
-
Tightening and re-terminating connections
-
Repairing or replacing damaged components
-
Upgrading overloaded feeders or distribution gear
-
Service Entrance Section (SES) upgrades
-
Load balancing and distribution reconfiguration
-
Replacing deteriorated equipment supports or enclosures
-
Planned shutdown tie-ins for safe repair and verification
How Bunney’s Inc. Supports Corrective Work After Infrared Findings
Once thermal inspections identify issues, facilities often need fast, safe execution especially when problems affect critical loads. Bunney’s Inc. supports the implementation side of infrared inspection programs by providing construction and outage support services that help correct findings efficiently.
Our support capabilities include:
-
Industrial construction services supporting electrical infrastructure improvements
-
Heavy lifting and rigging for transformers, switchgear, and major gear changeouts
-
Precision equipment positioning for accurate placement and clearance requirements
-
Outage support services for shutdown repairs and cutovers
-
Safety-first field execution aligned with facility and utility standards
Benefits of Acting on Infrared Inspection Results
When findings are addressed promptly, facilities benefit from:
-
Fewer unplanned shutdowns and improved uptime
-
Reduced arc flash and fire risk
-
Longer equipment life and fewer emergency repairs
-
Better system reliability for critical loads
-
Stronger maintenance planning with prioritized corrective work
Conclusion: Turn Infrared Findings into Reliable Results Contact Bunney’s Inc.
Infrared electrical inspections help you find hidden electrical problems before they become failures but the real value comes from correcting issues quickly and safely. Bunney’s Inc. supports facilities by executing the repair, upgrade, and outage work that often follows inspection findings keeping your reliability program moving from detection to resolution.
If your facility needs support implementing repairs or upgrades after an infrared electrical inspection, contact Bunney’s Inc. today. We’re ready to help you improve safety, protect uptime, and strengthen long-term electrical reliability.
Related Services:
