Thermography Inspection of Electrical Installations as per IS 16168

by Ohm Engineering Works | mar 04, 2025 | Electric Company 

Introduction

Electrical failures in industrial, commercial, and residential buildings can lead to unexpected downtime, safety hazards, and costly repairs. One of the most effective preventive maintenance techniques is thermography inspection, which helps detect hidden electrical faults before they cause severe damage.

This article explores thermography inspection as per IS 16168, its importance, process, benefits, and real-world applications—ensuring both technical and non-technical readers can grasp its value.

What is Thermography Inspection?

Thermography, or infrared (IR) thermography, is a non-contact, non-destructive testing method that detects temperature variations in electrical components using infrared cameras. By identifying hotspots, thermography helps prevent electrical failures by detecting:

✅ Loose or corroded connections – Increased resistance causes excessive heating.
✅ Overloaded circuits – Excess current flow leads to overheating.
✅ Imbalanced loads – Uneven power distribution strains electrical systems.
✅ Faulty insulation – Deteriorated insulation results in leakage currents and potential short circuits.

IS 16168: Indian Standard for Thermographic Inspection

IS 16168:2014 is the Indian Standard that provides guidelines for conducting thermography inspections of electrical installations. This standard ensures a systematic approach to inspections, improving safety and reliability by defining:

✔ Inspection Methods – Proper procedures for conducting thermographic surveys.
✔ Temperature Thresholds – Safe operating limits for electrical components.
✔ Reporting Requirements – Guidelines on documenting and analyzing findings.
✔ Corrective Actions – Steps to resolve detected faults.

By following IS 16168, businesses and industries can enhance preventive maintenance programs and comply with safety regulations.

How is Thermography Inspection Conducted?

Thermography inspection follows a structured process to ensure accurate fault detection and analysis.

1. Pre-Inspection Preparation

Before conducting the inspection, professionals:

✔ Review electrical layouts to identify critical components.
✔ Check system load conditions to ensure accurate thermal readings.
✔ Select an appropriate infrared camera based on sensitivity and accuracy requirements.

2. On-Site Inspection

During the inspection:

✔ The technician scans electrical panels, switchgear, cables, and connections using an infrared camera.
✔ Thermal images reveal hotspots (abnormally high temperatures), indicating potential faults.
✔ Readings are compared with IS 16168-defined temperature thresholds to assess fault severity.

3. Data Analysis and Reporting

After capturing thermal images:

✔ Faulty components are analyzed to determine the cause of overheating.
✔ A detailed inspection report includes:

• Thermal images of affected components.

• Temperature readings and deviations from normal.

• Severity classification (minor, moderate, or critical).

• Recommended corrective actions to resolve identified issues.

4. Corrective Action & Follow-Up

✔ Technicians address identified faults (tighten connections, balance loads, replace faulty parts).
✔ A follow-up thermographic survey ensures corrective measures have resolved the issue.

Practical Example: Real-World Application

Case Study: Preventing Electrical Failure in a Manufacturing Plant

Problem: A large manufacturing plant experienced frequent electrical breakdowns, disrupting production. A thermographic survey was conducted to identify hidden issues.

Findings:
✔ A busbar connection in the main panel showed an abnormal temperature rise of 95°C, while the normal operating range was below 60°C.
✔ The issue was traced to a loose connection, causing high resistance and excessive heat.

Solution:
✔ The connection was tightened and rechecked using a thermographic camera.
✔ The temperature dropped to 45°C, eliminating the risk of failure.

Result:
✔ The plant avoided unexpected downtime and saved on costly repairs, ensuring uninterrupted production.

Benefits of Thermography Inspection

✅ Prevents Costly Failures

Early detection of faults reduces the risk of sudden equipment breakdowns, saving on repair and downtime costs.

✅ Enhances Safety

By identifying overheating components, thermography helps prevent electrical fires and accidents.

✅ Non-Destructive & Non-Intrusive

Thermographic inspections are conducted without shutting down operations, ensuring zero disruption to businesses.

✅ Improves Energy Efficiency

Detecting overloaded circuits and imbalanced loads helps optimize energy consumption, reducing electricity costs.

✅ Ensures Compliance with IS 16168

Regular thermographic surveys help businesses meet Indian safety standards, ensuring regulatory compliance.

Conclusion

Thermography inspection, as per IS 16168, is a powerful preventive maintenance tool for ensuring electrical safety and reliability. By detecting hidden electrical issues before failures occur, businesses can:

✔ Prevent costly electrical breakdowns.
✔ Enhance workplace safety.
✔ Improve energy efficiency and system performance.
✔ Ensure compliance with Indian standards.

Regular thermographic surveys should be an integral part of every electrical maintenance strategy, ensuring uninterrupted operations and long-term safety.

If you need a professional thermography inspection for your facility, contact Ohm Engineering Works today to ensure your electrical systems are safe, efficient, and compliant!