Tekwell Services infrared thermography is a powerful diagnostic tool for electric motors, helping to detect overheating, inefficiencies, and potential failures before they lead to costly breakdowns. By identifying abnormal temperature patterns, thermographic inspections can improve motor reliability, extend lifespan, and enhance safety.
The early detection of this heat allows these problems to be corrected before a component fails possibly causing damage to it, creating safety hazards and productivity loss. Because increased heat is a sign of failure, infrared is the best–non-destructive–diagnostic tool available for finding hot connections in the early stages of degeneration.
Most insurance companies recommend–or even require–electrical infrared thermographic studies, to find and prevent problems before they cause damage to your personnel, equipment and facility.
Our field service technicians perform infrared thermographic studies using Flir® infrared cameras specifically designed for building, mechanical and electrical applications.
Problems/Conditions Detectable by Infrared Thermographic Studies
Electrical Issues in Motors
Thermal imaging can detect a variety of electrical faults in motor systems, including:
- Loose or Corroded Electrical Connections
– High resistance at terminals and connections causes excessive heat, which may lead to failures or fire hazards.
- Unbalanced or Overloaded Circuits
– Uneven or excessive electrical loads result in one or more motor phases running hotter than others.
- Insulation Breakdown in Windings
– Deteriorating insulation increases leakage currents, leading to excessive heat buildup and potential short circuits.
- Rotor and Stator Faults
– Overheating in localized areas may indicate problems with rotor bars, stator windings, or misalignment.
Mechanical Issues in Motors
Thermal imaging can detect abnormal heat patterns caused by mechanical problems, such as:
- Overheated Bearings
– Improper lubrication, excessive wear, or misalignment causes friction and temperature rise in bearings.
- Shaft Misalignment
– Misaligned shafts create excessive friction, leading to overheating and premature wear.
- Unbalanced Rotors
– An unbalanced rotor generates excess heat in bearings and motor housings due to uneven forces.
- Excessive Friction in Couplings and Gears
– Increased heat in these areas can indicate misalignment, lack of lubrication, or wear.
- Belt Slippage in Belt-Driven Motors
– Slipping belts generate friction and excessive heat, reducing efficiency and causing premature belt failure.
Cooling and Ventilation Problems
Proper cooling is critical for motor longevity. Thermographic studies can detect:
- Blocked or Obstructed Cooling Vents
– Dust, dirt, or debris blocking ventilation leads to overheating.
- Fan Malfunction or Inefficiency
– Cooling fans that are not operating properly cause heat buildup.
- Inadequate Heat Dissipation
– Poor airflow around the motor enclosure can cause the motor to run hotter than normal.
- Excessive Ambient Temperature
– Motors in hot environments may struggle to stay within their optimal operating range.
Power Supply and Transformer Issues
Electric motors rely on stable power input, and infrared thermography can detect related issues:
- Overheating Transformers or Control Panels
– Excess heat indicates overloaded circuits, poor connections, or insulation breakdown.
- High Resistance in Motor Starters and Contactors
– Poor contacts and worn-out components create excessive heat and potential failure points.
- Variable Frequency Drive (VFD) Issues
– VFDs that overheat may indicate harmonics problems, improper programming, or ventilation issues.
Bearing and Lubrication Failures
Bearing problems are one of the most common causes of motor failure. Infrared thermography can help detect:
- Overheated Bearings Due to Poor Lubrication
– Dry bearings create excessive friction, leading to overheating and failure.
- Overgreased Bearings
– Excess grease increases internal friction, generating unnecessary heat.
- Misaligned Bearings
– Misalignment increases stress on the motor shaft, causing uneven heat patterns.
Structural and Mounting Issues
Even the way a motor is installed can create heat-related issues, such as:
- Loose Mounting Bolts
– Vibrations from a loose motor mount can create excessive friction and heat buildup.
- Foundation or Baseplate Problems
– Uneven motor bases can lead to misalignment and increased stress on motor components.
Key Benefits of Infrared Thermographic Studies for Electric Motors
- Early Failure Detection – Identifies issues before they cause unexpected downtime.
- Prevents Catastrophic Motor Failures – Reduces the risk of unplanned shutdowns.
- Extends Motor Life – Helps improve maintenance practices to prolong motor performance.
- Enhances Safety – Detects overheating components that could lead to electrical fires.
- Improves Energy Efficiency – Helps optimize motor operation to reduce energy waste.
- Non-Intrusive Inspection – Allows for testing without shutting down operations.
Is it Time for an Infrared Thermographic Study?
Complete some electric motor preventive maintenance by scheduling an infrared thermographic study via our easy-to-complete Pump and Electric Motor Repair Form today.