Thermal Imaging for Predictive Maintenance

Understanding Thermal Imaging Technology in Industrial Applications

Thermal imaging, also known as infrared thermography, has revolutionised the way industrial facilities approach equipment maintenance and reliability. This non-invasive diagnostic technique captures the infrared radiation emitted by objects and converts it into visible images that display temperature variations across surfaces. For manufacturing plants, processing facilities, and utilities across Atlantic Canada, thermal imaging represents a powerful tool for identifying potential failures before they result in costly downtime or safety hazards.

The fundamental principle behind thermal imaging is straightforward: all objects with a temperature above absolute zero emit infrared radiation. Modern thermal cameras detect this radiation in the 7.5 to 14 micrometre wavelength range, producing detailed thermograms that reveal temperature differentials as small as 0.02°C in professional-grade equipment. These temperature anomalies often indicate underlying problems such as electrical resistance, mechanical friction, insulation degradation, or fluid leaks that would otherwise remain invisible until catastrophic failure occurs.

In Nova Scotia's industrial landscape, where facilities often operate in challenging environmental conditions ranging from humid coastal air to harsh winter temperatures, thermal imaging provides an essential diagnostic capability. The technology allows maintenance teams to inspect equipment while it remains operational, eliminating the need for costly shutdowns during routine inspections and enabling continuous monitoring of critical systems.

The Business Case for Predictive Maintenance in Maritime Industries

Traditional maintenance strategies fall into two categories: reactive maintenance, where repairs occur after equipment fails, and preventive maintenance, which follows fixed schedules regardless of actual equipment condition. Both approaches carry significant limitations. Reactive maintenance results in unplanned downtime, emergency repair costs, and potential safety incidents. Preventive maintenance, while more proactive, often leads to unnecessary part replacements and missed opportunities to address developing problems.

Predictive maintenance using thermal imaging offers a fundamentally different approach. By monitoring actual equipment conditions and identifying anomalies before they progress to failure, facilities can:

• Reduce unplanned downtime by 30-50% through early fault detection

• Extend equipment lifespan by 20-40% by addressing issues at optimal intervention points

• Decrease maintenance costs by 25-35% by eliminating unnecessary preventive activities

• Improve workplace safety by identifying overheating components and electrical hazards

• Enhance energy efficiency by detecting insulation failures and heat loss

For Maritime manufacturers and processors competing in national and international markets, these efficiency gains translate directly to improved competitiveness. A fish processing plant in Nova Scotia, for example, cannot afford refrigeration system failures during peak season. Similarly, a pulp and paper facility in New Brunswick depends on continuous operation of motors, bearings, and electrical systems to maintain production targets.

Industry studies indicate that the return on investment for thermal imaging programmes typically ranges from 400% to 1,000%, with payback periods often measured in months rather than years. When a single motor failure can cost $50,000 or more in emergency repairs, lost production, and overtime labour, the value of early detection becomes immediately apparent.

Critical Applications of Thermal Imaging in Predictive Maintenance

Electrical System Inspections

Electrical failures represent one of the leading causes of industrial fires and unplanned shutdowns. Thermal imaging excels at identifying electrical problems because increased resistance in connections, conductors, and components generates excess heat long before visible damage occurs. Common electrical anomalies detectable through thermography include:

• Loose or corroded connections at switchgear, motor control centres, and distribution panels

• Overloaded circuits and conductors operating beyond rated capacity

• Unbalanced loads across three-phase systems, often indicating motor or supply problems

• Failing fuses, breakers, and contactors exhibiting abnormal heating patterns

• Degraded insulation on cables, transformers, and bus bars

The Canadian Electrical Code and CSA standards recommend regular thermographic inspections of electrical systems, and many insurance providers offer premium reductions for facilities with documented thermal inspection programmes. A temperature differential of 10°C or more between similar components under similar loads typically warrants investigation, while differentials exceeding 40°C often indicate imminent failure requiring immediate attention.

Mechanical Equipment Monitoring

Rotating machinery, including motors, pumps, compressors, gearboxes, and conveyors, produces characteristic thermal signatures that change as components wear or fail. Thermal imaging can detect:

• Bearing failures, which generate localised hot spots due to increased friction

• Coupling misalignment, visible as asymmetric heating patterns across couplings

• Belt tension problems, indicated by temperature variations across pulleys and sheaves

• Lubrication issues, whether insufficient lubrication causing overheating or over-lubrication causing fluid churning

• Shaft seal degradation in pumps and compressors

When combined with vibration analysis, thermal imaging provides a comprehensive picture of mechanical equipment health. Many facilities in Atlantic Canada have adopted integrated condition monitoring programmes that use multiple technologies to maximise detection capabilities and minimise false positives.

Process and Building Envelope Applications

Beyond equipment maintenance, thermal imaging serves valuable roles in process monitoring and facility management. In Nova Scotia's climate, where heating costs represent a significant operational expense, thermal surveys of building envelopes can identify insulation gaps, air leakage paths, and moisture infiltration that compromise energy efficiency.

Process applications include monitoring refractory linings in kilns and furnaces, detecting blockages in piping systems, verifying steam trap operation, and identifying leaks in compressed air systems. A single malfunctioning steam trap can waste thousands of dollars in energy annually, while compressed air leaks typically cost industrial facilities 20-30% of their compressor capacity.

Equipment Selection and Technical Specifications

Selecting appropriate thermal imaging equipment requires careful consideration of application requirements, environmental conditions, and budget constraints. Key specifications to evaluate include:

Detector Resolution: Measured in pixels, detector resolution determines the level of detail captured in thermograms. Entry-level cameras offer 160 × 120 pixel resolution, suitable for basic inspections at close range. Professional predictive maintenance applications typically require 320 × 240 or 640 × 480 resolution to identify small anomalies on equipment inspected from safe distances.

Thermal Sensitivity (NETD): Noise Equivalent Temperature Difference measures the smallest temperature variation a camera can detect. Professional instruments achieve NETD values of 50 mK or better, enabling detection of subtle anomalies that indicate early-stage problems.

Temperature Range: Different applications require different measurement ranges. General industrial inspections typically need -20°C to 350°C capability, while high-temperature applications such as furnace monitoring may require ranges extending to 1,500°C or higher.

Accuracy: Professional thermal cameras typically offer accuracy of ±2°C or ±2% of reading, whichever is greater. For critical measurements, understanding accuracy limitations and performing regular calibration is essential.

Environmental Ratings: Given Atlantic Canada's variable weather conditions, cameras used for outdoor inspections should carry appropriate IP ratings for dust and moisture protection. IP54 or higher ratings are recommended for industrial environments.

Leading manufacturers including FLIR, Fluke, and Testo offer instruments meeting these specifications, with professional-grade cameras ranging from $5,000 to $50,000 depending on capabilities and features.

Implementing a Thermal Imaging Programme

Successful implementation of thermal imaging for predictive maintenance requires more than equipment purchase. A comprehensive programme includes several critical elements:

Baseline Documentation

Effective anomaly detection requires comparison against known good conditions. Initial thermographic surveys should document normal operating temperatures for all critical equipment, establishing baselines that enable meaningful trend analysis over time. These baselines must account for operating loads, ambient conditions, and seasonal variations relevant to Maritime climate patterns.

Inspection Procedures and Frequencies

Developing standardised inspection procedures ensures consistent, repeatable results regardless of which technician performs the survey. Procedures should specify equipment operating conditions required for valid measurements, camera settings, image capture angles, and documentation requirements.

Inspection frequencies vary based on equipment criticality and failure history. Critical systems may warrant monthly or quarterly inspections, while less critical equipment might receive annual surveys. Many facilities adopt risk-based inspection schedules that concentrate resources on equipment where failures would have the greatest operational or safety impact.

Personnel Training and Certification

Thermal imaging interpretation requires specialised knowledge to distinguish genuine anomalies from artifacts caused by emissivity variations, reflections, environmental factors, or equipment operation. The American Society for Nondestructive Testing (ASNT) and Infrared Training Center offer certification programmes at multiple levels:

• Level I: Basic thermography principles and data acquisition

• Level II: Advanced analysis, report writing, and programme development

• Level III: Programme management, procedure development, and training capability

For facilities without dedicated thermography personnel, partnering with qualified engineering firms provides access to certified expertise while avoiding the investment required to develop in-house capabilities.

Data Management and Trending

Individual thermal surveys provide snapshots of equipment condition, but the full value of predictive maintenance emerges through trend analysis over time. Modern thermal imaging software enables systematic organisation of inspection data, automated comparison against baselines, and tracking of developing anomalies across multiple inspection cycles.

Integration with computerised maintenance management systems (CMMS) links thermal findings to work orders, maintenance histories, and equipment records, creating comprehensive asset health profiles that support data-driven maintenance decisions.

Integration with Industry 4.0 and Automation Systems

The evolution of thermal imaging technology increasingly intersects with broader automation and digitalisation trends. Fixed-mount thermal cameras integrated with plant control systems enable continuous monitoring of critical equipment, with automated alerts when temperatures exceed defined thresholds. These systems prove particularly valuable for equipment operating in hazardous or inaccessible locations.

Integration with SCADA systems allows correlation of thermal data with process variables, revealing relationships between operating conditions and equipment temperatures. Machine learning algorithms can analyse historical thermal patterns to predict failures with increasing accuracy as datasets grow.

For facilities pursuing Industry 4.0 implementation, thermal imaging represents a mature, proven technology that integrates readily with digital infrastructure. The non-contact nature of measurement simplifies sensor installation compared to contact-based temperature monitoring, while the rich spatial information in thermal images captures temperature distributions across entire components rather than single-point measurements.

Drone-mounted thermal cameras extend inspection capabilities to elevated equipment, large facilities, and hazardous areas. In Atlantic Canada, where many industrial facilities include extensive outdoor infrastructure subject to harsh weather, aerial thermography offers efficient inspection of overhead lines, tank farms, and building roofs without scaffolding or confined space entry.

Case Studies and Practical Applications in Atlantic Canada

The diverse industrial base across the Maritime provinces presents numerous applications for thermal imaging predictive maintenance. Food processing facilities, which represent a significant sector in Nova Scotia's economy, rely on refrigeration systems where early detection of compressor problems, condenser fouling, or insulation degradation prevents product loss and regulatory compliance issues.

Marine terminal operations, critical to Atlantic Canada's role as an international trade gateway, use thermal imaging to monitor ship-to-shore cranes, conveyor systems, and electrical infrastructure. The combination of heavy loads, continuous operation, and salt air exposure creates demanding conditions where predictive maintenance proves especially valuable.

Power generation and distribution facilities across the region employ thermal imaging extensively, with utilities conducting regular surveys of substations, transmission lines, and generation equipment. The consequence of electrical failures in utility systems extends beyond the facility itself, making predictive maintenance essential for grid reliability.

Manufacturing operations ranging from aerospace component production to building materials fabrication benefit from thermal monitoring of production equipment, HVAC systems, and electrical infrastructure. In competitive manufacturing environments, maximising equipment availability while controlling maintenance costs directly impacts profitability.

Partner with Sangster Engineering Ltd. for Your Predictive Maintenance Needs

Implementing an effective thermal imaging programme requires technical expertise, appropriate equipment, and systematic procedures. Sangster Engineering Ltd. brings decades of engineering experience serving industrial clients throughout Nova Scotia and the Atlantic region. Our team understands the unique challenges facing Maritime industries, from coastal environmental conditions to seasonal operational demands.

Whether you require comprehensive thermographic surveys of existing facilities, development of predictive maintenance programmes tailored to your operations, or integration of thermal monitoring with automation systems, Sangster Engineering Ltd. provides the professional engineering services to achieve your reliability and efficiency goals.

Contact Sangster Engineering Ltd. today to discuss how thermal imaging and predictive maintenance can reduce your operational costs, improve equipment reliability, and enhance workplace safety. Our Amherst-based team is ready to analyse your specific requirements and develop solutions that deliver measurable results for your facility.

Partner with Sangster Engineering

At Sangster Engineering Ltd. in Amherst, Nova Scotia, we bring decades of engineering experience to every project. Serving clients across Atlantic Canada and beyond.

Contact us today to discuss your engineering needs.