5 Generator Problems Thermal Imaging Can Detect Before They Cause Downtime

Thermal imaging is especially valuable for inspecting automatic transfer switches (ATS), helping identify loose connections, overheating components, and other issues that could prevent your backup power system from operating when utility power is lost.

Generator failures have often been described as being akin to going bankrupt – they happen very slowly over time, with little to no visible warning signs. Then, they happen all at once. To the average layman, it can be difficult to ascertain when there’s a problem that could be addressed proactively rather than reactively. That’s where thermal imaging comes in as a predictive maintenance tool that can help prevent many of the most common issues generators face before they escalate into catastrophe.

What is Thermal Imaging in Generator Maintenance?

Thermal imaging is a non-contact method of measuring the surface temperature of an area or a component. Infrared cameras are used to measure the amount of heat energy a component is giving off. This reveals hot spots and uneven temperature gradients that are invisible to the eye and can reveal developing faults in the equipment. There’s no need to shut a generator down to perform a thermal imaging assessment; it works best when the generator is running and thus minimizes service disruptions. It makes for an excellent complement to other forms of maintenance and testing, which can help detect numerous potential faults.

Loose or Failing Electrical Connections

Because generators are mechanical devices, natural motion can affect them over time. Additionally, the continual process of thermal expansion and contraction can also subtly warp and loosen connections over time. Thermal imaging can reveal this through hot spots in terminals, bus bars, breakers, or cable connections themselves through uneven temperature gradients compared to similar components. Thermal imaging for generators can detect and help correct this before overheating and equipment damage can occur.

Overloaded Electrical Components

Electrical components can commonly be overloaded by excessive demand, improper load balancing, or simply the components themselves aging and wearing out with time. This will often appear on thermal imaging in the form of components operating significantly hotter than their standard operational temperature or persistently high temperatures under standard loads. This can lead to premature component failure, dramatic reductions in generator efficiency, and potential electrical fires if not corrected.

Bearing and Mechanical Wear

Insufficient lubrication, misalignment, and the simple passage of time can all lead to mechanical wear and tear. On thermal imaging, this is commonly detected in the form of elevated temperatures around the bearings and rotating assemblies, with high temperatures and localized heat buildup compared to the surrounding equipment. Detecting wear early helps prevent catastrophic mechanical failure, enhancing the life of the unit and minimizing the cost of repairs.

Cooling System Issues

The cooling system is essential to ensuring normal generator operation and longevity. Blocked airflow, failing cooling fans, radiator restrictions, and coolant circulation issues can all serve to prevent the cooling system from functioning as it should. This can be detected in the form of uneven cooling across the unit and hot spots in the engine. It is vital to correct these issues to prevent overheating that can damage the mechanical components or even potentially lead to fires.

Failing Alternator or Electrical Windings

Insulation deterioration can lead to a failing alternator or electrical windings, causing an imbalance of power output across the unit. This is commonly detected in the form of localized hot spots.

Thermal Imaging With GenTech

At GenTech, our technicians are pros at thermal imaging diagnostics for generators. Trust us to find, diagnose, and correct the problem before it becomes a crisis. Contact us today.