Safety & Compliance · SOP

Electrical Panel Infrared Thermography Inspection Checklist

This standard operating procedure details the process for conducting infrared thermography inspections on low- and medium-voltage electrical panels. It covers pre-inspection safety, camera setup, thermal scanning techniques, and documentation requirements to identify loose connections, overloaded circuits, and failing components.

Estimated Time

45 min

Difficulty

Advanced

Regulation

CSA Z462 / NFPA 70E

Version

1.0

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Purpose

The purpose of this SOP is to establish a consistent and safe method for using infrared thermography to detect abnormal temperature patterns in electrical equipment. Proactive identification of hotspots prevents arc flash incidents, unplanned downtime, and equipment damage. This checklist ensures that every inspection follows the same critical steps, from hazard assessment to final reporting.

Scope

This procedure applies to all energized electrical panels rated up to 600 VAC in industrial, commercial, and institutional facilities. It covers both enclosed (cover-on) scanning and open-panel scanning after lockout/tagout. This SOP is intended for qualified electrical workers who have completed thermal imaging training and are familiar with CSA Z462 arc flash safety requirements. It does not apply to high-voltage switchgear (>600 V) without additional approvals.

Safety Precautions

LOTOLockout/Tagout must be applied before opening any panel cover that exposes energized parts. Verify absence of voltage with a rated proximity tester after LOTO.
ARCWear arc‑rated PPE (face shield, balaclava, switching jacket, gloves) in accordance with the incident energy analysis. Minimum category 2 for most 480 V panels. Remove metallic jewelry.
HOTAfter scanning, allow 5 minutes for components to cool before touching. Hot surfaces may cause burns even at moderate temperature differentials.

Required Tools & Materials

Thermal imaging camera (minimum 160×120 resolution, with emissivity and reflected temperature compensation)
Arc flash rated PPE (face shield, gloves, jacket, balaclava, voltage-rated leather or rubber gloves)
Lockout/tagout kit (padlocks, hasps, danger tags, LOTO checklist)
Insulated hand tools (screwdrivers, nut drivers) rated for the panel voltage
Non‑contact voltage tester (CAT IV rated)
Inspection form / digital checklist (paper or app)

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Procedure: Step-by-Step

1 Preparation and Safety Briefing: Review the electrical one‑line diagram and identify the panel to be scanned. Perform an arc flash risk assessment and select appropriate PPE. Confirm the area is free of combustible materials. Brief the inspection team on the plan.

2 Thermal Camera Setup: Turn on the camera and allow it to warm up for 3–5 minutes. Navigate to the measurement settings and set emissivity to 0.90 for painted metal (adjust per surface). Input reflected temperature (ambient). Set temperature span to 20–60 °C as a starting window.

3 External Panel Scan (Cover On): With the panel closed and energized, scan the entire front surface, door gaskets, and visible cable entries. Capture thermal images. Record any hot spot that exceeds ambient temperature by more than 5 °C. Note the exact location on the panel.

4 Lockout/Tagout & Cover Removal: Notify affected personnel, then apply LOTO per site procedure. Use an insulated tool to remove panel cover screws. Verify absence of voltage at the main bus using a non‑contact tester held at each phase.

5 Internal Infrared Scan: With the panel open (but still under LOTO), methodically scan all bus bars, breaker terminals, fuse holders, relay contacts, and control transformers. Pay attention to uneven heat distribution across breaker phases. Capture at least one thermal image per distribution section. Record any delta‑T greater than 10 °C between adjacent phases or between the component and ambient.

6 Documentation & Follow‑Up: Log all readings and images onto the inspection form. Flag any component exceeding the threshold as Immediate Action or Scheduled Repair. Reinstall panel cover, remove LOTO, and verify operational status. Submit the report to maintenance management within 24 hours.

Electrical Panel Infrared Thermography Inspection Checklist

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