Overtemperature events in electrical systems pose a serious threat that can lead to costly failures if not addressed promptly. I’ve seen the impact of these events firsthand — from unexpected failures to catastrophic fires that result in injury, lost productivity, and costly downtime. Despite advances in technology, the risks associated with overtemperature conditions remain a persistent problem for industrial facilities.
UNDERSTANDING THE DANGERS OF OVERTEMPERATURE EVENTS
Overtemperature events are a silent hazard. Terminals can degrade with poor electrical connections, and operating equipment under heavy loads for extended periods can cause resistive heating that can eventually lead to dangerous failures. The consequences of such events are severe: electrical fires, equipment damage, and unplanned shutdowns that can cripple production.
In facilities where large-scale machinery and complex electrical systems operate continuously, overtemperature events can pose a significant risk to personnel. The heat generated by undetected problems can spark fires, expose workers to electrical hazards, and create dangerous working conditions. A well-functioning electrical system is essential for production efficiency and safety, and detecting overtemperature issues early is crucial.
The Unpredictable Nature of Overtemperature Events
Unpredictability makes overtemperature events particularly dangerous. A loose connection might not cause a problem during routine operation, but under high-load conditions or over time, it can create localized heating that accelerates degradation. Heat often builds slowly and is visually undetectable. By the time the issue becomes apparent, significant damage may have already occurred. The ability to detect these problems early is critical for ensuring the safety, reliability, and longevity of electrical systems.
Intermittent overtemperature events are especially tricky to identify. They may only occur under specific operating conditions, such as peak load times. This further complicates the detection process, making continuous monitoring essential.
The Importance of Early Detection
To mitigate the risks of overtemperature events, early detection is paramount. Facility engineers or maintenance personnel have relied on infrared (IR) thermography for years as a powerful tool in identifying hot spots in electrical systems. IR thermography provides technicians with a non-contact real-time method of assessing surface temperatures, allowing them to spot areas where heat indicates a potential issue.
The National Fire Protection Association (NFPA) requires IR thermography inspections in NFPA 70B, Standard for Electrical Equipment Maintenance. Still, while thermography is highly effective, it is not a continuous monitoring solution. Inspections typically occur at scheduled intervals, meaning intermittent overtemperature events may go undetected between inspections.
IR THERMOGRAPHY: A PILLAR OF ELECTRICAL SYSTEM MAINTENANCE
IR thermography remains an essential part of electrical system maintenance. It’s a proven method for identifying possible electrical faults and preventing failures before they escalate. IR cameras can quickly identify areas of concern, especially in high-voltage environments, allowing for immediate action to prevent potential risks or failures.
The challenge with thermography lies in its periodic nature. You can only catch what you can see during the inspection, and the electrical system isn’t always operating under its heaviest load at that time. As a result, thermographers might miss transient or intermittent overtemperature events that occur between inspections. This gap in monitoring can leave facilities vulnerable to the risks mentioned earlier.
The Need for Continuous Monitoring
This is where thermochromic overtemperature indicators come into play. Unlike IR thermography, these indicators provide continuous, real-time monitoring of electrical systems by permanently changing color when a critical temperature threshold is exceeded. They offer a simple, yet effective solution for detecting overtemperature events, especially in environments where periodic inspections might not catch every potential issue.
These indicators respond to temperature changes by shifting color, providing a clear visual cue when critical temperature thresholds are exceeded. This color change is easy to recognize, even for personnel without specialized training, making it an effective tool for early detection.
Simple, Effective, and Easy to Install
One of the key advantages of thermochromic indicators is their simplicity. They don’t require any power source, wiring, or complex electronics to function. Whether in the form of cable clips, self-adhesive wraps, or paints, these indicators are easy to install on a wide range of electrical components. A technician can apply a cable clip or a self-adhesive wrap to de-energize equipment in seconds, and once in place, they provide constant monitoring.
Their ease of use extends to personnel outside the maintenance department. Unlike thermal imaging equipment, which requires a trained professional to interpret the data, thermochromic indicators are readable by anyone. A change in color means the system has overheated — no advanced analysis is required. This accessibility extends the responsibility of monitoring from specialized technicians to operators and facility staff, increasing the likelihood of early detection.
A Novel Use of Thermochromic Technology
Thermochromic technology is not new. Thermochromic inks and dyes were developed in the 1970s and have been used in a variety of applications from novelty dyes to medical training simulations. Where thermochromic indicators for electrical systems differ from the standard technology is that the color change is permanent; the indicators do not revert to their original color upon cooling.
The permanent color change occurs due to a thermally activated, irreversible chemical reaction within the indicator’s thermochromic pigment. When the temperature exceeds a predetermined threshold, the molecular structure of the pigment undergoes a one-way transformation through thermal decomposition. This change permanently alters how the pigment absorbs and reflects light, leading to a visible color shift that remains even after the component cools.
Seamless Integration with IR and Visual Inspection Windows
A major advantage of these thermochromic indicators is their compatibility with infrared (IR) and visual inspection windows, which have been a critical tool allowing technicians to safely inspect energized electrical equipment without removing panel covers.
Thermochromic indicators applied directly to critical electrical components, terminations, or busbars provide the added benefit of real-time, continuous, and visual monitoring.
This synergy is powerful: during routine IR inspections, the technician can observe the color shift through the window, further validating the presence of an overtemperature event. Not only does this enhance safety, but it also streamlines the inspection process by providing multiple layers of data — thermal and visual — without additional equipment.
Extending Reliability and Safety
Because thermochromic indicators are easy to read, they empower every member of a facility’s staff to be involved in maintaining system reliability. Operators who might not have access to thermography equipment can easily spot an overtemperature event by looking at the color of a cable clip or a painted surface. This expands the capability of monitoring from a select few to everyone on-site, ensuring that issues are caught quickly and addressed before they escalate.
A Sustainable Solution for Industrial Facilities
Sustainability is an increasingly important consideration in industrial settings, and thermochromic overtemperature indicators fit perfectly into this philosophy. Unlike traditional electronic monitoring systems, these indicators don’t require an external power source. They operate passively, relying only on temperature changes to function.
Because they are durable and long-lasting, thermochromic indicators reduce the need for frequent replacements, reducing material waste. By helping prevent equipment failure and prolonging the lifespan of electrical systems, they contribute to overall energy efficiency. In the long run, avoiding costly repairs and downtime also has a positive environmental impact.
GAME-CHANGING APPLICATIONS
While thermochromic overtemperature indicators are relatively new to the industrial market, they may soon prove to be an indispensable part of electrical system maintenance. They fill a critical gap in the monitoring landscape, providing continuous, reliable, and easy-to-read temperature monitoring that extends beyond the capabilities of periodic inspections like IR thermography.
Few advances in safety and reliability offer the combination of simplicity, effectiveness, and sustainability that thermochromic indicators do. As more facilities adopt this technology, they will play a significant role in preventing overtemperature events and improving the overall safety and reliability of electrical systems.
CONCLUSION
Overtemperature events remain a constant threat in industrial facilities, but with the right tools, they can be effectively managed and prevented. While IR thermography remains a cornerstone of electrical system maintenance, its effectiveness is limited by the periodic nature of inspections, leaving gaps between assessments where overtemperature events can go undetected.
Thermochromic overtemperature indicators offer a complementary, continuous monitoring method that is simple, reliable, and accessible to everyone on-site. As we continue to prioritize safety, reliability, and sustainability, these innovations can become a valuable part of every industrial facility’s maintenance toolkit.
Josh Robinson is an experienced leader in Condition-Based Maintenance (CBM) and a dedicated advocate for electrical maintenance safety and reliability. With a career focused on keeping maintenance workers safe from electrical hazards, he has championed the adoption of advanced technologies such as infrared thermography, ultrasound testing, and vibration analysis to enhance safety and efficiency in industrial settings. His expertise extends to motion amplification and root cause analysis, making him a sought-after expert in predictive maintenance and strategic asset management. He holds an MBA from Louisiana State University Shreveport and a Bachelor of Science in Business Administration from the University of South Florida Sarasota-Manatee. He is also deeply involved in innovation at IRISS, driving initiatives that push the boundaries of maintenance safety and technology.