Industrial and manufacturing facilities rely on power for their business. But with that power comes risk. When electrical equipment malfunctions, you can damage machinery, lose work time, and worst of all, injure your employees.
What Are Some of the Most Common Challenges? And How Can You Prevent Them?
- Overloading Circuits
Overloading circuits occurs when the demand for electrical current exceeds the capacity of the circuit. This can happen when you add new equipment, production demands increase, or loads aren’t distributed properly. Overloading not only increases the risk of electrical fires but also leads to premature equipment failure (and downtime). Prevention: Routinely assess electrical loads and distribution, along with proper circuit design. - Poor Electrical Connections
Loose or corroded electrical connections are a recipe for disaster in industrial settings. These can lead to voltage fluctuations, overheating, and even arcing, posing significant safety hazards. Common culprits include aging equipment, inadequate maintenance, and improper installation. Prevention: Include checks for tight connections, corrosion, and signs of overheating in your regular inspections and maintenance. - Grounding Problems
Proper grounding seems basic. But improper grounding happens! When it does, you’ll see issues like high resistance or improper connections that can result in electrical shocks, equipment damage, and malfunctioning sensitive electronic devices. Prevention: Regularly test grounding systems and follow industry standards. - Voltage Fluctuations and Surges
Voltage fluctuations and surges are common in industrial environments. With heavy machinery, motor starting currents, and external factors like lightning strikes, it’s easy for these to happen. When they do, the fluctuations can damage sensitive equipment, disrupt operations, and affect product quality. Prevention: Implement voltage regulation devices, surge protectors, and transient voltage surge suppressors (TVSS). - Inadequate Maintenance Practices
Everyone has good intentions, but unfortunately, sometimes regular maintenance falls behind schedule. Over time, accumulated dust, debris, and corrosion can compromise the performance and safety of electrical components. Prevention: Conduct routine inspections and testing and implement preventive maintenance schedules. - Insulation Deterioration
Insulation deterioration, due to heat, moisture, and chemical exposure, is a common issue in aging electrical systems. Degraded insulation increases the risk of short circuits, electrical arcing, and equipment damage. Prevention: Identify deterioration early through thermal imaging, insulation resistance testing, and periodic inspections. - Inadequate Training and Awareness
Last but not least, human error contributes to electrical problems. No one is trying to create an unsafe workplace, but whether it’s due to inadequate training, not knowing about safety protocols, and simply feeling overly confident can lead to accidents, injuries, and equipment damage. Prevention: Invest in updating your training at least annually, promote a culture of safety that goes beyond posters, and provide clear guidelines (in words and in visuals) for electrical work practices.
No company can completely prevent electrical problems, but by staying vigilant and proactive, organizations can minimize risks, maximize productivity, and enhance the longevity of their electrical infrastructure. When it comes to electrical systems, prevention is always better than cure.
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Arc flash safety experts at EPSCO perform a full system analysis of every piece of equipment at your facility. We can help you achieve compliance in an efficient, sustainable, and friendly way to your budget. Connect with us HERE.
