Power problems show up without warning. A motor trips offline during peak production.
Control systems reboot randomly throughout the shift. Machine tools suddenly lose accuracy.
Each minute of downtime means lost production and frustrated operators.
Quick troubleshooting saves thousands in lost output—if you know where to look. Here are some of the key troubleshooting steps:
Voltage sags create sudden production line stoppages. Heavy equipment startup drags down voltage levels throughout the facility.
Large motors starting directly online cause plant-wide voltage drops that affect multiple production areas.
Modern electronics malfunction when the voltage falls below their rated specifications. Installing soft starters and variable frequency drives minimizes startup impact.
Advanced monitoring systems pinpoint the exact source of voltage problems.
Strategically placed power conditioning equipment creates protected zones for sensitive machinery.
Harmonics turn transformers into heaters. Variable frequency drives and LED lighting inject harmonic currents into power systems.
These currents flow backward through transformers, creating extra heat.
A transformer running hot probably has harmonic problems. Measuring total harmonic distortion at key points identifies problem areas.
Harmonic filters installed near large drives prevent distortion from spreading. K-rated transformers handle harmonics without overheating.
Poor grounding causes mysterious equipment problems. Electronic noise couples between circuits through ground loops.
Multiple ground paths create circulating currents. Equipment that works fine in one location fails in another. Ground fault indicators show current flowing in ground conductors.
Thermal imaging spots hot ground connections. Proper bonding and single-point grounding eliminate most problems.
Regular testing catches degraded ground connections early.
Low power factor wastes electrical capacity. Motors and transformers need magnetizing current to operate. This current doesn't do useful work but takes up system capacity.
A power factor of 0.8 means 20% wasted capacity. Utility companies charge penalties for low power factor.
Capacitor banks installed near large motors improve power factor. Automatic power factor correction adjusts as loads change.
Overloaded transformers fail early. Each transformer has optimal loading for best efficiency. Running above nameplate rating increases losses dramatically.
A fully loaded transformer runs 55-65°C above ambient temperature, and hot spots inside windings run even hotter.
Temperature monitors on critical transformers prevent overloads. Load tap changers maintain voltage under varying loads.
Regular oil testing catches developing problems.
Aging electrical equipment degrades performance gradually. Insulation breaks down under heat and mechanical stress. Connection points loosen from thermal cycling. Contamination builds up on insulators and bushings.
Visual inspections catch external deterioration. Diagnostic testing reveals internal problems. Preventive maintenance schedules extend equipment life.
Condition monitoring helps plan replacements before failure.
Power reliability demands both preventive action and rapid response to issues. Our manufacturing expertise helps identify potential problems before they affect production.
We repair and refurbish transformers to extend their operational life while maintaining performance. When emergencies strike, our standby transformer service keeps production running during repairs.
From complete overhauls to targeted upgrades, we help industrial facilities minimize downtime and maintain power quality.
This comprehensive approach ensures reliable power distribution in demanding industrial environments. To learn more, get in touch with us and let’s talk.
