A Facility At Risk
In the industrial world, problems can come up often, and it is not always easy to tell if they are minor or serious. In this article, we explain which electrical issues to watch for in your facility.
If you notice any of these warning signs, contact us right away to schedule an inspection and protect your facility. Call 864.972.4720 or reach us through this form.
JDI Industrial Services provides industrial electrical services, and we will investigate the cause of your electrical issues.
Here are 10 signs you have electrical issues inside your facility.
1. Frequent Breaker Trips
When a breaker trips, it cuts power to prevent overheating, fire, or equipment damage. Frequent trips can indicate overloaded circuits, short circuits, ground faults, or aging connections.
Fix: Measuring amperage during operation, checking terminations, torquing and wiring, and adding receptacles to balance the load.
2. Unstable Power Supply
An unstable power supply can damage equipment and machines. Whether it is undervoltage or overvoltage, both present a problem. When the voltage is too low, equipment works harder; when it is too high, it poses a risk of electrical fire.
Fix: Installing power monitoring or upgrading the electrical infrastructure for steadier power delivery.
If you suspect overvoltage, call an electrical professional immediately for a risk evaluation. Call 864.972.4720 or contact us through this form.
3. Burning Smells, Discoloration, or Popping Sounds
A burning smell, heat marks, or discoloration around electrical components may signal overheating, arcing, or damaged insulation. Address these warning signs immediately to prevent an electrical fire. If you hear a popping sound by an outlet, it could also indicate a short circuit.
Fix: Contact an electrician immediately. JDI Industrial Services provides prompt electrical evaluations for industrial facilities.
4. Excessively Hot Panels or Equipment
Electrical panels, disconnects, transformers, and motor control centers should stay cool during normal operation. If they are hot to the touch, to the point that it leaves a red mark on the back of your hand, there may be an underlying problem.
Fix: Checking for loose connections, overloaded circuits, failing components, or unbalanced loads, then correcting the insulation.
5. Foreign Objects
Poorly sealed panels can allow dust, oil, moisture, and debris to build up on electrical components, increasing the risk of performance issues and equipment failure.
Fix: Cleaning the electrical panel, replacing damaged parts, and resealing it to keep contaminants out.
6. Motor Control Malfunctions
Motors that overheat, trip frequently, or stall may have control circuit issues. Your motor control center or MCC is a vital component for your production lines, right? Treating that MCC correctly will keep yielding the positive benefits for your overall company.
Fix: Inspecting motor starters, contactors, and VFDs, then repairing the fault.
7. Increased Energy Bills Without a Clear Explanation
A sudden increase in energy use may be caused by inefficient motors, failing equipment, overloaded systems, or a deeper electrical issue such as inefficient power delivery. Tracking energy trends can help identify issues early.
Fix: Calling a professional for thermal imaging, load monitoring, and panel diagnostics to find the root cause.
8. Outdated, Missing, or Inaccurate Labels
Panels, disconnects, and control equipment should have clear labels so workers can identify circuits and safely isolate equipment. Missing or outdated labels may also point to incomplete documentation or maintenance records.
Fix: Calling a professional to update and correctly label wires, panels, and disconnects, including arc-flash labels to meet code requirements.
9. Visible Damage
Cracked insulation, damaged conduit, exposed wires, loose fittings, corroded enclosures, or improper extension cord use can increase the risk of shock, fire, and equipment damage.
Fix: Assessing the damage, replacing damaged components, and adding guarding where needed.
10. No Recent Maintenance or Inspection
Without recent electrical inspections, thermographic scans, arc flash reviews, or preventive maintenance, hidden issues may go unnoticed.
Regular maintenance helps identify hazards, improve reliability, and reduce unplanned downtime.
Fix: Scheduling regular preventive maintenance and load tests to catch issues early.
What to Do If You Notice These 10 Warning Signs
Don’t ignore these 10 signs you have electrical issues. Contact us, your licensed industrial electricians, immediately. JDI will inspect your system, identify the cause, and recommend the right solution.
Our team is NFPA 70 Certified, Lock-Out/Tag-Out Trained, Arc-Flash Certified, FOA Splicing Certified, and Fiber Optic Technician Certified. We look forward to helping you!
