Identifying Electrical Problems in Industrial Operations

Industrial facilities rely on stable electrical systems, but issues like outages, short circuits, overloads, and equipment faults can disrupt operations. This blog highlights common problems, why they happen, and how preventive maintenance keeps workplaces safe.

Industrial Electrical Issues and How to prevent Them

Industrial facilities depend on intricate electrical systems to keep machinery, production lines, lighting, and automated processes running efficiently. When everything is functioning as intended, operations remain productive, safe, and stable. However, because these systems handle high loads and operate continuously, even a small electrical issue can trigger significant problems. From sudden equipment shutdowns to hazardous faults, disruptions in electrical infrastructure can quickly lead to lost time, reduced output, and increased operational costs.

Recognising and addressing common electrical problems early is essential for maintaining a safe and efficient work environment. In this blog, we’ll explore the most frequent electrical issues in factories, warehouses, and manufacturing plants, explain why they occur, and discuss how professional industrial electricians can resolve them before they escalate. Below are the electrical issues most frequently encountered in industrial environments, and how they can be effectively managed.

1. Power Outages and Interruptions

Industrial facilities rely on high levels of power, making them vulnerable to outages caused by grid issues, faulty wiring, overloaded circuits, or equipment startup surges. Even brief interruptions can reset machinery, disrupt automated processes, and cause costly downtime.

How to Prevent It:

Conduct load assessments to confirm your system can handle demand.
Install backup generators, UPS units, or voltage stabilisers to protect critical machinery.
Schedule routine inspections to identify overheating panels, loose connections, or damaged wiring early.

Proactively managing your electrical infrastructure helps minimise interruptions and keeps your operations stable, safe, and efficient.

2. Short Circuit Faults

Short circuits occur when electrical current travels along an unintended path, commonly caused by damaged insulation, moisture intrusion, rodent interference, or loose wiring. These faults can lead to repeated breaker trips, equipment damage, unexpected machinery shutdowns, and, in severe cases, electrical fires.

Common Signs of Short Circuits:

Burning smell near electrical panels
Frequent tripping of circuit breakers
Sparks or visible arcing
Sudden machinery shutdowns

How to Fix or Prevent Short Circuits:

Replace damaged wiring and check for insulation deterioration
Install RCDs, circuit breakers, and other protective devices
Improve moisture control and ensure proper cable sealing in vulnerable areas

3. Overloaded Circuits

As industrial facilities expand, new machinery is often added without upgrading the electrical infrastructure. This can push circuits beyond their designed capacity, resulting in overheated cables, melting insulation, frequent breaker trips, fire risks, and machinery that operates inconsistently.

How to Prevent Circuit Overload:

Distribute electrical loads evenly across multiple circuits
Install dedicated circuits for high-demand equipment
Upgrade switchboards, wiring, and panels to support increased power requirements
Use load-logging and power quality monitoring tools to track usage

4. Equipment Failures and Unplanned Downtime

Industrial machinery, such as motors, conveyors, compressors, VSDs, and robotics, requires a stable electrical supply to operate efficiently. Inconsistent power can cause overheating, excessive vibration, intermittent shutdowns, and premature equipment failure.

How to Prevent Equipment Failure:

Conduct regular electrical testing on motors, drives, and control panels
Replace worn cables, switches, and connectors promptly
Use infrared thermography to detect hotspots and stressed components
Ensure machinery operates with the correct voltage, phase balance, and grounding

5. Voltage Fluctuations, Surges, and Spikes

Industrial facilities frequently experience voltage dips (brownouts), spikes, lightning-induced surges, and harmonic distortion from variable-speed drives. These power fluctuations can damage sensitive equipment, disrupt PLCs and automation systems, and reduce overall operational efficiency.

How to Prevent Voltage Problems:

Install surge protection devices across the facility
Ensure proper grounding and earthing across all electrical systems
Use voltage regulators, power conditioners, and harmonic filters
Conduct regular power quality monitoring and analysis

6. Automation and PLC Malfunctions

Modern industrial automation systems, including PLCs, SCADA, and sensors, are highly sensitive to electrical inconsistencies. Common causes of malfunctions include signal interference, damaged wiring, software faults, unstable power supply, and poorly shielded cables.

How to Prevent Automation Issues:

Regularly inspect PLC power and grounding
Test and secure sensor and actuator wiring
Update firmware and software
Use shielded cabling to reduce interference

Maintaining automation systems ensures smooth production, reduces downtime, and protects critical equipment.

7. Lighting issues in industrial facilities

Poor lighting in industrial settings can compromise safety, reduce accuracy, hinder visibility, and increase energy costs. Common problems include flickering lights, dim performance, blown globes, high energy consumption, and insufficient emergency lighting.

How to Resolve Lighting Issues:

Replace damaged fixtures
Upgrade to industrial-grade LED lighting for efficiency and durability
Install compliant emergency and evacuation lighting
Use motion sensors to optimise energy use

Keep Your Industrial Operations Running with Aquila Electrical

Maintaining a safe, efficient, and reliable electrical system is important for an industrial facility. From power outages and short circuits to overloaded circuits, voltage fluctuations, equipment failures, and automation malfunctions, electrical problems can disrupt operations, reduce productivity, and pose serious safety risks. Addressing these issues early through regular inspections, preventive maintenance, and timely upgrades ensures your industrial electrical safety and avoids costly downtime.

At Aquila Electrical, we specialise in providing tailored industrial electrical solutions designed to meet the unique demands of factories, warehouses, and manufacturing plants. Our team of experienced industrial Adelaide licensed electricians can handle everything from preventive maintenance and emergency repairs to electrical audits, system upgrades, and automation support. Don’t let electrical problems disrupt your operations. Contact Aquila Electrical today to ensure your facility remains safe, efficient, and fully operational.

📞 Call us on 0488 551 630

‍📍 Based in Hove, SA 5048