How Monitoring Prevented a Major Equipment Issue

Electrical systems depend on overcurrent protection to safeguard critical equipment and maintain safe operations. When current levels spike beyond design limits, protective devices like circuit breakers or relays are meant to interrupt the flow and prevent serious damage. But what happens when these protections fail—and no one knows?

A recent case involving a Volta Insite customer shows how predictive monitoring can be the difference between minor alerts and major system-wide failures.

An Unexpected Overcurrent Event

One of Volta Insite’s clients received an overcurrent alert on a monitored piece of equipment. These alerts are relatively common and often tied to short-term operational conditions. But in this instance, something was different. The current spiked to over 300 amps—well above the expected range—and beyond what should have been possible given the system’s built-in overcurrent protection.

The equipment had multiple layers of protection specifically designed to prevent such a spike. Yet the event still occurred. This anomaly raised a red flag, prompting further investigation by both Volta Insite and the customer’s maintenance team.

Failure in Protection Devices

What they discovered was concerning. The secondary overcurrent protection system—intended to act as a backup safety net—was not functioning properly. It had allowed the equipment to reach dangerous current levels without triggering a shutdown or alarm.

This discovery led the team to inspect other equipment at the facility. The issue was not isolated. Multiple units were operating with the same flawed protection, putting the entire operation at risk. Without the initial overcurrent alert and the deeper insight it triggered, this systemic failure would have remained undetected.

The Role of Predictive Monitoring

Volta Insite’s monitoring system didn’t just identify an overcurrent—it uncovered a failure in the very systems designed to prevent electrical faults. That’s the difference between standard alerts and predictive maintenance.

By continuously analyzing equipment behavior and comparing it to expected patterns, Volta Insite delivers actionable insights, not just notifications. This level of monitoring allowed the customer to:

• Detect protection failures before equipment was damaged

• Launch a full system review that uncovered widespread issues

• Repair and restore overcurrent protection to prevent future risks

Why It Matters

Overcurrent protection is a fundamental part of electrical system design—but it’s not foolproof. Devices can degrade, misconfigure, or fail over time. Without intelligent monitoring, those failures can go unnoticed until something breaks.

This case highlights the real value of predictive maintenance. It’s not just about catching faults—it’s about understanding the health of the entire system and catching failures before they become crises.

Is Your Protection Working Like It Should?

If you’re relying solely on built-in safeguards without real-time insight, you might be missing critical issues. Volta Insite can help you stay ahead of failures and maintain safer, more reliable operations. Contact us today to learn how.

Resources:

Overcurrent Protection Failure: How Monitoring Prevented a Major Equipment Issue