Why electrical equipment gets damaged during lightning and voltage spikes and how an SPD prevents it

 

You experience a sudden stop in your system without any clear reason, no warning signs or damage, just a sudden shutdown. But the reason is unknown. Now the team starts troubleshooting, and the answer turns out to be something unexpected. A voltage spike or a nearby lightning event. Neither the equipment nor the installation was incorrect; something else caused the damage.


If you have experienced this, you know how costly it can be. In this blog, we will understand what really happens behind the scenes. Today, industrial systems are smarter than ever, but are they designed to handle sudden voltage spikes? Not really!

Studies show that sudden voltage spikes caused by lightning or switching events are one of the most common causes of equipment damage in electrical networks. The lightning may not strike directly, but even a nearby strike can lead to high voltage surges and damage the equipment through:

  • Power lines
  • Communication cables
  • Grounding systems

This means the problem lies in how the energy travels, not in the lightning.

 

Where does this damage start? 

The equipment does not fail instantly. When a voltage spike hits it, it weakens the internal components. This damage is not enough to stop the equipment immediately, but over time, repeated exposure to small surges can degrade circuit insulation and electronic boards, and one day, the failure occurs. And it feels sudden, even though the damage has been building up quietly in the background. 

 

Modern Equipment 

Today, we use equipment such as:

  • Drives
  • PLC systems
  • Sensors
  • Automation panels
  • Control units

These systems are advanced, but are also sensitive. 

 

According to the Uptime Institute, Power disturbances remain one of the most common reasons for system failures. The more advanced the system, the more vulnerable it becomes to electrical disturbances. 

 

Where do surges come from? 

Are surges caused by lightning only? Not really. In reality, a large number of voltage spikes originate within the facility itself. Motor switching, transformer operations, power supply fluctuations, and capacitor banks all create internal surges. That's where a surge protection device (SPD) comes in. It offers protection against external threats and internal electrical disturbances. 

 

Why does equipment fail without visible signs?

Sudden equipment failures? Confusing right? Internally, electronic components experience stress beyond their tolerance limits, increasing the likelihood of failure. This is why you struggle to detect the actual cause. Without proper protection, these invisible events continue to weaken the system until failure becomes unavoidable and costly. 

 

The right protection solution

Looking at these challenges, the pattern becomes clear. The issue is not just lightning or a sudden surge; it is a lack of control over where that energy goes. A surge protection device Type 2 is crafted to handle these issues. It is installed at distribution panels, where it diverts excess voltage to ground. and stops it from reaching the sensitive equipment. This helps in smoother operations and prevents unexpected failures. 

 

Frequently asked questions


What is a Type 2 SPD? 

A Type 2 SPD directs excess voltage to ground before it reaches sensitive equipment, helping ensure smoother operations. 

 

Where is Type 2 SPD installed?

It is installed at distribution boards or sub-panels.

 

What causes voltage spikes?

Voltage spikes are caused by:

  • Lightning strikes
  • Motor operations
  • Power switching
  • Sudden changes in electrical loads

To conclude

What makes lightning and voltage spikes challenging is that they do not instantly damage equipment. It builds up over time and appears when it is least expected. This makes it essential to understand how surges behave and how we can prevent the failures. 

 

Axis offers reliable surge protection solutions and engineered designs for your system. Our solutions are designed for stability, protection, and efficiency. If you are tired of unexpected equipment failures and downtime, this is the time to look. This is the time to explore reliable surge protection solutions. 

 

Connect with our team today.

 



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