Power quality is often overlooked, yet modern industrial and commercial facilities are increasingly exposed to voltage disturbances that can damage sensitive equipment. While surge protection is commonly associated with lightning or visible spikes, most damaging transients originate from internal sources such as switching events, harmonics and fast-rising voltage anomalies from power electronics. Here Mike Torbitt, managing director of resistor manufacturer Cressall, explains how next-generation surge protection approaches can strengthen system resilience while improving reliability and reducing maintenance demands.
The challenge of hidden transients
Voltage transients are brief, high-speed deviations from standard supply levels and represent one of the most widespread power quality issues in modern systems. Although external influences such as lightning can introduce high-energy surges, most transient events are internally generated.
According to Eaton, a global power management company, “up to 80 per cent of power surges occur on the customer side of the electric meter, with high-powered electrical devices within a facility generating internal surges through switching and load cycling.”
Industry data suggests that a significant majority of surges occur downstream of the utility meter, often triggered by routine operations of high-powered equipment. Motors, transformers and variable speed drives (VSDs) are key contributors, producing frequent high-frequency spikes during switching and load cycling. These disturbances can gradually degrade insulation and electronic components, often without immediate or visible symptoms.
Supporting this, a survey by the Electrical Safety Foundation International found that nearly half of industrial and commercial facilities experienced surge-related interruptions in the past year, with many reporting measurable improvements in uptime after installing surge protective devices.
Evolving protection strategies
Traditional surge protection devices alone are no longer sufficient for complex electrical environments. Modern approaches focus on coordinated, multi-stage protection systems designed to respond to different types of transients across the network.
In these systems, an initial stage reacts almost instantaneously to fast-rising voltage spikes, while subsequent stages absorb and dissipate residual energy. This layered approach helps prevent overvoltage conditions from reaching critical equipment and reduces stress on both protection devices and connected systems.
Effective solutions must also account for system-specific characteristics, including operating voltage, network impedance and the expected magnitude and frequency of transient events. Proper engineering ensures that protection remains consistent, reliable and capable of handling repeated exposure.
The role of resistive technologies
High-power resistors are increasingly used alongside surge suppression devices to improve overall system resilience. By absorbing excess energy, they reduce the load on primary protection components and help manage voltage levels more effectively.
This is particularly beneficial in high-energy applications, where frequent transient events can accelerate wear on protection devices. Incorporating resistive elements enhances durability and contributes to more stable system performance over time.
Practical implementation in industrial environments
Integrating surge protection into a broader electrical strategy is essential for achieving optimal results. In motor control centres and VSD installations, coordinated protection can isolate disturbances at their source while preventing disruption elsewhere in the system.
For sensitive electronics, including control systems and data acquisition equipment, fast-acting suppression is critical. Even microsecond-scale voltage spikes can lead to data errors or hardware damage. By addressing these risks proactively, facilities can significantly improve reliability and reduce unplanned downtime.
Additionally, well-designed protection systems can lower maintenance demands by minimising component stress and enabling more predictable service schedules.
Tailored solutions for complex systems
Selecting the right surge protection approach requires a detailed understanding of the application. Factors such as transient amplitude, environmental conditions and system configuration all influence component choice.
Custom-engineered solutions that combine surge suppression with resistive technologies offer a flexible and effective way to address site-specific challenges. Emphasising thermal performance, longevity and ease of maintenance ensures that protection systems remain effective throughout their operational life.
Supporting long-term reliability
As industrial systems continue to evolve and incorporate more advanced power electronics, the importance of managing hidden transients will only increase. Facilities that prioritise robust surge protection strategies can reduce operational risk, extend equipment lifespan and maintain consistent performance.
By adopting a comprehensive and engineered approach to power quality, operators can safeguard critical assets and ensure reliable operation in increasingly demanding electrical environments.
To explore how next-generation surge protection can safeguard your facility, contact our team for expert advice tailored to your system.
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