Are the circuit breakers in your plant tripping unexpectedly and you don't know why?

Are the circuit breakers in your plant tripping, and you don’t know why? Modern industrial systems critically depend on the stability and quality of their electrical infrastructure, and such setbacks can cause significant operational complications and serious safety risks. In this situation, an advanced measurement campaign can be your best ally, helping you reduce unexpected tripping by 100%.  

Thanks to innovative measures, CIRCE – Technological Center has been helping various industrial production plants like Chocolates Lacasa, MRA, and Mann Hummel tackle and resolve this critical issue for years. In addition to enhancing safety and operational efficiency, we have also established a new standard in the management and stabilization of complex electrical systems. 

What are the 10 most common causes of circuit breaker tripping? 

• Incorrect installation of protections: errors in installing protection equipment. 
• Incorrect equipment readings: faulty measurements due to equipment failures. 
• Inappropriate differential protection: incorrect selection without considering the type of load. 
• Lack of protection coordination: absence of vertical and horizontal selectivity. 
• Incorrect protection settings: inadequate adjustments in protection systems. 
• Incorrect distribution of differential devices: improper allocation of differential devices per circuit. 
• Leakage amplification: increased leakage due to transient or permanent electrical events. 
• Presence of harmonics: distortions caused by high harmonic levels in the network. 
• Improper operation of capacitor banks: failures in the operation of these devices. 
• Deficiencies in grounding and insulation networks: problems with grounding systems and cable and equipment insulation resistance. 

To understand and counteract these issues, it is advisable to implement an advanced measurement campaign focused on the accurate collection of data.  

This campaign should focus on identifying the root causes of unexpected circuit breaker tripping, analyzing phenomena such as overloads, which activate breakers to protect equipment; short circuits, which trigger breakers to prevent overheating and fires; insulation defects, which cause current leaks and preventative tripping; and elevated current harmonics, generated by non-linear loads that can cause overheating and tripping. This issue can have both internal and external causes, as explored in this article on the external and internal causes of unexpected tripping.

Advanced technology allows the capture of a wide range of electrical variables and quality parameters. This includes the strategic selection of several points within the plant’s electrical network for the deployment of state-of-the-art equipment. These devices enable the monitoring of electrical variables and the detection of anomalies such as overloads and short circuits. 

Advanced solutions for electrical system stabilization  

Thanks to measurement campaigns, it has been possible to address harmonic distortions and strengthen the stability of the electrical network through the implementation of effective solutions. For example, the installation of harmonic filters, essential for reducing distortions and ensuring network stability, or reconfiguring the electrical infrastructure, adjusting network configurations to increase its capacity to handle fluctuations.  

The implementation of advanced technology for real-time monitoring and periodic evaluation of the electrical infrastructure’s condition is key to mitigating future risks and ensuring efficient and safe operation 

Improving operational continuity and safety 

Continuous monitoring and detailed analysis of the electrical network’s condition are fundamental to achieving good results, demonstrating how interventions not only mitigate existing problems but also prevent new incidents. 

The implementation of advanced technology for real-time monitoring and periodic evaluation of the electrical infrastructure’s condition is key to mitigating future risks and ensuring efficient and safe operation. 

In response to the challenges identified, CIRCE has prioritized advanced research and a proactive strategic approach to mitigate these issues. This approach not only aims to address current problems but also to prevent future complications, thus ensuring continuous and efficient operation. Among the solutions already investigated and tested is the integration of compensation devices such as D-STATCOM, which stabilize the network and compensate for voltage fluctuations.