Current Surges at a Food Processing Plant

During a routine power quality health check at a Calgary food processing facility, SineWave Solutions uncovered a recurring electrical issue that was going unnoticed – but could have become catastrophic over time. The case is a clear example of how waveform diagnostics can reveal what standard electrical troubleshooting might miss.

The Problem: Unexpected Midnight Current Spikes

Mysterious Power Surges in the Main CDP

While monitoring the facility’s Main Central Distribution Panel (CDP), we noticed something troubling:
Current surges were appearing shortly after midnight, almost every day. These weren’t just fluctuations – they were sharp spikes that, if left unchecked, could cause damage to sensitive equipment or trip protective systems.

We knew it was more than just coincidence, so we decided to dig deeper.

The SineWave Approach: Following the Current

Step 1: Tracking Waveforms Through the Electrical System

To locate the origin of the surges, we followed standard diagnostic protocol:

• We began tracing the current waveforms downstream, panel by panel.

• Since all electrical activity must pass through the system from mains to load, this method allowed us to gradually pinpoint the problem area.

*Graphs below show the results and are clickable to enlarge*

Step 2: Isolating the Problem Device

Our analysis led us to one specific unit that showed signs of surging activity consistent with our waveform captures. The timing matched up almost perfectly with the midnight anomalies we observed on the Main CDP.

But identifying the device was just half the puzzle.

Cross-Referencing With Surveillance: Confirming the Cause

To confirm what was happening at that exact moment each night, we worked with the facility’s internal surveillance team. Reviewing security footage taken during the same time window, we observed the night cleaning crew spraying down the problem unit at precisely the same moment the current spikes were occurring.

This correlation between electrical surges and cleaning activity gave us the breakthrough we needed.

The Root Cause: Worn Weatherproof Gaskets

Upon physical inspection of the equipment, we discovered worn-out weatherproof gaskets. These seals, intended to keep water out of electrical components, had degraded over time allowing moisture to enter when sprayed during the cleaning process.

The result? Brief short circuits or ground faults, showing up as current surges on our meters.

The Fix & Outcome

We recommended immediate replacement of the faulty gaskets and reviewed cleaning procedures with the night staff. Once the issue was resolved:

• The current spikes stopped occurring

• The system returned to stable baseline operation

• The facility avoided a costly equipment failure or safety incident