Power Surge Protection

Power Surge Definition: What is a Power Surge?


A power surge is a sudden and brief spike in electrical voltage that can exceed the standard flow of electricity. In industrial facilities, where machinery and equipment rely on a stable power supply, even small fluctuations can lead to significant problems. Power surges can originate from various sources and have the potential to disrupt or damage your electrical systems.

External Power Surges

These are surges that come from outside your facility, such as those caused by lightning strikes, utility grid switching, or power outages followed by restoration. These surges can travel through power lines and affect any connected equipment within your facility.

Internal Power Surges

These occur within the facility itself. Heavy-duty industrial machinery, motors, compressors, or HVAC systems can generate electrical disturbances that lead to surges. Switching on or off high-powered equipment can cause sudden voltage spikes, which can affect sensitive electronics or other machinery in the same system.

How Power Surges Affect Industrial Equipment

Industrial equipment is often designed to handle a specific voltage range. When a power surge hits, the sudden spike in voltage can cause the following issues:


  • Component Damage: Power surges can fry circuit boards, motors, and transformers, leading to costly repairs or complete equipment replacement.
  • Data Loss: For facilities with integrated control systems or computerized operations, a surge can result in data loss, corrupted files, or operational disruption.
  • Operational Downtime: When equipment is damaged by a surge, facilities may experience costly downtime, affecting productivity and output.

Common Causes of Power Surges in Industrial Settings

Heavy machinery operations that draw large amounts of power and create electrical fluctuations.

External factors such as lightning strikes, grid malfunctions, or sudden power cuts and restorations.

Internal electrical issues like faulty wiring or overloaded circuits.

Most customers that call the Electric Utility Company that are experiencing events do not get any specific helpful information because all the events are happening past the Utility distribution point.

Voltage Regulation Solutions. Delivered.


At Voltage Correction, we offer advanced solutions tailored to industrial environments to protect your systems from power surges. Our equipment is designed to stabilize voltage and ensure consistent power supply, helping safeguard critical machinery and systems. Voltage conditioners actively monitor and adjust voltage levels, correcting under- or over-voltage conditions to protect sensitive controls and heavy equipment. For continuous protection, voltage regulators maintain stable voltage levels, preventing damaging spikes and surges. With our high-performance solutions, you can reduce downtime, avoid costly repairs, and ensure smooth, uninterrupted operations in your facility.

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Benefits of Power Surge Protection for Industrial Facilities

Implementing power surge protection through voltage conditioners and voltage regulators offers several key advantages for industrial facilities:


  • Increased Equipment Lifespan: Protect expensive machinery and electronics from voltage damage.
  • Reduced Downtime: Avoid costly shutdowns caused by power surges.
  • Enhanced Safety: Prevent dangerous electrical faults that can compromise worker safety.
  • Cost Savings: Reduce repair and replacement costs by preventing surge-related damage.

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Do everyday Power Sags and Surges Wear out my Controls Equipment? – YES


Every type of voltage fluctuation affects your operating equipment and controls. The voltage vs. current relationship is never perfect and constantly changing unless you have a correction device installed. Because most facilities don’t, equipment and controls are constantly bombarded with voltage deviations that cause sags and spikes that damage equipment. This is one of the leading causes for PLC board and controls systems replacements. Not to mention shut down for maintenance or resetting equipment. A change in voltage always results in a direct opposite effect in Amperage. Each time the voltage sags current (Amps) increase, vice versa each time voltage spikes, amperage decreases. Causing wear and tear on drives, boards and controls equipment. This is easily corrected with an Active Voltage Correction Device or Industrial UPS System. It is a small investment to install correction compared to the long-term capital implications of replacing and maintaining equipment.

90% of power related problems for industry are sag related, not outages.

Contact a Voltage Correction consultant today to discuss power correction options for your facility. Leasing options available that match cost of owning one to one with cost/efficiency savings.

Why Doesn’t the Power Utility Company understand my power issues?


Many utility customers experience both voltage sags and also occasional short term loss of power. These momentary outages or short term loss of power may occur if utility reclosers operate in order to try to isolate faults on the line and to protect the balance of the utility network. Such recloser events are more frequent during stormy weather when high winds may cause tree branches to touch power lines but can also occur if birds or animals stray too close to transformer terminals or bridge across power lines.


The Electric Utility Company measures its voltage and quality of power at the distribution point. It does not follow downstream to transformer distribution, or to the distribution points local to the customer. Most customers that call the Electric Utility Company that are experiencing events do not get any specific helpful information because all the events are happening past the Utility distribution point. The Utility Power Industry is also federally regulated. Therefore they are unable to provide any solution referrals to the problem. Their information only shows good power being made at the distribution point which frustrates the customer as it is impossible for them to help. Almost all of these customer instances can be corrected locally with a Voltage Correction Device or Industrial UPS System and should not rely on the transmission distribution to get better.

If the Utility Company isn’t Causing Power Surges, What is?


It is certainly possible and likely that power issues are derived internally downstream from the utility service entrance. Facility equipment cycling on and off will pull on various phases. It is never constant and voltage is always changing inside a facility if there are any sorts of dynamic loads. Most surges you will not see with your naked eye. Most events are undetectable to the naked eye. If you see light flickering, that is 100% fluctuations in voltage and causing different variances in the amperage to all your loads. Therefore you feel as if power is OK, in reality, equipment is being damaged and worn. Best way to find out is a meter and power study.

Have a site survey done to survey your facility and install a power metering device.

When you install equipment that will correct power and hold voltage within your facility, you will be providing your facility with protection against all outside influences of power. Halting wear and tear on other equipment in the facility by having stable voltage and power factor is the goal. The long term positives are lowered operations and maintenance costs by limiting voltage and amperage anomalies inside the facility. It is common to vet these issues by installing a monitoring device at the service entrance of the facility utility power. This is a low-cost method to really understand these issues and to make a proper diagnosis.


We are available to review electrical one-lines, Power Reports, Demand Usage, and any other data on your facility power.


Contact your Voltage Correction Technical Representative today to discuss options to increase efficiency in your facility and correct our facility power issues!

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