Industrial facilities across Tulsa rely on massive electrical feeders to power heavy equipment, production lines, industrial HVAC, motors, compressors, welders, and automation systems. When those feeders become overloaded, the entire facility becomes vulnerable to shutdowns, overheating, and serious electrical hazards. I am Terry Davis, Master Electrician, and I’ve seen what happens when an industrial feeder is pushed far beyond its designed capacity — the warning signs are subtle at first, but the consequences can be catastrophic.
Here is what every Tulsa industrial operator needs to know.
Why Overloaded Feeders Are A Growing Problem In Tulsa
Industrial Loads Have Increased Dramatically
Older Tulsa industrial buildings were not built for modern power requirements. Plants today rely on:
• robotics and automation
• high torque motors
• complex conveyor systems
• large compressors
• industrial HVAC systems
• welders and plasma cutters
• CNC machinery
• server racks and control stations
When these loads increase over time, but the feeders stay the same size, the feeder begins carrying far more current than it was originally designed for.
Building Expansion Without Electrical Expansion
Many plants add new machines, shift production areas, or increase capacity, but never upgrade their electrical feeders or panels. I see overloaded buildings all across Tulsa’s industrial areas, especially in:
• North Tulsa industrial district
• the Airport Industrial Zone
• Broken Arrow industrial parks
• East Tulsa warehouses
• West Tulsa manufacturing corridors
These electrical systems were never updated to match new load demands.
Long Feeder Runs Increase Voltage Drop
Industrial buildings are large. Feeder runs often stretch hundreds of feet. The longer the run, the more voltage drop occurs, especially under heavy load. When feeders are undersized or old, voltage drop becomes severe, equipment overheats, motors fail prematurely, and breakers trip unexpectedly.
Warning Signs That Your Feeder Is Overloaded
Breakers Or Main Disconnects Feel Warm
Feeder breakers and disconnects should never feel warm. Heat means the feeder is carrying too much current.
Lights Flicker When Heavy Equipment Starts
This is one of the biggest red flags I see in industrial environments. Flicker means voltage is collapsing under load.
Motors Start Slow Or Stall
If your motors hesitate, hum, or draw excessive amp load, your feeder may be reaching its limit.
Equipment Randomly Shuts Down
Voltage drop or feeder overload causes unexpected shutdowns in:
• CNC machines
• conveyor belts
• compressors
• welders
• robotic arms
• PLC control systems
Frequent Breaker Trips
Industrial breakers are designed to handle heavy loads. Frequent tripping usually means your feeder is overloaded or your equipment is outgrowing the electrical service.
Overheated Wiring Or Conduits
If your conduits or feeders feel warm, the load is exceeding the safe operating temperature, a dangerous condition.
The Hidden Dangers Of Overloaded Feeders
Fire Hazards
Overloaded feeders generate excessive heat inside conduits and panels. This can melt insulation, damage conductors, and ignite surrounding materials.
Equipment Damage
Low voltage and unstable power cause motors and VFDs to overheat, burn windings, or fail prematurely.
Production Loss
A single feeder failure can shut down entire sections of a plant.
Premature Breaker And Panel Damage
When feeders operate beyond their limit, the main gear takes a beating — breakers weaken, lugs loosen, and bus bars overheat.
Safety Violations
Overloaded feeders violate electrical safety codes and create OSHA compliance issues.
How I Correct Overloaded Feeders In Tulsa Industrial Facilities
Step One: Comprehensive Load Study
I perform a detailed load calculation to measure actual amp draw across the feeder. This identifies whether the feeder is undersized or overloaded.
Step Two: Infrared Thermal Scanning
I scan panels, disconnects, MCC rooms, and conduits to find heat signatures that indicate overload, loose connections, or insulation breakdown.
Step Three: Inspect Feeder Size, Condition, And Length
I check wire gauge, conductor type, termination torque, insulation condition, and the total length of the run to calculate voltage drop.
Step Four: Evaluate Panel And Equipment Layout
Overloaded feeders often lead back to improperly distributed loads. I look at how circuits are allocated, whether loads are balanced, and whether equipment is grouped inefficiently.
Step Five: Recommend Feeder Or Panel Upgrades
Depending on what I find, I may recommend:
• installing larger feeders
• adding new feeders to split the load
• installing new subpanels
• relocating loads closer to power sources
• upgrading primary equipment
• correcting unsafe or outdated installations
Step Six: Improve Bonding, Grounding, And Connections
Loose lugs and bad grounding cause voltage instability — fixing these dramatically improves feeder performance.
Why Industrial Feeder Problems Should Not Wait
An overloaded feeder is one of the most dangerous electrical conditions in an industrial environment. Waiting too long can lead to:
• equipment burnout
• fire hazards
• damaged conductors
• production shutdowns
• expensive repairs
• emergency outages
The earlier the problem is diagnosed, the easier and cheaper it is to fix.
If Your Tulsa Industrial Facility Is Showing Signs Of Feeder Problems, I Can Help
I’ve worked with industrial plants across Tulsa to correct overloaded feeders, stabilize voltage, protect equipment, and increase production reliability. Whether you need a load calculation, new feeder installation, or a complete power distribution redesign, I can diagnose the problem and deliver a safe, long lasting solution.
Your operation depends on stable, reliable power. I can help you protect it.