Internal Arc Tested Panels: Protecting Pharma & Data Centers from Downtime

Introduction

Few hazards to electricity infrastructure are as costly or hazardous as an internal arc fault.  Massive energy is released inside a panel as a result of these occurrences, which might be brought on by equipment failure, weak connections, or insulation breakdowns.  Fires, destroyed equipment, or even staff injuries could be the outcome.

Downtime is not an option for sectors like data centers and pharmaceutical cleanrooms.  Whole production batches in the pharmaceutical industry can be destroyed by contamination or equipment failures.  Even a brief power outage in a data center may cost millions of dollars and erode customer confidence.  Arc-tested power distribution panels and switchgear are therefore an essential first line of defense.

The definition of internal arc testing, how medium voltage and low voltage switchgear can be made arc resistant, and the tactics facility owners and EPC contractors can use to maintain dependable and safe operations are all covered in this article.

Internal Arc Testing – What It Proves and Why It Matters

When electrical energy abruptly deviates from its designated course inside a switchboard or panel, an internal arc occurs.  Imagine it like a lightning strike inside a box: intense heat, dazzling light, and a pressure surge that can spray molten metal or blow doors wide.

Panels that have undergone arc testing are designed and tested to contain this energy.  The testing demonstrates the following:

Protection of personnel:  No doors are flying open or parts are being thrown at operators; panels are still in place.

Enclosure integrity: Arc gases are safely channeled by the structure, frequently via pressure relief vents.

Service continuity: Other components of the system may continue to function even in the event of an arc fault in one area.

Arc resistance significantly lessens the implications of risk, although it does not completely remove it.  It is the cornerstone of defense in an all-encompassing electrical safety strategy, together with protective relays, maintenance procedures, and PPE guidelines.

Medium Voltage Switchgear (MV) for Critical Facilities

When it comes to medium voltage switchgear, which usually operates between 3.3 kV and 33 kV, internal arc protection is crucial.  Data halls, production rooms, and entire buildings are fed by these assemblies.

 Important aspects of the design include:

• Compartmentalization: Each functional unit is isolated, so a fault in one area doesn’t spread to others. 
• Pressure relief systems: Built-in ducts or flaps vent gases upwards or away from operators. 
• Mechanical interlocks: Prevent unsafe operations like opening a breaker cubicle while energized.

Systems of protection are also important.  Damage is limited by the ability of modern relays to identify anomalous current or arc signatures and trip breakers in milliseconds.  Before panels leave the plant, EPCs and owners should anticipate comprehensive test evidence (arc classification reports from accredited labs) as well as documentation of routine checks.

Low Voltage Switchgear (LV) Arc-Fault Mitigation

At the low voltage switchgear level – 415 V up to 690 V – the risks may seem smaller, but the fault currents are still high enough to cause major damage.

Common failure factors include loose connections, dust buildup, and lack of maintenance. Mitigation strategies include:

• Arc-flash detection systems: Optical sensors combined with high-speed relays can isolate faults almost instantly. 
• Segregation and compartmentalization: Preventing faults from spreading between sections. 
• Withdrawable feeders: Allow safe maintenance without live exposure.

Proper system design also ensures coordination and selectivity so that only the faulty section trips, while the rest of the system continues operating. This minimizes downtime for critical facilities like cleanrooms or server halls.

Power Distribution Panels Strategy in Pharma & Data Centers

Whether in a pharma plant or a hyperscale data center, the strategy for power distribution panels can make the difference between a contained event and a total blackout.

• Topologies that limit impact: Using designs like N+1 redundancy, ring networks, or dual incoming feeds reduces the “blast radius” of a fault. 
• Zoning considerations: Panels serving cleanroom suites or rows of servers should be separated physically, with clear maintenance access routes. 
• Monitoring and alarms: Real-time monitoring, event logging, and alarm systems help operators respond quickly, shortening mean time to repair (MTTR).

These strategies ensure that even if an arc occurs, it doesn’t cascade into full system downtime.

Risk Assessment to Operations Playbook

Arc-tested panels are one piece of the puzzle. Equally important is a structured risk assessment and operations plan.

• Conducting arc risk assessments: Facility and EPC teams should review load profiles, panel locations, and operator exposure risks. 
• PPE and safety policies: Operators should follow lockout/tagout (LOTO) rules and wear arc-rated PPE during live maintenance. 
• Maintenance schedules: Periodic inspections, infrared (IR) scanning, cleaning, and torque checks on connections can catch issues before they trigger faults.

This playbook ensures that compliance isn’t just a design specification but a daily operational reality.

Validation, Testing & Handover

When new panels are installed, EPCs and owners must focus on testing and handover.

• Factory Acceptance Testing (FAT): Done at the manufacturer’s site to confirm functionality and compliance. 
• Site Acceptance Testing (SAT): Performed after installation to verify correct wiring, interlocks, and safety systems. 
• Handover package: Should include as-built drawings, test certificates, maintenance manuals, and operator training sessions.

A robust O&M manual is critical. It should cover operating instructions, safety procedures, and maintenance schedules to guide the facility team throughout the lifecycle.

Conclusion & Call to Action

In pharma and data center environments, uptime and safety are two sides of the same coin. Internal arc tested panels – both in medium voltage switchgear and low voltage switchgear – provide the assurance that even when faults occur, people remain safe and operations stay resilient.

For EPC contractors and facility owners, investing in properly tested power distribution panels is not just about compliance – it’s about protecting lives, production, and reputation.

If you’re planning a new facility or upgrading existing infrastructure, our team can help with site surveys, detailed specifications, and product recommendations. Explore our MV and LV product pages or reach out today to discuss how we can help safeguard your project against arc-related risks.