Okay, let's break down this buzzing electrical mystery and the potential solutions.

Analysis of the Situation

You've presented a classic electrical troubleshooting scenario. The "buzzing" sound is a critical clue, as is the heat on specific breakers. Here's a more detailed breakdown of each element: The Buzzing Sound

Electrical buzzing typically indicates a loose connection, vibration of components due to current flow, or arcing. While it can be related to a short or ground fault, it's less likely if the system isn't tripping breakers or experiencing a significant voltage drop.

The Heat

This is a major red flag. Breakers and conductors getting hot to the touch under normal load is a sign of resistance. Resistance generates heat. Possible causes include:

Overloading

Even though your nameplate calculations seem to indicate compliance, there might be issues with the actual load draw or how it's being applied.

Loose Connections

Anywhere along the circuit, including at the breaker, in the junction boxes, at the receptacles, and within the equipment itself. Loose connections create resistance.

Corrosion

If there's any corrosion on the conductors, terminals, or breaker contacts, that will increase resistance.

Faulty Breaker

The breaker itself could be failing internally, creating excessive resistance.

Undersized Conductors (Unlikely but possible)

Although you specified #12AWG, verifying its existence is necessary, especially if it's getting hot.

Addressing Your Questions

Let's tackle your specific questions one by one

A. Is it safe to say that "Buzzing Sound" was not a short or a ground fault, but the actual breaker(s) malfunctioning due to the continuous use of the medical equipment described above?

Not entirely safe to say. While the buzzing could be related to a failing breaker or the conductors, the fact that the breakers are noticeably warm suggests something is wrong with the load, the breakers, or the circuit wiring. It could very well be related to a high Neutral current due to harmonic distortion. The continuous use is contributing, but it's likely exacerbating an underlying issue. You can confirm this by checking the neutral conductor on each breaker and see if there's any current flowing through the conductor.

B. If (A) assertion is erroneous, then what else could cause the "Buzzing Sound" ? (which was made from Utility Room that housed panels, discos and pullboxes) Loose connections

This is the most common cause. Go through every connection in the affected circuits – breaker terminals, receptacle terminals, wire nuts in junction boxes, terminals in the equipment – and ensure they are tight and clean. (Make sure to de-energize circuits).

Arcing

This is a serious hazard. Arcing occurs when electricity jumps a gap, often due to a loose connection or damaged insulation. It produces heat, light, and a buzzing or crackling sound.

Transformer Vibration (if applicable)

The step-down transformer for the vacuum system could be vibrating due to loose mounting hardware or an internal problem.

Loose Conduit/Enclosure Components

Vibration from equipment can loosen screws or other fasteners on the electrical enclosures or conduit, creating a buzzing sound.

Harmonic Distortion

Modern electronic equipment (like some medical devices) can introduce harmonic currents into the electrical system. These harmonics can cause transformers and other equipment to vibrate and hum. If you can get your hands on a good harmonics meter, verify the system for distortion.

Neutral Current

Sometimes a circuit breaker will get warm to the touch if the Neutral is carrying excessive current, but the breakers don't trip.

C. if (A) assertion is agreed upon by majority consensus of wizards. then can i upsize these specific 6 circuits from 20A -> 30A and #12 - > #10AWG ? Absolutely NOT without a thorough investigation! Code Violation

You cannot simply upsize a breaker without ensuring the entire circuit is rated for the new amperage. This includes the wiring, receptacles (must be rated for 30A), and all associated components.

Underlying Problem

Upsizing a breaker without addressing the root cause of the overheating is a recipe for disaster. You're just masking the symptom and creating a fire hazard.

The wires are overheating for a reason; fixing that reason is critical, not just bumping up the amperage. Medical Equipment Approval

Altering circuits that supply medical equipment might require approvals from regulatory bodies or the equipment manufacturers to ensure continued safety and compliance.

Receptacle Limitations

If the receptacle that the devices are plugging into is rated at 20A, then this is a violation because these receptacles are not intended to handle 30 amps.

Recommended Troubleshooting Steps (The Wizard's Approach)1. Safety First

De-energize the affected circuits before doing any work. Use proper lockout/tagout procedures.2.

Visual Inspection

Carefully inspect all components of the affected circuits:

Breakers

Look for signs of discoloration, melting, or damage. Sniff the breakers - a burnt smell is a bad sign.

Wiring

Check for signs of damage, fraying, or overheating.

Connections

Check for loose connections at the breaker, receptacles, and junction boxes.

Equipment

Inspect the equipment for any signs of damage, overheating, or loose connections.3.

Tighten Connections

Systematically tighten all connections in the affected circuits. Use a torque screwdriver to ensure proper torque (check manufacturer specifications).4.

Measure Voltage and Current



Voltage Drop

Measure the voltage at the receptacle while the equipment is running. Excessive voltage drop indicates a problem with the circuit.

Current Draw

Use a clamp meter to measure the current draw of each piece of equipment under normal operating conditions. Compare this to the equipment's nameplate rating.

Crucially, measure the neutral current. High neutral current can be a result of non-linear loads creating harmonics.5. Breaker Testing (If Possible)

If you suspect a faulty breaker, replace it with a new breaker of the same type and rating. Observe if the new breaker also gets hot.6.

Infrared Thermography (Ideal)

If you can get access to a thermal camera, use it to scan the panels, breakers, and wiring while the equipment is running. This will quickly identify hot spots that indicate problems.7.

Neutral-Ground Voltage

Measure the voltage between the neutral and ground conductors. A reading of more than a few volts can indicate a problem with the grounding system.8.

Address Harmonic Distortion

If you suspect harmonic distortion, consider installing harmonic filters to reduce the harmonic currents in the system. If the system isn't properly grounded, you could be in trouble with medical tools.9.

Consult a Qualified Electrician

If you're not comfortable performing these tasks, or if you're unable to identify the source of the problem, consult a qualified electrician. Electrical work can be dangerous, and it's important to have it done by someone who is experienced and knowledgeable.10.

Document Everything

Keep detailed records of your troubleshooting steps, measurements, and any repairs you make.

Important Considerations for Medical Environments Safety

Patient safety is paramount. Any electrical issues in a medical facility must be addressed promptly and effectively.

Code Compliance

Ensure that all electrical work complies with the National Electrical Code (NEC) and any applicable local codes.

Grounding

Proper grounding is critical in medical facilities to minimize the risk of electrical shock and interference with sensitive equipment.

Emergency Power

Ensure that the emergency power system is functioning properly.

Regular Maintenance

Implement a regular electrical maintenance program to prevent future problems.

In summary: The buzzing sound and hot breakers indicate a problem that needs to be addressed immediately. Do NOT upsize the breakers. Instead, systematically troubleshoot the circuits to identify the root cause of the overheating and fix it. And if unsure, call a qualified electrician experienced in medical facility electrical systems. Flag for review