Power disruptions are rising, placing industrial businesses at risk.
Data shows that significant power outages have increased tenfold since 1980. Extreme weather events and the aging electrical grid are critical variables that can cause severe losses in machinery applications.
Power reliability is critical in manufacturing, oil and gas, mining, pharmaceutical production, and other assembly-line operations to avoid equipment damage and production downtime while enhancing worker safety.
To help mitigate risk, companies invest in uninterruptible power supply (UPS) systems. Here is what you need to know to remain competitive.
The Role of UPS Systems?
Uninterruptible power supply (UPS) systems prevent equipment shutdowns, protect sensitive machinery, and ensure operational continuity during outages.
These systems provide backup power during a power outage, disturbance, or fluctuation. Companies benefit from a nearly instant power supply replacement for industrial applications. If the primary power source fails, a UPS system provides immediate backup power to protect hardware, data, and other critical equipment while reducing the risk of injuries or fatalities.
During an outage, a UPS system helps with power bridging. These systems provide temporary power and bridge the gap between an outage and a backup power solution, such as a generator.
For these reasons, you often hear of UPS solutions in hospitals, telecommunication facilities, and data centers. But what about industrial machinery applications?
Why UPS Systems Matter for Industrial Applications
When operating an industrial facility involving machinery, you need to consider your backup power strategy carefully. For example, if you’re in the manufacturing sector, an outage could lead to lost productivity, a drop in revenue, damaged products (which could tarnish your reputation in the supply chain), and worker injuries.
For example, data shows that the manufacturing industry could lose as much as $6.45 million an hour when facing downtime. Power failures can be life-threatening when considering work safety, especially if chemicals are involved. For example, a California-based plant experienced a power interruption after a truck struck a utility pole, as reported by the EPA. As a result, sulfur dioxide and sulfur trioxide escaped a boiler flue. Up to 100 people required medical attention.
The same applies to critical operations, such as water treatment facilities. In addition to potentially damaging sophisticated equipment, an outage could disrupt treatment processes, leading to water contamination. These facilities must also adhere to strict regulations and guidelines imposed by authorities, such as the Environmental Protection Agency (EPA), concerning backup power solutions.
UPS Systems Reduce Downtime and Serve as Power Conditions
Unexpected accidents and weather events are inevitable and cause unplanned outages — there is no room for error when millions of dollars and human lives are on the line.
A UPS system provides reliable backup power during these emergencies, which allows other power sources to kick in or systems to shut down slowly, reducing the risk of damage. This controlled shutdown also reduces waste, as the current line can be completed without disruption.
The best critical power solutions pair a UPS system with a backup generator. In an emergency, that means your facility remains operational. At the very least, it keeps the lights on, protects workers and data, and reduces the risk of equipment damage.
In addition, a quality UPS system serves as a power conditioner. This advantage helps protect your industrial facility, as it controls and smooths voltage fluctuations, sags, and surges, contributing to better power quality. As long as you build a UPS system based on your facility’s power requirements, it can handle everything from motors and drives to robotics.
Learn more: What is a Power System Integrator and Why You Need One.
Tailored Solutions for Industrial Applications
UPS systems must be chosen based on your industrial facility’s capacity, environmental conditions, and specific power requirements. Each facility is unique, and that’s why it’s critical to work with an expert power supplier like Global Power Supply (GPS). This type of partnership ensures you gain access to the customized support you need to maintain uptime while reducing the risk of damage or life-threatening events.
Here’s what to consider when speaking with your expert critical power supplier:
Power Capacity
Calculate the total power consumption for the equipment connected to the industrial UPS system. Be sure to allow some leeway for growth and expansion, but avoid oversizing your UPS system. If you don’t adequately estimate the power capacity, you could see overloads that lead to failure or equipment damage. However, you also want to avoid extra costs and inefficiencies.
It’s recommended that you select a UPS system with an output watt capacity 20-25% higher than the total power drawn by any connected equipment. You can also invest in a modular UPS system that scales alongside your company. Scalability and redundancy are two critical factors to consider.
Related: Going Beyond The Basics Of UPS Sizing.
Runtime
Consider how long you expect your industrial UPS system to power the connected equipment via its battery bank. To determine the optimal runtime requirement, consider the connected load, any necessary redundancies, and the UPS battery capacity.
As reported by Eaton, a typical UPS battery will provide five to 15 minutes of backup power. Supplemental battery modules or cabinets are advantageous for industrial circumstances. They can add hours of runtime during an emergency situation. However, industrial applications should add a backup generator and/or BESS to ensure zero downtime.
Learn more: Choosing the Right Generator for Your Business: A Comprehensive Guide.
Environmental Conditions
When discussing your UPS system with an expert supplier, you’ll need to consider variables like temperature, dust, humidity, and location. For example, if you’re located in a coastal area, exposure to salty sea air must be evaluated.
Ensuring Optimal Installation and Maintenance Practices for Industrial Uninterruptible Power Supplies
Industrial UPS solutions are often more rugged, but proper installation and maintenance are essential to ensure the most efficient, reliable operations.
Installation Best Practices
The first step is to follow the manufacturer’s guidelines for installing the industrial UPS backup system. However, it’s best practice to have an expert install your system, which GPS offers.
Also, consider the following:
- Know details such as the temperature, ventilation, humidity, and clearance as you prepare the site.
- Ground and bond the UPS system and connect equipment properly.
- Allocate the appropriate space for future expansion and maintenance.
- Follow the appropriate safety codes and regulations.
- Require a professional to test the system.
Learn more about GPS installation services and how GPS supported Peroxychem with a long-term UPS solution based on specific requirements.
Maintenance Best Practices
Follow regular maintenance best practices to ensure longevity and optimal performance in industrial UPS solutions. Here are our recommended maintenance best practices:
- Regularly test and replace your battery based on the manufacturer’s recommendations.
- Clear and inspect all fans, filters, and cooling systems.
- Test the UPS system under load conditions (simulations).
- Install firmware and software updates to ensure security, reliability, and compatibility.
- Maintain up-to-date records and maintenance logs.
- Roll out a preventative maintenance program.
Learn more about preventative maintenance.
Regulatory and Compliance for Industrial Uninterruptible Power Supplies
Understanding the regulatory and compliance requirements for your location and industry is essential. By following the regulations, you ensure the safety and security of your employees. It also helps protect your equipment and the stability of your facility’s environment.
Some organizations responsible for governing industrial UPS systems include:
- Occupational Safety and Health Administration (OSHA)
- National Electrical Code (NEC)
- International Electrotechnical Commission (IEC)
- Underwriters Laboratories (UL)
- European Union (EU) directives and standards
Resellers Play a Key Role in Industrial UPS Systems
Consider all the many variables when investing in an optimal UPS system for your needs. You’ll also want to examine other critical components to ensure a complete backup power system.
Depending on your situation, you may benefit from used equipment. GPS buys and sells equipment, helping businesses find the best option based on their budget, timeline, regulatory concerns, and other factors.
Global Power Supply Can Help
GPS recommends a power supply study to fully understand your existing power systems and create an optimal strategy. Expert engineers will collect and study data to better understand your critical loads, risk of power disruptions, existing power infrastructure, and more.
Request a power study to get started.
If you have questions about the best UPS solution for your business or how to implement your backup power strategy, contact GPS today!
Discover more:
UPS System Trailers: Portable Power Solutions for Critical Operations
Factors to Consider When Selecting a UPS Backup System
Why GPS Is Your One-Stop Shop for All Power System Needs