How Emergency Power Services Protect Industrial Facilities

Industrial and manufacturing operations will come to a grinding halt without a dependable power source. Still, natural disasters and other emergencies make it impossible to eliminate unexpected downtime resulting from power outages.

Instead, businesses must have plans to ensure safety standards are met, and production gets back on track as quickly as possible when the inevitable happens.  An emergency power services plan is the best way to protect your assets and your crew.

Understanding the Risks of Power Outages in Industrial Settings

When power outages occur in industrial and manufacturing settings, the first thing that happens is that production lines suddenly stop. The immediate result is often a loss of material currently in the machine and the inability to continue production. Every minute that machines sit idle costs the company money.

In some cases, worker safety can be put at risk during an outage, especially if emergency response service plans are not in place. Blackouts can make it dangerous to maneuver in hazardous environments, and the storage of hazardous materials can become compromised, for example. Power outages can also damage equipment, mainly if power surges occur when electricity is restored, or equipment is not properly shut down.

The Impact of Downtime on Financial and Operational Performance

When production lines come to a halt, the entire supply chain connected to those lines also stops. Power outages that affect a wide area will cause even more significant problems as delivery networks are disrupted and customers are affected.

Customers who rely on the continual supply of certain products, such as hospital medical supplies, may have to turn to other suppliers. Repeated or sustained outages can damage a company’s reputation with its customers as products become increasingly unreliable.

Another possible consequence is unsold inventory remaining in storage when delivery channels are disrupted or customers need help to make purchases and cannot access online materials or office personnel. Perishable items may have to be discarded, and the quality of sensitive items may drop if environmental requirements are not met.

Downtime due to power outages also makes it difficult for some workers to do their jobs at all, while others may have to work overtime to resolve problems. Balancing the bottom line will become more difficult the longer the outage lasts, especially when revenue streams are also disrupted.

The Critical Role of Emergency Power Services in Maintaining Operations

Emergency power services are vital for keeping critical systems online during a power outage and for allowing the safe shutdown of large machinery and equipment. One crucial system that emergency power should facilitate is communications and data storage systems. Emergency services personnel and repair services will rely on both systems to maintain operations and return all services online.

How do emergency power services benefit industrial operations?

Along with providing continuous power for critical systems, emergency power services allow industrial operations to transition to backup power supplies or power down equipment safely rather than abruptly.

Key Components of a Robust Emergency Power Plan

With so many potential consequences facing manufacturers during a power outage, the importance of an emergency power services plan becomes clear. Here are the key components of a robust strategy.

• Determine Your Requirements. Depending on the complexity of your operations and source of backup power, it may not be feasible to have your entire system on a redundant emergency power service source. In some cases, any interruption in production may be intolerable, and a powerful backup generator system may be necessary.
• Choose Backup Equipment. Generators and uninterrupted power supplies (UPS) can be chosen by prioritizing various features. These features can include auto start-stop capability, charging alternator, sight gauges, security features, fuel priming pumps, and EPA emissions certifications.When choosing a generator, emergency power service requirements will be determined by the size and type of equipment. Fuel types will depend on the availability and price of fuel, along with the generator’s environmental impact. The facility must also consider the space needed for an appropriately sized generator and the weight of the equipment.
• Secure a Fuel Supply. A reliable fuel supply is critical for emergency power generation, and you’ll want to secure your source and delivery options long before an emergency occurs to ensure demand from affected businesses and communities does not threaten your supply. Depending on the type of fuel your generators use, it may be beneficial to store fuel onsite so it is ready to use in an emergency.
• Perform Regular Testing. Executing an emergency plan under adverse conditions is far more likely to be successful if the participants are familiar with their role and have practiced their tasks. Staging drills for the entire crew will help reduce the impact of an outage when it occurs.

It’s also important to regularly test your emergency power service system, including backup generators, UPS systems, and associated equipment such as circuit breakers.

How often should emergency power systems be tested?

According to the National Fire Prevention Association’s (NFPA) standard 110, complete emergency power supply system testing should be performed once every three years, inspected weekly, and exercised monthly. Regular maintenance schedules for each component of an emergency power service system should also be followed.

Why is it important to have both a UPS system and a generator in an industrial facility?

UPS systems are not designed for long-term power supply. Instead, they are used to protect from short-term blackouts and power surges. Once the batteries from UPS systems become depleted, a backup generator supplies power. In other words, a UPS system is perfect for short outages and to bridge the power gap while generators from an emergency power service system are started up and synchronized.

Emergency Power Solutions, Including Generators and UPS Systems

A combination of UPS systems and backup generators is necessary for emergency power services in industrial and manufacturing settings. Here are different types of generators a facility can choose from.

• Natural Gas. Natural gas burns cleaner and produces less noise than other fuel sources. However, it can also be less efficient than other fossil fuels, and improper handling can pose serious safety risks.
• Diesel. Diesel is the most commonly used fuel in manufacturing and industrial operations. It is more stable and efficient than gasoline, allowing large quantities to be stored onsite.
• Portable. Perfect for remote locations or short-term use, large commercial portable generators can supply large amounts of power for extended periods.
• Standby. For larger operations that are usually connected to a power grid, a standby generator is ready to switch on if an outage occurs and can provide power for several days.

Three main types of UPS systems are divided by how power flows through the unit. A standby UPS protects against surges and provides a short duration of battery backup during an outage. AC power runs through a standby UPS under normal conditions. When a power outage is detected, it switches to battery.

A line-interactive UPS provides conditioned power, eliminates voltage fluctuations, and provides a backup battery power source. AC power runs through a voltage regulator during regular operation and switches to the battery when an outage is detected.

An online, double-conversion UPS converts AC power to DC and then back to higher-quality AC power with no distortions or voltage fluctuations, which are often expected from grid power. Intelligent systems also use a high-efficiency mode to suspend double conversion when the input power quality is high enough.

Training and Preparedness to Ensure Your Team Is Ready

Having the right equipment for emergency power services is only the beginning. Regular testing and maintenance of UPS systems, backup generators, and associated equipment is critical to ensure they are ready to work when a power outage occurs.

Plus, your entire team should be familiar with your emergency preparedness plan and practice the steps needed during a power outage.

The NETA-accredited technicians at Quad Plus can test your UPS batteries for charging station voltage, specific gravity, cell voltage, load bank, and cell/inter-cell impedance. We also test and maintain all aspects of your emergency power services system and can help your facility design a backup system that protects your workers, equipment, and bottom line.