"Regular power system studies (monitoring and modelling) coupled with failure mode evaluation analysis (FMEA) helped identify a critical weak point within the facilities electrical distribution system. Power system health checks gave early warning, which helped prevent potential downtime and financial loss of €2 million. Moving from fire fighting mode to a controlled position that prevents potential downtime allows for a more efficient, profitable and safer site."
Barry Nicholson
Associate Director
UPS Failure - BioTechnology Plant
A large multinational biotechnology facility was experiencing catastrophic downtime events causing huge damage to their production line. We worked hard to identify what was causing this UPS failure and implemented a mitigation design process to prevent further issues.
Client:
Bio-Technology
Location:
Ireland
Premium Power Role:
Power System Consultant
Project Description
In order to alleviate the clients issues we:
- Installed fixed metering equipment on Pri/Sec side of UPS
- Used PMS to auto transfer UPS into bypass in the event of PQ problems arising on the secondary
- Integrated alarms/pager alerts for UPS, TXFR’s, Generators and VSD
- Advised them on what equipment needed to be kept in stock – to reduce failure to repair time (FTRT)
- Reduced potential downtime (calculated using statistical analysis) of 6 hours/year to 30 mins/year
Project Challenges
After suffering a UPS failure this multinational biotechnology facility tasked us with the job of identifying the critical single points of failure within the electrical distribution system. In order to do this we used both state enumeration statistical analysis and failure mode evaluation analysis. We then designed a mitigation process so they could avoid waste of the product in the future.
Project Outcomes
By implementing the solutions we recommended the client was able to avoid a catastrophic event when the mains supply to the cold store failed. Shift technicians were trained and able to respond immediately restoring full power to the cold store in under an hour. This prevented a waste in product estimated to be in the region of €2m. Taking into account the mitigation and study costs it is estimated the company saved €1.9m overall.
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