Out Of Sight, Out Of Mind – Why Even Your Backup Supply Plan Needs A Backup Plan

-Andy Palmer, Operations Director, Secure Power Ltd-

Whilst browsing the net, I came across a question that had been posed on a hardware website regarding an old UPS system. The owner had purchased it twenty years earlier as a backup unit but it had never been taken out of its box during that time. When he went to plug it in he found that the battery was dead. A little taken aback this was the case, he had queried whether it was worth replacing the battery.

The response began, “You didn’t charge it in 20 years?!!!!!” ……. the ensuing conversation is not necessarily relevant however the subject matter resurfaced a couple of weeks later when we were approached with a similar situation through the Secure Power helpline.

Senior management at a data centre contacted us for help when their existing UPS system became temporarily out of action due to the need for a replacement part. A few years prior to this, the company had experienced a similar issue so had purchased a secondary backup UPS which had been kept in storage for emergency situations. Similar to the above, no thought had been given to maintaining battery life during the systems 6 years in storage.

Unfortunately, the unit had never been charged and the batteries would not charge. When the data centre’s existing UPS failed, the company was left without a fallback system in place exposing critical infrastructure to numerous supply risks. Thankfully, Secure Power was able to offer emergency cover with a replacement unit however all agreed the situation could have been prevented. It was a classic case of ‘out of sight, out of mind’.

A vital part of the continuity of modern day business, data centres are responsible for storing, processing and disseminating the data that companies use on a daily basis. It is a prerequisite they remain online all day, every day without interruption. As such, it is crucial to their operation that a reliable backup system is in place to mitigate the threat of all potential supply issues. In these situations, it is essential to have a backup plan for your backup plan!

The requirement for a consistent and dependable electrical source is by no means exclusive to the data industry however. Improvements in technology have led to an increase in the demand for UPS systems across all sectors. Regular servicing and preventative maintenance are key to guaranteeing the unit’s remain online.

What often goes unrecognised and was certainly the case with the data centre in quesion, is that all batteries lose charge when kept idle. If not regularly re-energised it is highly unlikely they will be able to provide sufficient charge or be reliable enough to put the UPS system into service when it is most needed.

Maintain 100% charge state

To maintain 100% charge state the UPS unit must be ‘plugged in’ to a power supply and charged at a low rate, even when it is not being used. The circuits in the unit are designed to stop charging the battery when it is fully charged and will just add what is known as a trickle charge now and again to keep it topped up and ready for use. When the data centre’s system had been put in storage, the batteries had literally been left to discharge, resulting in the unit becoming unsalvageable and unusable.

The majority of UPS faults encountered are largely due to battery failure and more often than not completely avoidable. The most frequent issues including battery blocks reaching a premature end of life and batteries beginning to fail. Through impedance testing it is possible to measure the batteries’ internal resistance by applying direct current to each battery, via probes attached to the block terminals. The lower the internal resistance, typically the higher the capacity therefore any increases in the internal resistance levels over time could highlight declining battery capacity.

By periodically conducting these tests every six to 12 months it is possible to compile a timeline of the unit’s battery performance. This allows for more accurate forecasting of expected end-of-life battery dates, to ensure replacements can be arranged promptly and ensure a successful power protection strategy remains in place.

Secure Power offers comprehensive ups maintenance support

Secure Power offers a comprehensive range of uninterruptible power supply maintenance support plans for small, mid-market and enterprise organisations. Each scheme is tailored to meet customer requirements, ensuring optimal performance and reliability throughout the lifetime of their critical infrastructure.

All support programs include battery testing and preventative maintenance of ‘active’ units and where required, also secondary or ‘idle’ units that are being held onsite for emergency situations. Where the protection strategy does not require there to be an additional unit held on site, Secure Power can offer temporary UPS solution cover in the event of failure (up to 10kVA single phase).

Our dedicated team of engineers are highly trained across a wide range of manufacturers, including APC, Eaton, Riello, Socomec, Salicru, Vertiv and many more allowing us to offer a range of support packages to match all needs.

Features available through the Bronze, Silver and Gold support plans include:

Recommendations:

It is vital that anyone with responsibility for stock management of a UPS system understands the basic requirements of their operation. Any backup or idle system held on site must be maintained alongside the active one to safeguard critical infrastructure in the event of primary system failure. Not following this course of action, is quite simply, throwing money down the drain.

It is also worth noting that whilst purchasing a secondary backup unit may seem a sensible option, unless business needs dictate this is an absolute requirement, it can lead to wasted capital outlay. Business expansion and growth may dictate that old stock UPS no longer meets current organisational needs and the ‘backup plan’ is no longer capable of supporting the business when it is needed the most.

The more prudent course of action, is undoubtedly to consider a maintenance support package that optimises battery health and is capable of ensuring the current or active UPS system remains in peak condition, whilst also providing the guarantee of temporary UPS cover in the event of any failure.

For further information on the range of Secure Power’s maintenance support plans or for power protection strategy advice, why not speak to one of our technical advisors on 0800 080 3118 or email [email protected].

Secure Power has been providing critical power solutions for over a decade and has an industry wide reputation for delivering first class backup power services. With preventative maintenance at the core of its business, Secure Power has its own team of engineers, available nationwide, 24/7. The company offers a wide range of UPS end-to-end project management solutions alongside ongoing maintenance and service works, battery testing, removal and relocation.