Case Study #150 | The Importance of Prevention

Case Study #150 | The Importance of Prevention

Case Study

Case Study #150 | The Importance of Prevention

Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies and UPS batteries, along with supporting other critical power components such as emergency generators, switch gear, and HVAC. We publish critical power related case studies, highlighting best practices and quality standards.

In this case study, we highlight batteries in a Liebert NXb, in which the Critical Power Professional™ found loose battery connections during a routine preventive maintenance (PM) inspection.

Product Liebert NXb UPS
Application Manufacturing Data Center
Synopsis During the first visit with a new customer, a regularly scheduled minor battery PM inspection was performed by the Critical Power Professional (CPP™), who identified three batteries that load tested as weak.
Preliminary Actions

Part of the CPP’s standard procedure for performing preventive battery maintenance is to load test each battery. While batteries may show correct voltages with a standard Fluke meter, placing a battery under load will identify true cell integrity and any degradation weaknesses.

With the CPP measuring battery system voltages, currents, and ohmic values, a final load test of each battery identified three batteries load testing under 60% (56%, 41%, 17% respectively).

Resolution

Upon further inspection of the three weaker load tested batteries, the CPP found that all three batteries had loose battery cable connections, one of which was only finger tight. After torquing to the correct battery hardware specifications, the batteries were load tested again and readings were in acceptable ranges.

Since the customer was under an emergency service contract with Nationwide Power, this preventive maintenance inspection was part of the included coverage and there was no out-of-pocket expense to the customer.

Root Cause The battery connections were improperly torqued by the previous service provider. As a result of routine preventive maintenance inspections, system load loss was avoided. Additionally, loose connections could have caused excessive resistance/heat, leading to a possible “thermal condition” or fire.
Additional Reading

https://nationwidepower.com/news/case-study-145-another-reason-why-preventive-maintenance-is-so-important-liebert-nx-40kva/

ttps://nationwidepower.com/news/case-study-133-overheated-ups-batteries-in-eaton-93e-30kva

 

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

 

Latest News

Case Study #150 | The Importance of Prevention

Case Study #150 | The Importance of Prevention

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies and UPS batteries, along with supporting other critical power components such as emergency...

Case Study #148 | The Cost of Deferred Maintenance

Case Study #148 | The Cost of Deferred Maintenance

Case Study In this Nationwide Power™ Case Study, we show the importance of routine maintenance and its impact on the overall health and life of UPS systems. This case study specifically looks at the Toshiba 1600EP 22kVA UPS. A new customer reached out to our team...

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Case Study #149 | The Additional Hidden Costs of Choosing the Lowest Price

Case Study #149 | The Additional Hidden Costs of Choosing the Lowest Price

Case Study

Case Study #149 | The Additional Hidden Costs of Choosing the Lowest Price

In this Nationwide Power™ case study, we show the importance of having a qualified Critical Power Professional™ (CPP™) perform maintenance on your critical infrastructure equipment. This case study specifically looks at the Liebert NX 120kVA UPS.

A Nationwide Power CPP was onsite to perform a regularly scheduled preventive maintenance (PM) inspection. During the PM inspection, the CPP noticed that the input voltages were running high, and the output voltages were unbalanced.

Product Liebert NX 120kVA UPS
Application Medical Facility
Synopsis During a regularly scheduled PM inspection, high input and unbalanced output readings were found. To further troubleshoot, the uninterruptible power supply (UPS) was placed into maintenance bypass to observe the voltages. No changes were observed and as the unit was being transferred back out of bypass, a short buzzing sound was heard. The transfer had failed, and the critical load was lost.
The downtime was further extended because the failure cleared a fuse in the maintenance bypass panel. Site electricians were called in to help repair the bypass panel. After several hours, a replacement fuse was found and installed, and the maintenance bypass was operational again.
Preliminary Actions A Critical Power Professional™ (CPP™)initiated troubleshooting and found 3 blown output fuses, 3 failed static switch silicon controlled rectifiers (SCRs), and a possible bad SCR driver board. Parts were ordered and shipped from Nationwide Power’s inventory via next day air. Upon returning to the site to repair, the CPP replaced all the parts that were ordered. Continuing the troubleshoot, the CPP focused on the output capacitor section, based upon the output voltage symptoms. Additionally, the output capacitors were recently replaced by another vendor who was awarded the job based upon lowest price, and therefore seemed like a logical place to start.
Resolution After in-depth troubleshooting and removing UPS covers, the CPP was able to determine that the capacitor pan assembly wiring harness plug was not plugged into the UPS. After plugging the capacitor pan connector into the UPS and returning all other parts that were removed, the UPS was restarted, with customer approval, and placed back online in normal mode.
Root Cause Human error caused by a simple electrical connection not being completed.
Even though Nationwide Power was the service provider contracted to maintain the customer’s critical power infrastructure, a lower price option was selected to replace the UPS capacitors. The quality of service, or lack thereof by the other vendor resulted in the “lowest price” costing an additional $5,000 in repairs. The cost of downtime is not included.
Unfortunately, the lowest price is not always the best price, and true cost of total ownership.
Additional Reading

https://nationwidepower.com/news/case-study-145-another-reason-why-preventive-maintenance-is-so-important-liebert-nx-40kva/

https://nationwidepower.com/news/case-study-146-when-to-upgrade-or-repair-a-ups-system-eaton-9315-ups-system/

 

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

 

Latest News

Case Study #150 | The Importance of Prevention

Case Study #150 | The Importance of Prevention

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies and UPS batteries, along with supporting other critical power components such as emergency...

Case Study #148 | The Cost of Deferred Maintenance

Case Study #148 | The Cost of Deferred Maintenance

Case Study In this Nationwide Power™ Case Study, we show the importance of routine maintenance and its impact on the overall health and life of UPS systems. This case study specifically looks at the Toshiba 1600EP 22kVA UPS. A new customer reached out to our team...

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September 02, 2021

"Everything went as planned. Michael was a pleasure to work with. He’s very knowledgeable, courteous, and professional."

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Alabama

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Case Study #148 | The Cost of Deferred Maintenance

Case Study #148 | The Cost of Deferred Maintenance

Case Study

Case Study #148 | The Cost of Deferred Maintenance

In this Nationwide Power™ Case Study, we show the importance of routine maintenance and its impact on the overall health and life of UPS systems. This case study specifically looks at the Toshiba 1600EP 22kVA UPS.

A new customer reached out to our team after their UPS failed to carry the critical power load. Their Toshiba 1600EP 22kVA UPS system is 9 years old and has not had regular preventive maintenance.

Product Toshiba 1600EP 22kVA UPS
Application Radio Communications
Synopsis The business recently conducted a generator test, which included a load test on their 9-year-old Toshiba 1600EP 22kVA UPS system. When the UPS system was unable to carry the load, the on-site generator technician reported a burnt smell.
Our team was contacted for further inspection.
Preliminary Actions A Critical Power Professional™ (CPP™) was dispatched to the site where the CPP found older batteries installed in the unit, along with inductor failure and lack of capacitor maintenance.
Resolution After in-depth troubleshooting and pricing repair costs, it was determined that the most cost-effective and reliable solution to the customer would be a full system replacement. A full system replacement would come with a one-year manufacturer warranty, newer and more efficient technology, and the option of going with a modular unit for better future scalability and redundancy.
Root Cause Some businesses often choose deferred maintenance as part of cost saving efforts. Unfortunately, this can lead to larger out-of-pocket expenses in the future.
In this scenario, it is reasonable to expect that the customer would have extended the life of their UPS system by at least 5 years with proper maintenance, lowering the overall cost of ownership.
Additional Reading

https://nationwidepower.com/news/case-study-145-another-reason-why-preventive-maintenance-is-so-important-liebert-nx-40kva/

https://nationwidepower.com/news/case-study-146-when-to-upgrade-or-repair-a-ups-system-eaton-9315-ups-system/

 

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

 

Latest News

Case Study #150 | The Importance of Prevention

Case Study #150 | The Importance of Prevention

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies and UPS batteries, along with supporting other critical power components such as emergency...

Case Study #148 | The Cost of Deferred Maintenance

Case Study #148 | The Cost of Deferred Maintenance

Case Study In this Nationwide Power™ Case Study, we show the importance of routine maintenance and its impact on the overall health and life of UPS systems. This case study specifically looks at the Toshiba 1600EP 22kVA UPS. A new customer reached out to our team...

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September 02, 2021

"Everything went as planned. Michael was a pleasure to work with. He’s very knowledgeable, courteous, and professional."

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Case Study #147 | What Could Possibly Go Wrong – Eaton 9330 15kVA

Case Study #147 | What Could Possibly Go Wrong – Eaton 9330 15kVA

Case Study

Case Study #147 | What Could Possibly Go Wrong – Eaton 9330 15kVA

In this Nationwide Power™ case study, we hope to show our customers another example of how a full-service contract will save our customers time, money, and headaches in both  the short term and in the long run. In this case study, we particularly focus in on a 15-year-old Eaton 9330 UPS system.

In 2018, Nationwide Power acquired a customer who purchased new batteries and installation, along with a preventive maintenance contract. Due to budget constraints, they opted for annual maintenance only in place of a full-service contract that would have covered parts, labor, and travel.

Product Eaton 9330 15kVA UPS
Application Local County Support
Synopsis The Eaton 9330 UPS system is located in the basement of the facility and is not often monitored. Upon a random inspection, an on-site team member reported that the unit was in alarm but was not aware of how long the system had been in an alarm status.
Preliminary Actions A Critical Power Professional™ (CPP™) was dispatched to the site. After in-depth troubleshooting, it was identified that the power supply board had failed and required replacement.
Resolution One of the major competitive advantages that Nationwide Power holds is the vast inventory of parts and equipment on-hand, totaling over $10 million in value and covering 57,000 square feet of warehouse space.

Once the customer approved the parts order and repair, the Nationwide Power team was able to expedite the shipment of the parts and installation within just 2 calendar days.

Under a full-service contract with Nationwide Power, the power supply board would have been repaired/replaced the same or next day with no additional expenses. The customer would have also saved over $5,000 over the course of the calendar year.

Root Cause While the power supply board failure may have been inevitable in this situation, the out-of-pocket expense to our customer was not.

Our job as a critical power service provider is to guide our customers in the best way possible. We understand the market, the limitation on available parts inventory – particularly in obsolete UPS models, and the potential compound expense of deferred maintenance.

Our ultimate goal is to provide value to our customers by offering affordable and predictable service plans, where Nationwide Power takes the guesswork out of “what could possibly go wrong?”

Additional Reading For a common list of questions to ask when receiving quotes from multiple service providers, visit us at:

https://nationwidepower.com/news/case-study-145-another-reason-why-preventive-maintenance-is-so-important-liebert-nx-40kva/ 

https://nationwidepower.com/news/case-study-146-when-to-upgrade-or-repair-a-ups-system-eaton-9315-ups-system/

 

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

 

Latest News

Case Study #150 | The Importance of Prevention

Case Study #150 | The Importance of Prevention

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies and UPS batteries, along with supporting other critical power components such as emergency...

Case Study #148 | The Cost of Deferred Maintenance

Case Study #148 | The Cost of Deferred Maintenance

Case Study In this Nationwide Power™ Case Study, we show the importance of routine maintenance and its impact on the overall health and life of UPS systems. This case study specifically looks at the Toshiba 1600EP 22kVA UPS. A new customer reached out to our team...

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September 02, 2021

"Everything went as planned. Michael was a pleasure to work with. He’s very knowledgeable, courteous, and professional."

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Case Study #146 | When to Upgrade or Repair a UPS System – Eaton 9315 UPS System

Case Study #146 | When to Upgrade or Repair a UPS System – Eaton 9315 UPS System

Case Study

Case Study #146 | When to Upgrade or Repair a UPS System – Eaton 9315 UPS System

Part of the job of our Critical Power Professionals™ (CPP™) is to educate our customers on their Uninterruptible Power Supply (UPS) equipment over the lifespan of their system.

In this Nationwide Power ™ case study, we feature a scenario where our CPPs serviced an Eaton 9315 UPS unit that was over 20 years old and provide a cost-benefit analysis to the customer on upgrading the UPS system.

Product Eaton 9315 UPS
Application Government Facility
Synopsis

Finding the right timing to upgrade a UPS system can often be a complex decision based on many factors: age of unit, customer budget, risk of critical failure and level of impact to the business, lack of replacement parts on the market, and the consistency of preventive maintenance performed over the life of the unit as a few examples.

Part of our responsibilities at Nationwide Power is to provide our customers with the best possible direction and guidance, based on all known factors.

Preliminary Actions

Nationwide Power has been servicing this customer’s unit intermittently over the past several years. In 2017, our CPP made the first recommendation for a full unit replacement. While Nationwide Power has the capacity to continue servicing the unit even passed its OEM-stated end-of-life, that was not in the customer’s best interests in this scenario.

Factors for the customer to consider include:

  • Age of equipment
  • Inconsistent routine maintenance over the life of the unit
  • Risk of critical failure and impact to the business
  • Cost benefit analysis, with more efficient equipment on the market today that would not require costly repairs over the remainder of the equipment’s life
Resolution

The customer had not been in a position to upgrade the unit and has elected to have Nationwide Power continue servicing it.

With over 57,000 square feet of warehouse space and over $10 million in parts and equipment inventory, Nationwide Power is one of the very few service providers able to continue maintaining this customer’s equipment.

So far, the customer has been able to stretch the end-of-life on the unit for an additional 3 years, however, not without intermittent failures and downtime.

Root Cause Eventually, the customer will have no other option but to upgrade the unit due to age. In doing so, they should expect to find a quick break-even point simply due to more efficient models on the market with lower energy usage, coupled with lower overall maintenance cost.
Additional Reading

For a common list of questions to ask when receiving quotes from multiple service providers, visit us at:

hhttps://nationwidepower.com/news/case-study-138-powerware-9315-repair-end-of-life

https://nationwidepower.com/news/case-study-126-eaton-9315-160kva-load-los/

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.

Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

Latest News

Case Study #150 | The Importance of Prevention

Case Study #150 | The Importance of Prevention

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies and UPS batteries, along with supporting other critical power components such as emergency...

Case Study #148 | The Cost of Deferred Maintenance

Case Study #148 | The Cost of Deferred Maintenance

Case Study In this Nationwide Power™ Case Study, we show the importance of routine maintenance and its impact on the overall health and life of UPS systems. This case study specifically looks at the Toshiba 1600EP 22kVA UPS. A new customer reached out to our team...

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September 02, 2021

"Everything went as planned. Michael was a pleasure to work with. He’s very knowledgeable, courteous, and professional."

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Alabama

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Case Study #145 | Another Reason Why Preventive Maintenance Is So Important (Liebert NX 40kVA)

Case Study #145 | Another Reason Why Preventive Maintenance Is So Important (Liebert NX 40kVA)

Case Study

Case Study #145 | Another Reason Why Preventive Maintenance Is So Important (Liebert NX 40kVA)

At Nationwide Power, we make it a top priority to educate our customers on their critical power equipment and keep them informed of any maintenance items on the horizon.

In this case study, a customer had regularly scheduled preventive maintenance (PM) for their Liebert NX 40kVA Uninterruptible Power Supply (UPS) system. Recommendations were made that saved the customer both money and possible downtime.

The customer was so impressed with the service and recommendations, he provided the following comment:

“Fantastic job by Darren. This is why everyone should have a maintenance contract in place. Had I not had a contract, then I would not have known I had batteries failing and would have been up a creek if something had happened. Darren explained in detail what needed to be done, and I am thankful you have such a conscientious worker. Hats off once again for his dedication to his job and working with us to ensure we don’t have any issues with our UPS. Thanks Darren.”

Product Liebert NX 40kVA
Application Restaurant Equipment Supplier
Synopsis A Critical Power Professional™ (CPP™) conducted regularly scheduled preventive maintenance on the customer’s Liebert NX 40kVA UPS. During the PM, faulty batteries were detected and recommended for replacement.
Preliminary Actions

As part of standard PM protocols, the CPP reviewed alarms and unit performance; recorded measurements for line input/output, bypass, and battery voltages and currents; verified meter calibrations; performed infrared temperature checks; and inspected fans for proper operation.

While measuring battery system line voltages, currents, and ohmic values, the CPP identified four weak and/or failing batteries.

Resolution The CPP recommended immediate replacement. Had the failing batteries gone undetected, those batteries could have brought down the entire string and ultimately, the entire UPS system.
Root Cause Through regular routine maintenance, this issue was detected in the very early stages, and as a result, had minimal impact to the customer.
Additional Reading

For a common list of questions to ask when receiving quotes from multiple service providers, visit us at:

https://nationwidepower.com/news/case-study-125-preventive-maintenance-only-vs-full-service-contract-schneider-electric/

https://nationwidepower.com/news/case-study-124-preventive-maintenance-only-vs-full-service-contract-liebert-ap367-75kva/

 

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.

Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

Latest News

Case Study #150 | The Importance of Prevention

Case Study #150 | The Importance of Prevention

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies and UPS batteries, along with supporting other critical power components such as emergency...

Case Study #148 | The Cost of Deferred Maintenance

Case Study #148 | The Cost of Deferred Maintenance

Case Study In this Nationwide Power™ Case Study, we show the importance of routine maintenance and its impact on the overall health and life of UPS systems. This case study specifically looks at the Toshiba 1600EP 22kVA UPS. A new customer reached out to our team...

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Feedback

September 02, 2021

"Everything went as planned. Michael was a pleasure to work with. He’s very knowledgeable, courteous, and professional."

View All - Keith J
Alabama

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