Case Study #126 | Eaton 9315 160kVA Load Loss

Case Study #126 | Eaton 9315 160kVA Load Loss

Case Study

In this case study, we feature a recent scenario where an Eaton 9315 160kVA experienced a load loss which could have been prevented. The Eaton 9315 UPS is over 20 years old. The customer formerly held a contract with Nationwide Power but switched service providers to save on annual service costs. However, this move cost them substantially more in the end, and they returned to having Nationwide Power service their critical power equipment.

Note: Many companies will assert their ability to service legacy units like the Eaton 9315 featured here. However, it is very limited as to what these companies can do to repair the unit and extend the EOL without access to parts inventory should the system experience failure.

Nationwide Power boasts a 57,000 square foot warehouse with over $10 million in equipment and parts inventory. This uniquely positions Nationwide Power as the industry leading independent UPS service provider.

 

Product Eaton 9315 160kVA
Application Data Center at State University
Synopsis Inadequate maintenance and service recommendations by previous service provider, along with the inability to access necessary parts caused a critical load loss.
Preliminary Actions

Upon arrival, observed previous service provider logs from the past 6 months. Status was noted as “No Issues.”

Found battery #1 in a failed state, dropping to 4 volts when load tested. All batteries were past due for replacement and were in a deteriorated state.

In the presence of the site contact, critical load was transferred to Static Bypass and then maintenance bypass. Within two minutes, the Maintenance Bypass circuit breaker tripped and dropped the critical loads.

Resolution

Maintenance Bypass circuit breaker requires immediate replacement. Customer must weigh the cost of a battery replacement in a 20-year-old unit or a full unit replacement with 50% less capacity.

By returning to Nationwide Power, the customer had renewed confidence that their Eaton 9315 UPS could be adequately serviced to extend the EOL. They then opted to replace the maintenance bypass circuit breaker and install new batteries.

Root Cause

In a cost cutting effort, the customer switched to the low-price leader service provider without realizing what they were sacrificing in quality.

The maintenance bypass was not operated/exercised by the former service company during preventive maintenance 6 months prior, and a note should not have been written on the service sticker stating, “No Issues”. Identifying and resolving the key issues noted here would have prevented a critical load loss.

The customer now sees the value of quality over lowest price and is once again a Nationwide Power customer.

Additional Reading The Importance of UPS Preventive Maintenance
Preventive Maintenance or Full Service Contract?

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!

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News Article Lead-acid and lithium batteries have many uses in all parts of the world. Lead-acid or lithium batteries are the backbone to any uninterruptible power supply system, and a lot goes into their proper recycling and disposal. The combination of sulfuric acid...

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Case Study #125 | Preventive Maintenance Only vs Full Service Contract: Schneider Electric

Case Study #125 | Preventive Maintenance Only vs Full Service Contract: Schneider Electric

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 generators, switch gear, and HVAC.

We publish critical power related case studies, highlighting best practices and quality standards. In this case study, we feature a recent scenario where an NP customer moved from a full UPS service contract to a PM only contract in an effort to reduce costs. In the long run, however, the customer’s out-of-pocket expense significantly exceeded the cost to maintain the full UPS service contract.

Product Schneider Electric
Application Technology Data Center
Synopsis Lack of full UPS service contract cost client roughly $29,000 in ongoing, billable repairs.
Preliminary Actions Ongoing repairs over the course of 6 months.

Customer had placed multiple service calls due to concerns with power quality and issues with their UPS equipment. All calls resulted in billable events. In each event, the required repairs were completed and the UPS was returned to a normal mode.

Resolution After approximately $29,000 in out-of-pocket expense, the UPS is back to useful operating condition.

The NP recommendation stands for customer to complete preventive maintenance in a timely fashion and reconsider upgrading to a full UPS service contract where time and materials are covered.

Root Cause In a cost cutting effort, the customer opted for a preventive-maintenance-only contract instead of continuing their full UPS service contract. The difference in price between the two contracts is roughly $1,500. Assuming the customer would not experience any issues with their UPS equipment over the contract period, they could potentially save that $1,500 difference. However, due to the age and condition of the equipment, having no billable incidents was very unlikely.

The customer’s total out-of-pocket expense during the contract period was roughly $29,000. Had the customer invested that $1,500 into the full-service contract, 100% of the out-of-pocket expense ($29,000) would have been covered by Nationwide Power.

In addition, customer was unresponsive in scheduling preventive maintenance service calls to keep the equipment in optimal running condition, further putting their equipment at risk.

Additional Reading The Importance of UPS Preventive Maintenance
Preventive Maintenance or Full Service Contract?

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

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Recycling and Proper Disposing of UPS Batteries – Doing Our Part

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News Article Lead-acid and lithium batteries have many uses in all parts of the world. Lead-acid or lithium batteries are the backbone to any uninterruptible power supply system, and a lot goes into their proper recycling and disposal. The combination of sulfuric acid...

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"Tobias was very professional. I felt comfortable leaving him unattended in our server room while he did the Preventive Maintenance."

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Case Study #124 | Preventive Maintenance Only vs Full Service Contract: Liebert AP367 75kVA

Case Study #124 | Preventive Maintenance Only vs Full Service Contract: Liebert AP367 75kVA

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 generators, switch gear, and HVAC.

On a monthly basis, we publish critical power related case studies, highlighting best practices and quality standards. In this case study, we feature a recent scenario where an NP customer moved from a full UPS service contract to a PM only contract in an effort to reduce costs. Furthermore, the client was unable to follow recommendations made by our Critical Power Professionals™, resulting in critical system failure.

 

Product Liebert AP367 75kVA
Application Transportation Industry
Synopsis During routine maintenance on a Liebert AP367 75kVA UPS, recommendation was for complete battery, fan, and full AC/DC capacitor replacement. Recommendation made due to both age and inspection data. An additional recommendation was made to ensure proper room temperature of 68-72° Fahrenheit.
Preliminary Actions Due to budgetary constraints, client was unable to move forward with NP recommendations.

Within the next 60 days, client requested emergency service for their unit in bypass after dropping the load due to bad batteries. Through 24/7 live phone support, NP walked the client through resetting the UPS and clearing the alarm. Recommendations to replace batteries, fans and capacitors were reinforced. Customer replaced 10 out of 30 bad UPS batteries and planned to budget for the remaining replacement recommendations.
(NOTE: Replacing the full string would have saved $965 in additional freight and labor.)

Less than 30 days later, the client placed another emergency service call. Upon arrival, our Critical Power Professional™ (CPP™) found a burnt phase inductor in their Liebert AP367 75kVA UPS. Recommendation to replace capacitors and fans was again reinforced.

Resolution Regarding both emergency calls to service the Liebert AP367 75kVA UPS, an NP Critical Power Professional™ was dispatched to repair damaged parts. Because initial recommendations were not followed, the UPS equipment experienced additional failures, costing the client approximately $2000 in otherwise unnecessary expense and costly downtime.

The client was not initially able to pay for a full-service maintenance contract due to budget constraints, but in the end the total out of pocket expense for PMO (Preventive Maintenance Only) far exceeded the cost of a full service contract. NP is still recommending the client participate in a full coverage service contract. Should either of the two remaining inductors fail, the client would have no additional out of pocket expense.

Root Cause Recommendations of CPP™ were not followed in a timely manner, causing critical failure.
Additional Reading Case Study #118 | Symmetra PX Good and Bad UPS Batteries

Case Study #107 | Eaton 9315 Rotation Alarm

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

A Holiday Tradition

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News Article As a part of our holiday tradition, the corporate team at Nationwide Power came together to celebrate another successful year. Each year, Nationwide Power selects a local business to support, and this year’s location was at the family-owned Italian...

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The Inaugural Nationwide Power Chili Cook-Off

News Article Nothing says fall like a company chili-cookoff!  Chili, cornbread, pellet smoked bacon-wrapped dogs, and all the right toppings.   We were really hoping to see the Wienermobile show up…  maybe next year. The judges had a pretty challenging task ahead of...

Recycling and Proper Disposing of UPS Batteries – Doing Our Part

Recycling and Proper Disposing of UPS Batteries – Doing Our Part

News Article Lead-acid and lithium batteries have many uses in all parts of the world. Lead-acid or lithium batteries are the backbone to any uninterruptible power supply system, and a lot goes into their proper recycling and disposal. The combination of sulfuric acid...

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"Tobias was very professional. I felt comfortable leaving him unattended in our server room while he did the Preventive Maintenance."

View All - Andy L
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Case Study #123 | Crisis averted: UPS battery install Mitsubishi UPS 2033D 30kVA

Case Study #123 | Crisis averted: UPS battery install Mitsubishi UPS 2033D 30kVA

Case Study

Product Mitsubishi UPS 2033D 30kVA
Application Manufacturing Data Center
Synopsis New client hired Nationwide Power to inspect and maintain their Mitsubishi UPS 2033D-30kVA, which provides critical power for an existing data center.
Preliminary Actions Upon inspection, our Critical Power Professional (CPP™) found a battery cable inside the battery cabinet, where the cable’s lug eyelet had melted due to improper torquing /fastening to the battery insert by the previous service company.

If left in its current condition, the cable could have melted during an outage causing a domino-effect including breaking the string’s integrity, dumping the load, and possible risk of fire.  It could have also caused a ground fault which would have not only dumped the load, but also damaged the UPS.

Resolution Our CPP™ team is equipped with some basic universal repair parts, and in this case a spare battery cable saved the day and was promptly replaced.  By being prepared, our CPP™ left the battery string in a condition that no longer presented a safety threat and left the UPS in proper working condition.

Ongoing and regular UPS battery inspections are recommended by a qualified Critical Power Professional™.

Root Cause The damaged battery cable appears to be the result of negligence from the previous service provider.  This should have been identified and repaired in previous inspections and is a basic element of any quality maintenance inspection.
Additional Reading UPS Battery Preventive Maintenance and Service

UPS Battery Case Study with Poor Maintenance

UPS Batteries with No Preventive Maintenance

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

A Holiday Tradition

A Holiday Tradition

News Article As a part of our holiday tradition, the corporate team at Nationwide Power came together to celebrate another successful year. Each year, Nationwide Power selects a local business to support, and this year’s location was at the family-owned Italian...

The Inaugural Nationwide Power Chili Cook-Off

The Inaugural Nationwide Power Chili Cook-Off

News Article Nothing says fall like a company chili-cookoff!  Chili, cornbread, pellet smoked bacon-wrapped dogs, and all the right toppings.   We were really hoping to see the Wienermobile show up…  maybe next year. The judges had a pretty challenging task ahead of...

Recycling and Proper Disposing of UPS Batteries – Doing Our Part

Recycling and Proper Disposing of UPS Batteries – Doing Our Part

News Article Lead-acid and lithium batteries have many uses in all parts of the world. Lead-acid or lithium batteries are the backbone to any uninterruptible power supply system, and a lot goes into their proper recycling and disposal. The combination of sulfuric acid...

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November 30, 2018

"Tobias was very professional. I felt comfortable leaving him unattended in our server room while he did the Preventive Maintenance."

View All - Andy L
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Case Study #122 | A critical step in preventive maintenance for your uninterruptible power supply

Case Study #122 | A critical step in preventive maintenance for your uninterruptible power supply

Case Study

“We don’t want to take a chance on our UPS system not working.”
“What if there’s an outage while you’re doing your PM?”
“Can’t you just do all your checks with the UPS online?”
“We’re not ready to take that chance while you inspect it.”

All of the above comments and questions have been heard by Nationwide Power’s Critical Power Professionals™ at some point while performing preventive maintenance on uninterruptible power supply systems. This poses a problem that further exposes you – the customer, to potentially unforeseen problems.

Certain issues can be overlooked by not allowing your UPS system to be transferred to or from bypass mode. More thorough inspections can be performed that include vital checks for loose mechanical connections, loose wiring to and from circuit boards, visual checks deep inside the UPS (in areas that would be powered down while in bypass mode), and operational verification of motorized breakers or contactors. By avoiding these necessary examinations, your UPS system may be vulnerable to more costly problems and repairs in the future.

Unfortunately, one of our customers just found themselves in this exact situation. They refused to allow their UPS system to be transferred to bypass mode for many years, citing that “the risk was too high that we might lose power during the preventive maintenance”. Very recently, their UPS system had failed. Upon further inspection, it was noted that the magnetics of the system needed a major cleaning – the kind of cleaning that is safely done with the unit offline, isolated, and panels removed. Because this cleaning did not take place, excessive dirt and debris had built up on these critical components. This caused excessively high operating temperatures and eventually a catastrophic failure. The customer had been notified of the need to allow service while in bypass but opted to forego this due to concerns of an outage during the inspection.

In previous case studies, similarities between vehicle and UPS system maintenance have been used. In this case comparison, it would be as if you were to leave the car running while requiring the auto-mechanic to carefully examine the vehicle before a family road-trip. It is highly doubtful that the inspection would be very thorough.

Our Critical Power Professionals™ recommend annual preventive maintenance, with the UPS system placed offline in bypass mode. Scheduling the inspection during the most “non-critical” time for your company, as well as precise coordination between all departments may be required to mitigate a potential utility outage while in bypass. This planning will go a long way to ensuring that a more detailed inspection is performed on your UPS system under controlled circumstances, as opposed to an unwanted emergency call.

Have questions or ready to schedule your next preventive maintenance? Our Critical Power Professionals ™ are here to help.

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

A Holiday Tradition

A Holiday Tradition

News Article As a part of our holiday tradition, the corporate team at Nationwide Power came together to celebrate another successful year. Each year, Nationwide Power selects a local business to support, and this year’s location was at the family-owned Italian...

The Inaugural Nationwide Power Chili Cook-Off

The Inaugural Nationwide Power Chili Cook-Off

News Article Nothing says fall like a company chili-cookoff!  Chili, cornbread, pellet smoked bacon-wrapped dogs, and all the right toppings.   We were really hoping to see the Wienermobile show up…  maybe next year. The judges had a pretty challenging task ahead of...

Recycling and Proper Disposing of UPS Batteries – Doing Our Part

Recycling and Proper Disposing of UPS Batteries – Doing Our Part

News Article Lead-acid and lithium batteries have many uses in all parts of the world. Lead-acid or lithium batteries are the backbone to any uninterruptible power supply system, and a lot goes into their proper recycling and disposal. The combination of sulfuric acid...

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November 30, 2018

"Tobias was very professional. I felt comfortable leaving him unattended in our server room while he did the Preventive Maintenance."

View All - Andy L
Washington

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Case Study #121 | The Forgotten Link: The Automatic Transfer Switch (ATS)

Case Study #121 | The Forgotten Link: The Automatic Transfer Switch (ATS)

Case Study

Chances are, you have experienced a faulty Automatic Transfer Switch, know someone who has, or will at some point in the future. Here is how the story goes: The facility loses utility power. The generator starts, the uninterruptible power supply goes to UPS battery, and everything is working flawlessly. The generator should sync to the uninterruptible power supply in 10-15 seconds, and since you recently performed a proactive replacement of your previous set of 4-year-old UPS batteries, you should have a solid 15 minutes of buffer time. But for some reason, after a full minute, the uninterruptible power supply is still running on UPS batteries and the generator is not syncing. Your confidence is wavering.

  • Why am I still on battery?
  • The generator is running, right?
  • We did top it off with fuel, right?
  • Is the UPS synched?
  • Is the Generator stable?
  • What in the world is going on?

Wait, Why is the ATS still in Utility mode? You have found the culprit! Now you begin to recall your Nationwide Power service provider asking you to test the automatic transfer switch so they can verify proper operation. You also recall declining their request, cringing at the possibility that the automatic transfer switch won’t work, and that you did not want to take that chance at that moment.

Time remaining on UPS Battery

Now, a real scenario is here, and the automatic transfer switch is not working! It has not been serviced since, well, the facility was first put on-line. Now those mechanical contacts that have not been inspected won’t change state. The automatic transfer switch is even making a weird clattering noise.

Time remaining on UPS Battery

Someone call the Nationwide Power emergency line ASAP! We need this to transfer now!

Time remaining on UPS Battery

I need to let IT and the facility folks know they must start a controlled shutdown of all the equipment, severs, etc. before we have a load loss!

Time remaining on UPS Battery

The UPS beeps: “Shutdown Imminent”.

Time remaining on UPS Battery

Why is the automatic transfer switch not working? Maybe if I manually… too late! Load loss has occurred. The uninterruptible power supply has shutdown on Low DC / DC Under-Voltage.

Conclusion:  All of this could have been avoided.  To your credit, you did have the uninterruptible power supply properly serviced and maintained, up to and including a new UPS battery, fresh capacitors and fans – everything!  You also ensured the generator was properly serviced and checked regularly, up to and including new oil, oil filters, air filters, topped-off with fuel – everything!

If only the automatic transfer switch would receive as much attention in our industry as those other ‘obvious’ pieces of the critical power system, this scenario would not be as common as it is.  Often, performing a real test of the automatic transfer switch does equate to an actual power transfer of the facility, and most facilities do not want to schedule such a test, or take the chance it may not work.  By not testing the automatic transfer switch in a controlled environment, however, you are taking a risk of failure during the worst possible time. Test your automatic transfer switch in a controlled and planned environment to improve the likelihood your automatic transfer switch will work properly in an emergency.

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

A Holiday Tradition

A Holiday Tradition

News Article As a part of our holiday tradition, the corporate team at Nationwide Power came together to celebrate another successful year. Each year, Nationwide Power selects a local business to support, and this year’s location was at the family-owned Italian...

The Inaugural Nationwide Power Chili Cook-Off

The Inaugural Nationwide Power Chili Cook-Off

News Article Nothing says fall like a company chili-cookoff!  Chili, cornbread, pellet smoked bacon-wrapped dogs, and all the right toppings.   We were really hoping to see the Wienermobile show up…  maybe next year. The judges had a pretty challenging task ahead of...

Recycling and Proper Disposing of UPS Batteries – Doing Our Part

Recycling and Proper Disposing of UPS Batteries – Doing Our Part

News Article Lead-acid and lithium batteries have many uses in all parts of the world. Lead-acid or lithium batteries are the backbone to any uninterruptible power supply system, and a lot goes into their proper recycling and disposal. The combination of sulfuric acid...

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November 30, 2018

"Tobias was very professional. I felt comfortable leaving him unattended in our server room while he did the Preventive Maintenance."

View All - Andy L
Washington

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