In industrial settings, power interruptions can lead to costly downtime, equipment failures, and safety hazards. An Uninterruptible Power Supply (UPS) system is a critical safeguard, ensuring continuous operation during power disturbances. This article explores what industrial UPS systems are, why they are important, how they work, and their key applications across various industries.
What is an Industrial UPS?
UPS is a high-tech engineered device with batteries, inverters, cooling systems, rectifiers, static switches, and a control system. They work together for continuous electrical supply in case of a power outage, fluctuation, or any kind of disturbance.
Machine downtime or unexpected interruptions in industries reduce overall efficiency, especially where restarting the equipment and systems is time-consuming. Therefore, automotive plants, pharmaceutical processing, oil and gas supply, mining, and several other critical sectors use industrial UPS systems.
Offline, online, and line interactive UPS systems are the main types. Offline UPS directly supplies from mains and switches to provide backup, but online systems first convert AC to DC and back to AC. Meanwhile, line-interactive UPS are highly responsive systems(~ 2-4 ms) that have an automatic voltage regulator (AVR), and switch to battery backup if power fails.
Why are Industrial UPS Systems Important?
An industrial UPS system is important not only to address the power outage but also to ensure the seamless transition from the main supply to the backup source. It is also reliable in harsh environmental conditions. Other benefits of using industrial UPS systems include:
Preventing Financial Losses
First and foremost, a power outage leads to unexpected downtime and reduces revenue, whether in a manufacturing plant or healthcare facility. According to the US Energy Department, there is a $150 billion yearly loss. Effective use of UPS systems can help avoid these losses and maintain smooth workflow.
Machinery and Equipment Protection
In some industries, power-sensitive equipment and machinery can fail or cause low performance due to repetitive on and off. So, industrial UPS provides clean and stable power to protect them. Otherwise, they are likely to be damaged due to surges, sags, and harmonics.
Safety and Standard Compliance
Oil and gas, chemical processing, healthcare, auto plants, and many other industries pose safety risks during power outages. For instance, pipeline explosions, assembly failures, etc. Therefore, UPS is necessary in such facilities to avoid safety issues and to comply with safety standards.
Industry Automation
Industry 4.0 is on the rise, thus, making uninterrupted power a necessity for automatic systems, robotics, and IoT devices. An industrial UPS can continuously supply the electrical power requirements for these systems.
Energy Efficiency
UPS systems are built with highly efficient technologies. For example, ECO mode and advanced battery management, which optimize energy consumption for factories and facilities. Where power outages are frequent, they can reduce the energy cost by up to 30%
How do Industrial UPS Systems Work?
Industrial UPS systems ensure uninterrupted power by instantly switching to battery backup when the main power supply drops below a set threshold. A rectifier first converts AC power from the grid into DC to charge the batteries. When an outage occurs, a DC-to-AC inverter converts stored DC energy back into AC, delivering a steady and clean power supply to connected equipment.
While the grid remains active, the UPS continuously charges its batteries, ensuring they are ready for the next power disruption. Several key components work together to maintain this seamless transition:
- Batteries: High-capacity, modular, and rechargeable batteries (such as lithium-ion and VRLA) store electrical energy when the primary supply is stable. During outages, they discharge power to keep operations running.
- Rectifier: Converts AC power from the grid into DC so the batteries can charge efficiently.
- DC to AC Inverter: Converts stored DC power back into AC when the UPS takes over during an outage. This ensures a smooth transition and stable voltage output.
- Bypass Switch: A static switch that allows power to flow directly from the grid if the UPS fails or overloads. This guarantees continuous power supply, even if the UPS encounters an issue.
- Control Unit: Continuously monitors input power quality, battery status, load requirements, and system performance to optimize UPS operation.
Applications of UPS in Industry
UPS systems ensure operational continuity, safety, and efficiency across various industrial applications. The following table highlights various industries where UPS is important, why, and examples of applications.
| Industry | Why UPS? | Examples |
| Manufacturing | It ensures the uninterrupted operation of production lines and supports automation. | Auto assembly lines, food processing machines, etc. |
| Oil & Gas | UPS powers control systems, drilling equipment, and safety mechanisms. | Offshore drilling rigs, pipeline monitoring systems, refinery control, etc. |
| Data Centres | A backup power for servers, storage systems, and networking. | Cloud computing servers, IT infrastructure, network hubs. |
| Healthcare | It maintains power for life-saving medical equipment. | MRI machines, ventilators, surgical tools, etc. |
| Chemical Processing | UPS allows for continuous operation of process control systems, safety mechanisms, etc. | Chemical reactors, safety shutdown systems, etc. |
Key Considerations When Selecting an Industrial UPS System
Choosing the right industrial UPS system requires evaluating several factors to ensure compatibility, efficiency, and reliability. Like all UPS systems, the rating of industrial models is on the basis of power capacity in kilowatts (kW) or kilovolt-amperes (kVA). Another crucial factor is voltage rating, which determines whether the UPS can support your system’s input and output voltage levels. Common ratings include 230V, 480V, or higher, depending on the application.
Beyond power and voltage, here are other essential considerations:
Required Power Capacity for Load
Assess your application’s total power requirements by calculating load demand and ensuring the UPS can meet it. Consider power (kW), voltage (V), and current (A) ratings to select a UPS that provides adequate backup without overloading.
Battery Run Time and Scalability
Industrial UPS systems offer battery runtimes ranging from a few minutes to several hours. Determine the maximum backup time your operations require. Also, check if the battery system is modular to allow future expansion if extended runtime becomes necessary.
Environmental Conditions
If the UPS will be installed in harsh environments—such as high temperatures, humidity, dust, or areas with heavy vibrations—choose a model with a rugged enclosure. Look for IP54 or NEMA 4-rated designs that provide adequate protection against environmental hazards.
Cost vs. Efficiency
Higher-efficiency UPS models (95–99%) minimize energy consumption but come with a higher initial investment. Lower-efficiency models may cost less upfront but result in higher long-term electricity expenses. To make an informed decision, evaluate the Total Cost of Ownership (TCO). The TCO includes purchase price, installation, maintenance, and ongoing energy consumption.
By carefully considering these factors, you can select an industrial UPS system that meets your operational needs while ensuring reliability, efficiency, and long-term cost savings.
Getting the Right Industrial UPS Systems with Paradigm Controls
At Paradigm Controls, we work with globally recognized, trusted vendors in delivering the right UPS for your industrial systems. Our team of engineers are ready to take on your project right from inception to commissioning, and even beyond. No matter what your UPS needs may be, we are at your service. Contact us today for more details.
