CHEMICALS & PHARMACEUTICALS
THE POWER TO PREVENT UNPLANNED DOWNTIME
Here, Andrew Keith, division director at load bank
manufacturer Power Prove, explores the role of load bank testing in ensuring reliable backup power
systems that prevent unplanned downtime
ccording to 2022 data from Siemens, an average large plant loses 25 months to unplanned downtime. In chemical manufacturing, where production is highly process-driven and continuous by nature, downtime is more than an inconvenience; it’s a costly disruption that impacts productivity and profitability.
A
‘Unplanned downtime’ refers to unexpected stoppages or operational interruptions caused by equipment failure, power outages or system malfunctions. In industries where continuous operation is essential, downtime disrupts production, delays supply chains and creates safety risks.
Operational interruptions in chemical and pharmaceutical manufacturing can be especially dangerous. Chemical manufacturing relies on exact, uninterrupted chemical processes to maintain precise reactions. A shutdown in production can cause reactions to go off-course, leading to potentially hazardous situations, unsafe working conditions or a reduction in product quality. In pharmaceuticals, downtime can delay critical drug production, delay treatments or affect patient care. The financial and operational consequences are also significant. In the general manufacturing industry, including chemicals and pharmaceuticals, downtime can cost over £200,000 per hour. To mitigate these risks, chemical manufacturers depend on reliable backup power systems, such as generators and uninterruptible power supplies (UPS). These systems are critical for continuous processing industries, where downtime is not an option, working to maintain operations and prevent disruptions during power outages or equipment failures.
Generators typically provide long-term power during extended outages, while uninterrupted power supply (UPS) units offer immediate, short-term power to bridge the gap until generators activate.
However, these systems are only effective if they are in optimal condition. Neglected back up power systems may fail to deliver power during an emergency, causing costly downtime. Issues such as faulty wiring, degraded batteries or insufficient capacity often go unnoticed without regular maintenance, and this is where load bank testing is essential.
Load bank testing ensures backup power systems work in their time of need. The process simulates real-world conditions by applying electrical loads to verify a system’s ability to handle operational demands during outages. This proactive approach identifies issues such
as failing components or inadequate capacity, ensuring that generators and UPS units perform effectively.
Load bank testing is integral to a robust maintenance strategy, allowing issues to be detected and resolved before they lead to system failure. For industries reliant on continuous operations, this minimises the risk of unplanned downtime, safeguarding productivity and revenue.
Load banks can be further customised to offer additional benefits, such as remote monitoring capabilities to allow real-time system performance tracking. This feature helps maintenance teams address emerging issues, reducing the likelihood of unexpected failures and ensuring seamless operations. Power Prove provides versatile load bank solutions tailored to a variety of industries. Portable load banks enable on-site, flexible testing, while containerised systems cater to large-scale operations. These load banks can simulate resistive and reactive loads, offering comprehensive testing for generators and UPS units.
Unplanned downtime doesn’t just interrupt operations — it affects safety, revenue and long-term competitiveness. By integrating load bank testing into maintenance routines, vulnerabilities in backup power systems can be addressed before they escalate, causing disruption. This proactive approach ensures reliability during outages and helps chemical manufacturers maintain seamless operations. For more information on how Power Prove can support your chemical manufacturing operations with tailored load bank solutions, contact a member of the expert team today.
Power Prove
www.powerprove.com
28 NOVEMBER/DECEMBER 2025 | PROCESS & CONTROL
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40
