POWER
PREVENTING UNPLANNED DOWNTIME
‘U 20
According to 2022 data from Siemens, an average large plant loses 25 months to unplanned downtime. In industries where continuous processing is critical — such as chemical manufacturing, oil and gas and pharmaceuticals — downtime is more than an inconvenience; it is a costly disruption that impacts productivity and profitability. Here, Andrew Keith, division director at load bank manufacturer Power Prove, explores the role of load bank testing in backup power systems to prevent unplanned downtime.
nplanned 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.
For example, the oil and gas industry operates
continually to meet global energy demands. Unplanned downtime in this sector doesn’t just halt extraction or refining processes but disrupts the entire supply chain. Since energy production supports many industries, disruptions can affect everything from manufacturing and transportation to utilities and healthcare, amplifying the impact of even a brief operational stoppage. Operational interruptions in chemical and pharmaceutical manufacturing have similarly
amplified impacts by creating safety risks. 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. It is estimated that just three and a half days of unplanned downtime in the oil and gas sector can result in losses exceeding £4.1 million ($5M USD). Furthermore, in the general manufacturing industry, including chemical and pharmaceutical production, downtime can cost over £200,000 ($260,000) per hour.
PREVENTING DOWNTIME
To mitigate these risks, businesses invest in backup power systems, such as generators and uninterruptible power supplies (UPS). These systems are critical for industries where downtime is not an option, working to maintain operations and prevent disruptions during
Spring 2025 UKManufacturing
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