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BGI Awassa and Zebidar Brewery - Audit

UPS Audit Report

Abdulrahman Aboubaker
 In response to BGI's request to audit the uninterruptible power supplies at Castle Winery Hawassa and
Zebidar Factory, we embarked on an exciting journey to the factory. Our mission was to conduct a
comprehensive range of on-site tests and surveys to analyze any power-related issues that may have occurred.
We meticulously inspected the UPSs and evaluated the status of their battery systems. Utilizing advanced
thermal imaging technology, we identified potential "hot spots" caused by battery dry outs. Additionally, we
gathered valuable device data, including power usage metrics. After a thorough examination, we are delighted
to present our insightful findings, observations, and actionable recommendations to ensure the utmost power
protection for the factory's mission-critical operations.
Objective:
Ensuring uninterrupted power supply and proactive maintenance are vital services that form an integral part of a
comprehensive maintenance plan. These services aim to deliver a meticulous inspection and servicing of
essential equipment, enabling the identification and resolution of any underlying issues. By embracing this
approach, businesses can guarantee seamless operations and safeguard their critical infrastructure. The
management of this process holds immense importance as it directly impacts the security, efficiency, and overall
functioning of the organization.

Here below there are some anticipated outcomes that highlight the value of implementing an effective
maintenance plan:

 Minimize downtime: Through regular monitoring, inspection, and preventative maintenance of

industrial power supply to mission-critical infrastructure, downtime can be significantly reduced. By
ensuring peak performance through comprehensive inspections, testing, and cleaning performed by
trained technicians, potential wear and failures can be identified and resolved before they disrupt
operations.

 Enhance performance: Standard maintenance practices include regular cleaning to remove dust and
debris, as well as checks for faulty contacts and connections. These small yet essential maintenance
tasks contribute to improved performance. By addressing any non-functioning parts or components
due to age or wear, the strain on the rest of the system is reduced, leading to optimized performance
and prolonged lifespan.

 Boost productivity: By implementing a preventative maintenance plan, businesses can remove the
worry and distractions associated with lifespan management. Staff can focus on their core
responsibilities, as timely maintenance reports provide valuable insights for repair and replacement
decisions, preventing unexpected power stoppages and enabling informed actions.

 Streamline operations: Effective preventative maintenance requires a detailed inventory of each

component within the UPS infrastructure, providing critical information on operational status,
deficiencies, and service history. This precise understanding aids in planning future repairs, services,
and replacement parts. A well-executed preventative maintenance strategy is a cost-effective
decision that ensures the ongoing health of critical equipment and the overall business.

 Save costs: Frequent check-ups and inspections on UPS systems prove to be more economical than
dealing with sudden failures. Moreover, a comprehensive maintenance approach can extend the
working life of UPS components by 25 to 50 percent beyond the manufacturer's specified lifespan,
resulting in fewer replacements and substantial cost savings.

By embracing a proactive maintenance approach, businesses can achieve operational resilience, maximize
performance, and realize significant cost savings.

Methodology:
Site Visit – Data and Information Collected.
Assessment
For locations with a UPS already installed, based on the site survey, we observed the following findings and
provision of recommend/provide an essential advice on optimizing the system efficiency as follow. Listed
below are main inspections activities done with the UPSs at Castle Winery, Hawassa and Zebidar factory.

1. Visual Assessment Objective

a. Assessment Parameters
UPS inspection/audit incorporates a visual test of the UPS, plus a physical check of all electrical connections
using thermal imaging technology that can pick up more faults than the human eye and touch. Checking for
circuit breakers, contactors, fuses, cabling, transformers, printed circuit boards, capacitors, fans and
communications slots. Batteries are inspected for signs of damage, corrosion or leaks, with all terminal
connections checked to ensure they are at the correct torque setting. several mechanical tests on the
functionality of the UPS, recording the system’s operating state and vital electrical measurements.
In addition, a visit includes a download and full review of the UPS performance history logs, as well
as ensuring the unit has the latest firmware installed.

b. Assessment based on Visual Inspection

As a regular visual inspection is the most important step in UPS maintenance, we have performed some basic
visual inspections to check the appearance of the device and seen the below points:

 checked if there is any accumulation of dust or dirt that can block the ventilation holes of the device and
cause it to overheat. Subsequent to inspections, we have seen that all the UPS units are neat and clean.
 Besides, the inspection battery evaluation has been done as well. Have checked if there are dead battery
not providing enough backup time, are signs of corrosion, leakage or swelling, as these signs indicate
that the battery needs to be replaced. And found that four UPS batteries, one at castle winery one from
ZABIDAR and the other two from Hawassa Factory mentioned below are completed their cycles and
need to be replaced.
I. Location: Hawassa Factory – Administration Building
UPS Brand: APC
UPS Capacity: 10kva
Battery Capacity: 7.2Ah/12V, Qty: 128pcs
Model N°: G35TF10KB4H
Serial N°: PS0949141164
II. Location: Castle Winery
UPS Brand: HP
UPS Capacity: 3.3kva
Battery Capacity: 5Ah/12V, Qty: 16pcs
Model N°: R/T30001
Part N°: 637301-003
Serial No: 3083291786
III. Location: Hawassa Factory
UPS Brand: APC
UPS Capacity: 10kva
Battery Capacity: 7.2Ah/12V, Qty: 64pcs
Model N°: R/T30001MGE Galaxy 3500
Serial No: G35TF10KB2H
IV. Location: ZEBIDAR - in the MCC Room
UPS brand: Schneider Galaxy 300
UPS capacity: 40KVA
Serial No: G3HT40KHB1
 Number of batteries: 90
Battery type: HRC1234W
Battery capacity: 12V/7ah, QTY: 90
c. Checking for UPS room and system temperatures:
Temperature check using a thermal scanning, which uses a non-contact infrared thermometer to measure the
surface temperature of the chassis have been done in order to make sure that the temperature around the UPS is
within the manufacturer's operating specifications. All the UPS rooms have been equipped with air conditioning
unit and working with the specified range excepts one UPS unit located at main power distribution center that
need to be equipped with AC or relocated to a well-ventilated place.

In fact, comprehensive visual inspections also include internal component inspections such as checking whether
the AC input & output capacitors and DC filter capacitors are clean to make sure there are no signs of cracking
or expansion. However, one may get exposed to dangerous currents when doing such inspections. Therefore,
such inspections can only be performed during complete power outage or scheduled downtime in which
production not be interrupted.

d. Conclusions drawn on Visual inspection

Under manufacturer recommended conditions, the forecasted lifespan of a standard UPS battery is just 3 to 5
years. Maintenance free UPS batteries only means that they do not require any replacement fluid – therefore,
understanding how to properly care for batteries is always essential.

Recommendations & Observations:

To ensure the effective operation of an uninterruptible power system (UPS) and protect critical equipment from
power-supply fluctuations and distortions, it is important to incorporate regular testing and maintenance into the
facility's UPS maintenance schedule. In addition to the recommendations mentioned earlier, here are some
common UPS maintenance tips to consider:

1. Battery Replacement: Keep in mind that the actual lifespan of a UPS battery is often shorter than the
manufacturer's stated lifespan. It is advisable to replace batteries in a timely manner to avoid potential failures
during power outages.

2. Avoid Over-Discharging: Overly discharging a battery can have a detrimental impact on its ability to
recharge, leading to permanent damage. It is crucial to prevent excessive discharge and ensure that batteries are
recharged within 24-48 hours to maintain their service life.

3. Separate Battery Rack: Maintain and charge extra batteries on a separate rack. This allows for easy
replacement of problematic batteries without disrupting the overall UPS operation.

4. Use Recommended Batteries: When purchasing a new UPS system, always use the battery recommended by
the UPS manufacturer. Using the specified battery ensures compatibility and minimizes the risk of after-sales
UPS problems caused by improper battery selection.

5. Handle Batteries with Care: Be cautious when dealing with batteries and avoid using chemicals or solvents in
their vicinity. It is essential to use proper protective gear, such as gloves and goggles, when handling batteries to
ensure personal safety.

By following these UPS maintenance tips in addition to incorporating regular testing and maintenance into the
facility's schedule, maintenance and engineering managers can ensure the UPS remains in optimal operating
condition, safeguard critical systems, and enable reliable operation as designed.
If a generator is part of the factory emergency-power system and feeds the UPS, it also will need to be tested
monthly or quarterly. A UPS typically is sized to carry the load for a short period of time. Longer outages
require backup-power generation to maintain critical services.

Offers:
UPS battery replacement for: -
1. Location: Hawassa Factory – Administration Building
UPS Brand: APC
UPS Capacity: 10kva
Battery Capacity: 7.2Ah/12V, Qty: 128pcs
Model N°: G35TF10KB4H
Serial N°: PS0949141164
2. Location: Castle Winery
UPS Brand: HP
UPS Capacity: 3.3kva
Battery Capacity: 5Ah/12V, Qty: 16pcs
Model N°: R/T30001
Part N°: 637301-003
Serial No: 3083291786
3. Location: Hawassa Factory
UPS Brand: APC
UPS Capacity: 10kva
Battery Capacity: 7.2Ah/12V, Qty: 64pcs
Model N°: R/T30001MGE Galaxy 3500
Serial No: G35TF10KB2H
4. Location: ZEBIDAR - in the MCC Room
UPS brand: Schneider Galaxy 300
UPS capacity: 40KVA
Serial No: G3HT40KHB1
Number of batteries: 90
Battery type: HRC1234W
Battery capacity: 12V/7ah, QTY: 90

New offer
1. 25kw UPS for Hawassa factory Mash Tun Agitator
2. 6KVA UPS for ZABIDAR - BREW HOUSE SERVER- BREW HOUSE SERVER &server control room