The MCS Predictive Failure Analysis

A complimentary MCS Predictive Failure Analysis reviews your facility’s existing critical power systems to determine risks that could lead to unscheduled outages or worse. The idea is not only to plan for, but to avoid, your worst business nightmare – a prolonged unscheduled power outage, and/or catastrpophic equipment failure that leads to explosion and fire, with potential loss of life and building damage.

A Predictive Failure Analysis by MCS Includes:

  • An on-site walk through of your facility’s existing uninterruptible power supply system and related critical equipment, including:
    • Uninterruptible Power Supply (UPS)
    • Battery Systems
    • Power Distribution Units (PDU)
    • DC Power Systems
    • Automatic Static Transfer Switches (ASTS)
    • Automatic Transfer Switches (ATS)
    • Generators
    • Switch Gear
    • Individual Power Circuits
    • Branch Distribution Power Circuits
  • A prioritization of risk into three levels: high, medium and low
  • A detailed risk assessment for each level, if appropriate
  • Recommendations for mitigating risks noted at each priority level
  • A written Predictive Failure Analysis report for your facility


An Example From An MCS Predictive Failure Analysis:

A facility requested an analysis of its existing early 1980s-era UPS system, which uses flooded wet cell batteries. The unit is operating at 30% capacity leading to low efficiency of only 66%.

The first issue was a lack of preventive maintenance, which alone could lead to equipment failure and an outage. many components of the system were in use far beyond recommended operational life, which in the case of DC capacitors could lead to explosion.

Deteriorating parts in flooded cell bateries made them unreliable as well as posing a serious danger, including fire and sulfur gas leak. Because of the age of the UPS, replacement parts were no longer available. Newer equipment operates at a different voltage, making it incompatible with the existing system. A major failure of the UPS would require complete replacement, while the facility went without protected back-up power.

For low-risk areas, MCS recommended a schedule of routine maintenance. To address the high-risks associated with the outdated and deteriorating equipment, MCS recommended replacement with a new UPS supported by an automatic transfer switch and diesel standby generator. The new unit would operate at 97% efficiency.

The annualized cost savings is estimated at more than $40,000 annually, not including utility savings resulting from lessened UPS cooling requirements, and reduced maintenance costs.