DSM's Dalry facility operates a fully integrated manufacturing process reliant on continuous control room functionality. The existing parallel UPS infrastructure had reached end of serviceability, presenting an increasing operational and commercial risk.
As DSM's appointed UPS service partner, we were asked to review the installation and develop a compliant replacement strategy that would remove the risk without disrupting operations.
A full system replacement was required without interrupting production.
The Problem
The site was operating on two ageing 60 kVA UPS systems in parallel, supplying the plant control room. The units were no longer serviceable and posed a growing risk to process stability.
Key constraints
- The control room could not be powered down.
- No planned outage window was available.
- Existing units weighed approximately 780 kg each and were installed on the top floor.
- No lift access; equipment had to be manually handled via stairs.
- Industrial environment, yet originally installed with commercial UPS equipment.
- Requirement to introduce isolation transformers into a new N+1 configuration.
- Strict capital budget controls.
The risk profile was clear: any uncontrolled failure would impact production, safety systems and process continuity.
Our Approach
The project required more than a like-for-like swap. It demanded a controlled migration strategy that eliminated operational risk.
We carried out a full engineering review and developed a staged replacement plan that included:
- Retention and integration of the existing external bypass panel.
- Design and installation of a new junction panel arrangement to allow a live system transfer.
- Installation of dual input Riello S3T 60 kVA units in parallel.
- Integration of input isolation transformers located in the MCC switchroom above the UPS space.
- Upgrade of all new input/output cabling to latest requirements.
- Industrialisation of the selected UPS platforms with conformal coating, uprated IP protection and enhanced air filtration to suit site conditions.
- Reuse of viable battery infrastructure with additional blocks added to extend service life and control costs.
The Solution
We installed:
- 2 × 60 kVA Riello S3T (XTD) UPS systems in parallel
- External battery cabinets
- Parallel control kits
- Dual isolation transformers
- MultiCOM monitoring interfaces to integrate with site SCADA
- New electrical cabling
- New junction and distribution integration
The transformers were located directly above the UPS room to optimise space and maintain short cable routes.
A staged commissioning strategy allowed one UPS to carry the full load while the second unit was installed, energised and synchronised. Parallel redundancy was fully proven before final handover.
All works were delivered in-house by our UPS engineers, all of whom are qualified electricians. This ensured the installation was fully tested, signed off and certified in accordance with BS 7671.
Downtime
Zero.
The plant control room remained fully operational throughout the project.
The newly designed junction arrangement allowed the system to be placed on external bypass without requiring a full shutdown. Load transfer was controlled and phased. No interruption to process systems occurred at any stage.
For a live manufacturing environment, this was critical.
The Result
DSM now operates a fully supportable, redundant parallel UPS system engineered specifically for industrial resilience.
Commercial and operational outcomes
- Elimination of risk from obsolete, non-serviceable equipment.
- N+1 redundancy introduced with transformer-backed configuration.
- Improved environmental protection suitable for industrial conditions.
- Alignment with UPS platforms deployed across other DSM assets.
- Modern monitoring and alarm capability integrated.
- Project delivered within agreed capital budget.
- No production loss.
The site now benefits from a resilient, maintainable power platform with clear lifecycle support and improved operational security.
Project Highlights
- Live replacement of parallel 2 × 60 kVA UPS system
- Full plant control room protected throughout works
- Zero downtime delivery
- N+1 parallel redundancy configuration
- Dual isolation transformers integrated
- Existing bypass retained and engineered into new design
- 780 kg legacy units dismantled and manually removed
- Top-floor installation with restricted access
- Industrialised commercial UPS solution
- BS 7671 compliant installation