Case Study

Mission-Critical UPS Replacement for CCTV & IT Systems

A UK train station required replacement of a legacy UPS that had been forced into bypass due to battery failure. The objective was clear: restore reliable power protection for 24/7 public safety and security systems, improve efficiency, and remove downtime during utility disturbances — all within a challenging underground comms environment.

40 kVA Online UPS (3:1)
60 mins Backup at full load
Zero Downtime during works

Project Overview

Client: UK Train station (anonymous)
Location: England
Industry: CCTV & associated IT systems
Objective: Replace a faulty UPS with a modern, efficient and reliable system to ensure continuous power availability and protect critical CCTV & IT infrastructure.

Background & Challenge

The existing CCTV load ran 24/7 and remained fundamental to public safety and station security. The UPS and associated IT rack systems were installed within an underground communications room and operated via a three-phase to single-phase architecture to reduce electrical hazard at 230V.

The station environment experienced power disturbances, voltage fluctuations and short outages which introduced risk to data integrity and SLA performance. The legacy UPS was outdated and inefficient, and had been switched to bypass via its external EMBS after the batteries failed due to historic maintenance inaction — leaving critical loads exposed.

Logistics constraint: The systems were located multiple floors below ground level with stair-only access, single-door restrictions, limited loading space, no lift access, and the operational constraints of an ageing station.

Solution Delivered

UPS: 40 kVA 3:1 online double-conversion UPS providing zero transfer time.
Batteries: Dual-string VRLA for redundancy and resilience.
Autonomy: 60 minutes at full load; engineered with future load growth in mind.
Safety: Enclosed, lockable battery cabinets; additional battery protection added to meet 2025 standards.
Monitoring: SNMP-based remote monitoring for visibility and proactive response.
Removal: Existing equipment removed and disposed of in line with HASWA & WEEE requirements.

Engineering & Logistics Planning

Detailed site survey and load review, including discussions around engineered efficiency (right-sizing battery capacity and reducing wasted headroom).
Basement route planned as a controlled environment; mechanical aids selected for safe movement across multiple stair flights.
Access, PTW, and sequencing coordinated directly with site teams to protect operations and public areas.
Standards-compliant design incorporating new transition and protection equipment and clear labelling.

Installation Methodology

Site preparation: Transport route boarded and controlled; floor load-bearing verified; UPS room environmental checks completed; routing/containment planned; access and PTW coordinated.
Placement: UPS modules installed on a solid base; lockable battery cabinets positioned with safe clearances; new battery circuit breaker and transition panel mounted and labelled.
Cabling: Existing input/output cables utilised; additional DC cabling installed between UPS and battery banks; BS 7671 testing completed.
Testing & commissioning: NICEIC certification completed; pre-install inspection; functional no-load and load testing; battery autonomy test; mains-failure simulation.

Results & Benefits

Restored power availability for critical CCTV and IT loads supporting public safety and station security.
Zero downtime during installation and commissioning.
Improved energy efficiency compared to the legacy UPS system.
Improved SLA compliance and stakeholder confidence through resilient power protection and monitoring.

Lessons Learned

Correct load assessment and early site planning are critical for appropriate UPS sizing and future-proofing.
Clear coordination with facilities and IT teams improves installation efficiency and reduces operational risk.
Logistics-led site surveys reduce timeline risk and prevent unexpected access constraints during delivery/removal.
Independent delivery supports coordination with existing equipment, maintenance and future parts strategy.

Conclusion

The new 40 kVA online UPS and redundant VRLA battery system restored full confidence in station safety and security operations. This project demonstrates how disciplined planning, engineered right-sizing, and standards-compliant delivery enable resilient power protection for mission-critical infrastructure — even in constrained, high-risk operational environments.