Electrical systems will present potential problems during winter that are not present during other seasons. Winter brings cold and wet weather and shorter days, and when you are busy during peak times or when the warehouse is operating at full capacity, the last thing you need is for your electrical systems to fail.
Finishing this before winter problems materialize makes sense. Being proactive with some inspections and maintenance during October or November can save you expensive service calls during winter when everything seems to fail.
Inspection of Heating Systems
Even though the heat source for many commercial heating systems is an oil or gas, many of the systems are electrically powered. Boilers need electrical power for their pumps, controls, and ignition systems. Air source heat pumps are completely powered electrically. Warehouse heaters use a lot of power when they’re running all day.
The problem is that heating systems sit for the calender summer and then are expected to work flawlessly when everybody wants heat to come from the heating systems. Back in March when heating controls were functioning, the systems may have developed some faults over the summer months. Thermostats that are used to calibrate the temperatures can drift, and contactors that turn the heating on and off can become stuck or corroded.
Make sure you run a complete set of tests on the heating system well before you actually need it. You particularly want to avoid waiting until the first really cold morning when staff are complaining about freezing offices If you have multiple zones or time controls make sure you test those as well.
Make sure you have some sort of record of the electrical connections to heating equipment. Loose terminals cause problems. A connection that is slightly loose may work fine for months but will certainly cause problems when the load increases. Look for symptoms of overheating like discolored terminals, burnt smells, or melted insulation around the connections.
If the heating equipment is a three-phase heater that you have in a warehouse or workshop, make sure you check this carefully as well. If you lose one phase the heater may lose the ability to work properly and may actually damage itself trying to work. If the heater has gotten into a state of tripping out make sure that you investigate this before winter. You don’t want to be in a situation where the staff are working in a really cold environment.
Because of the nature of a commercial building’s functions, thermostats can sometimes get removed, painted, or obstructed. Make sure the thermostats in the building are located in the appropriate spots, and working properly. Sometimes a thermostat may seem to be located correctly, but there are filling cabinets in the way, or the thermostat improperly calibrated due to direct sunlight coming from a window.
Light Must be Provided for the Outdoors and for the Shorter Days
There are shorter amounts of daylight in the winter, however, there still are outdoor areas that need to be lit for safety from the darkness. In the winter, hold outdoor spaces need to be illuminated from 4pm. Make sure to check that external lights are working before winter to make sure they function in the dark. It’s much more pleasant to be working in the dark in the winter than working in the dark, cold, and possibly in icy weather.
Photocells that automatically turn lights on don’t really work sometimes. It’s quick and easy to check them by covering the sensor to simulate darkness. If the lights don’t turn on, the photocell needs a swap. Some units get covered in dirt or cobwebs which affects how they work.
Most businesses today install LED lights, but older models still in use (sodium or metal halide) take a while to warm up to full brightness. Consider how effective and safe your current lights are. If someone is trying to find their vehicle in a 5-minute parking lot, but it takes the lights 15 minutes to warm up and reach full brightness, that is not effective lighting.
Most people assume emergency exit lighting works until it needs to be used. In most verticals, regulations require you to disable the lights, and use the test buttons to confirm they illuminate the space. Emergency exit signs have maintenance free batteries, but if they are older than 4 years, they are probably not working.
Weather Protection for External Equipment
Weather and electronics do not mix, but when it comes to crafted external installations, you have to make the most out of it. Make sure that all installations that are supposed to be weatherproof are.
Look for signs of corrosion and box moisture. Storm water ingress in external box installations can be a big problem if not addressed. Rust and moisture issues are signs that the seals around the enclosures are failing. If a seal looks fine, it probably is.
Automatic doors and electric gates are especially at risk because they are located at the sides of a structure and have moving mechanisms. Moisture seeps into the motors and control and junction boxes that are installed in gate posts. Make sure that the cable glands are closed tightly and that drain holes in the equipment housings are cleared. Some gate motors have breather vents that should also be kept clear, but they should not be exposed to rain.
Outdoor sockets that are used for maintenance, window cleaning, or temporary equipment should also be examined. The covers on these are often left open or closed poorly. Moisture left in an outdoor socket can trip your RCD’s and leave room for dangerous faults.
Not to mention that cable runs on the outer walls are also exposed to UV degradation and room for physical damage. Make sure that all conduit and trunking are complete without gaps, damage, or loose covers that would allow water to enter.
Planning for Emergencies when Power Disconnects Occur
Winters present the highest risks for power outages. Ballistic storms can drop power lines. Heavy load equipment failures are common. Network issues also become problematic when the weather is bad.
Make sure you know where your main isolators and distribution boards are located, and ensure your staff know these locations too. In the event of an emergency, you will need to be able to isolate sections of the power supply rather than shutting the power off for the entire building. Clearly labeled breakers will ensure you know which breaker controls which power source in an emergency.
Emergency lighting is critical, but consider what other equipment will no longer function in the event of a power outage. Barriers and electric gates will no longer function, which could trap vehicles or restrict access. Loading bay doors become inoperable. Access control systems may fail without warning. Prepare a manual override and ensure staff are trained on it’s use.
Think also about backup power for critical systems. Full generator backup is costly, but it’s worth considering a UPS for essential systems like access control, server rooms, or some specialized production equipment. A few minutes of battery backup, even, is valuable to allow proper shutdown of a system.
Store contact information for your electrical contractor in a way that doesn’t rely on computers. When the power is out, you shouldn’t have to search through your emails on your dying laptop to find the number you need to call for assistance.
Problems during winter and the following months are somewhat predictable. Spending a day or two in the Fall should reduce or almost eliminate the expensive emergency call outs during the cold months.