In the high-stakes world of semiconductor manufacturing, power reliability isn’t just important – it’s mission-critical. A single power disturbance can halt precision processes, risking millions in losses and production delays. Galaxy UPS solutions from Schneider Electric are engineered to deliver unmatched reliability, efficiency, and scalability, ensuring fabs stay powered, productive, and protected.
The $270m US dollars that Samsung lost when it shut down a semiconductor plant in Austin, Texas during storms in 2021 underlines just how essential reliable power is to the industry. Semiconductor fabs require huge quantities of electricity, with some consuming 200 MW– much larger than factories in other sectors. What’s more, the silicon chips being produced are highly sophisticated components, built using a range of delicate procedures that last for months. Any slight disturbance to power quality, such as a sag or swell in voltage, can mean the whole process has to be abandoned. That’s why even disruptions that last for seconds can lead to millions of dollars of losses.
The importance of stable power means that uninterruptible power supply (UPS) systems are absolutely critical to semiconductor manufacturing. These smooth out fluctuations in power quality, converting AC electricity from the grid into DC, then back to AC as conditioned power. Typically, about a quarter (23% to 25%) of a plant’s total power use is backed up by a UPS in this way – including for crucial functions such as lithography, diffusion, wet processes and R&D. Given the amount of power that facilities use, UPSs are also an important factor influencing energy efficiency. A conversion rate of 95% may sound high, for instance, but a 5% loss means a lot of electricity going to waste every minute.
Why static UPSs outperform rotary systems
While UPSs are critical for semiconductor fabs, they’re not all the same – and they can be incorporated into power systems in many different ways. So to ensure reliability, support effective maintenance and minimise waste, it’s important for those designing and operating facilities to consider their options carefully.
Traditionally, UPSs used rotary technology, which relies on mechanical parts and diesel engines. But in recent decades, static UPS systems – which function through electronic components – have become increasingly favoured, particularly in sectors where uptime is critical. Static technology (such as that used in Schneider Electric’s Galaxy UPS models) offers higher efficiency, faster response times, and lower maintenance requirements – as well as less noise. The batteries in static models also help boost sustainability by reducing reliance on diesel generators. They can run for up to 15 minutes before these are required, compared to the 10 to 30-second timeframe with rotary systems (which leads to frequent generator starts and stops).
The type of UPS also has implications for power system architecture. Rotary UPSs require a centralized approach that covers critical as well as non-critical loads. Meanwhile, static devices support decentralized designs where UPSs provide support only for critical functions. Because decentralized architectures enable a more targeted use of UPS capacity, they may support more efficient capital and operational spending (such as through a ‘pay as you grow’ model).
These factors help explain why the majority of semiconductor fabs now use static UPSs. But the technology isn’t yet universal throughout the sector, and deciding whether to adopt it will involve a range of important considerations. These include decisions about related technology – such as batteries, which are essential to the functioning of static UPSs. Compared to traditional valve-regulated lead acid (VRLA) batteries, newer lithium-ion technology offers advantages including longer lifespans, faster charging, a smaller physical footprint and higher power density.
Redundancy that protects your precision
In addition, it’s crucial to think about the reliability of the UPS system itself. To provide additional power availability as well as reassurance about critical operations, semiconductor fabs can build redundancy into their UPS architectures. One way to do this is to connect a device to the system in parallel to the existing ones, to share the load evenly. This means that if a UPS is out of service, there’s enough capacity for the power flow through others alongside it to avoid a disruption. If one extra device is added, this approach is known as an N+1 parallel system. A parallel approach allows for maintenance without disrupting the supply and can be easily scaled up in line with requirements.
Another possible solution is to create internal redundancy within each UPS by adding power modules to the devices themselves. Or engineers can address the challenge through isolated redundancy. Here, a secondary UPS provides backup for a number of other devices, taking over if required. In the right circumstances, this can be a cost-effective and flexible model.
The terminology of parallel, internal, or isolation configurations can make it seem like there are a lot of different choices – perhaps even too many. But each option provides valuable pathways to achieving ‘N+1 redundancy’. All of these configurations involve unique advantages and technical considerations – empowering semiconductor fabs to tailor solutions to their specific goals. By carefully evaluating factors like risk, cost, and existing infrastructure, fabs can make informed decisions that align with their strategic priorities and drive operational excellence.
Galaxy UPS: Designed for semiconductor excellence by boosting efficiency and reliability
The issues discussed above highlight the range of important choices facing semiconductor fabs managers. As they seek to build electrical systems with the robustness and flexibility they need, many businesses are turning to modular, scalable UPS options such as Schneider Electric’s Galaxy series. These devices adapt wellto different system configurations and loads. Power modules can be added incrementally, for instance, to increase capacity or boost internal redundancy. The live swap capability means engineers can add, replace or remove modules without interrupting the flow of electricity, minimizing safety risks and downtime. The compact design helps optimize physical footprints. And high energy efficiency – up to 97.5% in double conversion mode and up to 99% in eConversion mode – contributes to lower operating costs and enhanced sustainability, leading to savings up to three times the cost of a device within a decade.
Smarter power management with EcoStruxure
Advanced UPS technology is most effective when combined with digital services that enable the devices to be managed as part of wider systems. Schneider Electric’s EcoStruxure Power supports integration with power distribution networks, while EcoStruxure IT does the same with IT networks.
Galaxy UPSs can be paired with EcoStruxure Power for real-time monitoring, predictive analytics, and proactive maintenance. IoT-connected sensors and AI-powered dashboards give facility managers the insights they need to prevent issues before they occur – boosting uptime, safety, and operational efficiency.
Make informed decisions with Schneider Electric
With so many factors to consider, deciding on the best UPS models and configurations to deploy in each situation can feel like a daunting prospect. To help guide your thinking, Schneider Electric’s interactive TradeOff Tools provide science-based insights to help businesses explore how different decisions about their UPS fleet could impact metrics including carbon emissions, efficiency and energy use. With our deep industry expertise and decades of experience working with customers to find effective solutions, we’re always happy to discuss questions like these. So if you’d like to learn more about how to build and manage reliable UPS architectures, please get in touch at the links below.
Find out more about how you can support reliable, efficient semiconductor manufacturing with Schneider Electric’s Galaxy UPS technology.
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