Findings from Uptime Institute’s 2022 Global Datacentre Survey highlight the fact that downtime in the data centre industry is becoming increasingly expensive, with the main cause identified as power failures. 

The report focuses on responses from more than 800 owners and operators of data centres, including those responsible for managing infrastructure at the world’s largest IT organisations. While sustainability, efficiency gains, staff shortages and supply chain issues also dominate the report, the issue of power resiliency remains dominant. 

$1m+ failures increasingly common

Data indicates that the costs of outages are on the increase. 

A quarter of respondents reported that their most recent outage cost more than $1 million in both direct and indirect costs. This is a significant increase from 2021, reflecting a continuing upward trend over the last five years. 

The report states, “Uptime’s 2022 annual survey findings are remarkably consistent with previous years. They show that on-site power problems remain the single biggest cause of significant site outages by a large margin.”

Backup power failure identified as the number one issue 

Further analysis in related research from the Uptime Institute identifies the biggest causes of power-related outages to be uninterruptible power supply failures, followed by transfer switch (generator / grid) and generator failures. 

Paul Brickman, Commercial Director at Crestchic Loadbanks, commented: “Although the data shows a trend towards improved outage rates, the frequency is still much too high and, with costs also on the rise, the consequences are getting worse. Data centre operators are well aware of the impact of a power outage and have measures in place to mitigate these risks. However, with backup power failures identified as the primary cause of power outages, as well as external issues around grid reliability, energy shortfalls, and the transition to more sustainable power sources, it has never been more important that operators test their backup power systems.”

Using a load bank to commission or regularly test the back-up power system not only tests the prime movers and the batteries (UPS), but ensures all other components such as the alternator and crucially the transfer switches are tested too. A load bank test not only proves that the UPS / generators will start, operate and run efficiently in the case of a power outage, but also that the sets can be safely turned off with no interruptions when mains power is restored. 

Paul concludes, “In a data centre environment, the business case for using a load bank is clear cut – not testing is an extremely costly risk to take.”

For more information on how load banks can offer increased power reliability in a data centre environment, please get in touch via our contact page.

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While government sources have stressed that this scenario is highly unlikely to materialise, Bloomberg has reported that the power shortfall could total about a sixth of peak demand, even if emergency plans to fire up retiring coal power plants are enacted. Paul Brickman, Commercial Director at Crestchic Loadbanks, highlights the importance of ensuring that backup power systems are ready for action, should the worst-case scenario arise.

What’s at the root of the power cuts? 

Since the Russian invasion of Ukraine, European nations have been in a rush for gas, with volumes in storage reservoirs running well below historic levels. This, combined with a reduction in electricity imports from Norway and France and low winter temperatures, has resulted in speculation that the government may be forced to enact emergency measures in order to conserve gas. If supplies to gas-fired power stations are halted, businesses and homes are likely to be hit by power cuts.

When power is critical, is confidence enough?

A Department for Business, Energy and Industrial Strategy spokesperson is quoted as saying that “Households, businesses and industry can be confident they will get the electricity and gas they need.” However, while confidence is nice, it simply isn’t enough. The only way for businesses to guarantee that they have the power required to remain operational is to have backup power in place that has been maintained and tested.

With power resilience a hot-topic, and businesses driven by increasingly demanding customer expectations, most bigger businesses have power resilience strategies in place. This often comes in the form of a generator – a hefty bit of kit which sits in a darkened room or corner and offers a temporary backup power source in the event of an outage. While having the equipment in place is certainly the first step to any power resilience strategy, the plan can fall down if the generator isn’t tested and maintained appropriately. The ideal way to do this is to use a load bank.

What should load bank/generator testing look like?

It is important that operators implement a testing regime that validates the reliability and performance of backup power under the types of loads found in real operational conditions. The only way to do this is to use a load bank to simulate the operational load that a generator would encounter. This process “tests” the generator – including fuel, exhaust and cooling systems, and alternator insulation resistance – to ensure that it is fit for purpose in the event that it is called upon.

Ideally, all generators should at very least be tested a minimum of once a year for real-world emergency conditions using a resistive-reactive 0.8pf load bank. If multiple gensets are run in parallel, they should be run in a synchronised state, ideally for 8 hours but for a minimum of 3. Where a resistive-only load bank is used (1.0pf), testing should be increased to 2-4 times per year at 3 hours per test minimum.

A robust testing regime ensures that generators are effectively tested and system issues can be uncovered in a safe, controlled manner without the cost of major failure or unplanned downtime.

The risk of not testing back up power systems

For most businesses – and indeed society as a whole – power is critical. It keeps our hospitals operational, our manufacturing industry productive and our food supplies stocked. It is also critical to our transport infrastructure, with the rail network in particular one of the largest commercial users of power in the UK. From the largest hyper-scale data centres, to the smallest sole-trader operator – power keeps people and industry moving.

The reality is, in many instances, that those in charge of maintaining backup power have no regular testing schedule. By not testing the system adequately, the generator is put at risk of failure – with the fuel, exhaust and cooling system untested, along with the potential for embedded moisture, putting the system in the very high-risk category.

Given that the cost of a load bank is typically only a fraction of the cost of the systems which it supports – and with businesses under a very real threat of power outages – now is the time to implement regular and rigorous testing. To find out more about how to incorporate backup power testing into your business continuity plan, speak to our team here: sales@crestchic.com or use our contact form here: Contact Form

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The event was attended by more than 100 customers, suppliers, and senior staff, who were invited to the opening ceremony, a tour of the Crestchic site, and lunch. A ceremonial ribbon-cutting and speech were carried out by former BBC journalist and Times Radio Presenter John Pienaar, and a plaque unveiled by Councillor Philip Hudson, the Mayor of East Staffordshire.

Despite the economic pressures of the pandemic and global political events, Crestchic has seen strong growth in demand for its products. Data centre and energy transition markets are growing rapidly, and demand continues from well-established, traditional sectors, such as critical infrastructure, marine engineering, and extractive industries. The new factory will allow the company to increase manufacturing capacity to respond to the growing demand for sales and rental of load testing equipment in the UK and beyond.

Peter Harris, Executive Chairman at Crestchic, commented, “As well as responding to customer demand, the investment in both our new and existing factories is part of our commitment to continuous improvement. Our vision is to be world-class manufacturers in every sense of the word – in our commitment to innovation, design excellence, product build quality, meeting delivery times and exceeding customer expectations. We’re continuing to invest in our people and technology – bringing on board new expertise and investing in R&D to ensure that Crestchic continues to lead the market.”

Paul Brickman, Commercial Director added, “Power resilience is becoming increasingly important across all industries. Load testing is no longer a nice-to-have, it’s an absolute necessity for any modern business that needs power to operate effectively. We’re undoubtedly seeing this reflected in our order books. The factory will allow us to fulfil demand across all of our existing locations, as well as our new depots in Antwerp and Texas. As we ramp up our production, we hope to open more depots to serve our rapidly growing global market.”

The senior team also thanked everyone who had been involved in the delivery of the new building, including architects and structural engineers AJS Structural Design; project manager/quantity surveyor Amsons-Barlow; main contractors BFG; electrical contractors SCI; planning advisor JMI Planning and everyone at Crestchic who had played a part. Everyone who works across the three Crestchic manufacturing and office sites was also invited to enjoy a celebratory lunch.

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If you require a quote for a load bank package, please contact us here: Contact Form

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Here, Paul Brickman, Commercial Director for Crestchic Loadbanks, a leading manufacturer of state-of-the-art load bank technologies asks ‘Is load bank testing necessary for containerised data centres?’

Typically housed within shipping containers, containerised data centres can be deployed easily, powered up quickly and scaled without delay in line with changing requirements. For the data centre sector itself, containerised solutions are widely used to accommodate surplus demand for data centres that need to grow but cannot yet do so, and often deliver continuity of performance when a primary data centre needs critical maintenance or refurbishment.

In other sectors they are equally as important. They provide “pop up” IT and communication services for music festivals and sporting events, support office relocations and major construction sites, and are a staple resource for the military, as well as complex industries such as offshore oil and gas, where data and communications demands are often remote and temporary.

Temporary by name, essential by nature

The temporary nature of these data centres often results in them being commoditised and overlooked when it comes to the maintenance procedures and performance best practice that would be considered essential for a bricks-and-mortar data centre.

But when in operation, these mobile data centres are just as much a necessity as their permanent counterparts, safe housing the same valuable data, and preventing the same financially catastrophic losses engineers so dread when maintaining their primary data centres.

It is important to remember that a data centre, is a data centre, whether that is a purpose built hyperscale campus, a colo or a temporary solution in a shipping container, and that means the same risks apply, and the same preventative measures are required.

No matter the type of data centre being used, the primary cause of unplanned downtime is power failure, something that the Uptime Institute calls “common, costly and preventable”. In fact, in its most recent Risk and Resilience Report, the Uptime Institute calculated that power failure accounts for around 36 per cent of all outages.

It is essential therefore that backup generators for containerised data centres are regularly tested, the same as permanent data centre facilities.

Critical applications require guaranteed resilience

Music festivals and sporting events aside, the vast majority of containerised data centre applications are critical. Military communications, major construction sites, data centre refurbishments and a temporary expansion of primary data centre capacity may all have a clear expiration date, but the situation is already fragile – risking a power outage in an already difficult environment could be catastrophic.

Although mobile data centres are designed to provide facilities with the perfect mix of temporary generators, networking essentials, cooling equipment, servers and UPS, the fact remains that a single point of failure can immobilise the entire data centre. This is an important consideration when deciding which maintenance procedures to uphold, and which if any, can be overlooked.

With power outages proven to be the biggest point of failure, correct load bank testing should be maintained at all times to provide reassurance that if required, the backup power system is capable of accepting the required load and maintaining uptime in the event of a power failure.

Understand the possibilities, prevent downtime

If it is not the temporary nature of a containerised data centre that prevents the required maintenance, then it is often the location, and the assumption that access will be impossible. Afterall, these small, highly portable load banks are often located in areas that have not been specifically constructed for such essential kit.

That said, leading load bank manufacturers have created backup generator testing equipment that can meet the testing demands of containerised data centres.

One example is Crestchic’s trailer mounted load bank solution that combines the powerful testing capability of its traditional resistive-only load banks, with the flexibility of a heavy-duty trailer for applications that require exceptional levels of manoeuvrability.

With load bank testing still achievable for mobile load banks, the risk of downtime is, as the Uptime Institute put it, preventable.

For More Information:

To read more about Crestchic’s experience within the data centre sector, download out handy guide and information leaflet.

To buy or hire a load bank for your facility, contact our team here.

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Here, we explore why this is not the case, and offer best practice advice for ensuring power resilience through regular testing of your backup generator power system.

1. The impact of onsite conditions

Factory conditions do not replicate the environment found onsite. It is, therefore, vital to consider variables such as climate, humidity and temperature differences, and how these will affect the performance of your UPS and backup power system once in-situ.

Even simple fluctuations in temperature can affect run time performance, battery capacity, cut off voltage, gassing and thermal runaway in UPS systems. Humidity and climate fluctuations can also cause longer-term performance issues including corrosion and condensation.

2. Factory conditions are rarely replicable

When tested at the factory, your backup generator will undoubtedly have been put through rigorous testing. However, even with the very best of testing, the fuel supply system, exhaust system, and cooling will differ from the system used in operational conditions. Equally, it won’t have been connected to your specific electrical system, with its own array of circuit breakers, instrumentation, and automatic changeover switches. The fact that the genset now has to operate to capacity with all these different supplying factors is reason enough to test at commissioning regardless of how recent a factory test was performed.

3. The impact of transportation and installation

At the point of factory testing, your equipment has been subjected to very little movement or human intervention. It has been constructed in a carefully controlled environment and handled with the utmost care. But by the time it reaches the point of installation, this sensitive equipment has been lifted, transported, installed, commissioned, and adjusted by human hands. Any one of these processes may throw performance off kilter. Again, the impact may not be visible straight away. For this reason, it is critical that power systems are tested in-situ, regularly and for backup power, this means using a load bank.

Testing backup power using a load bank

A load bank is used to create an electrical load that imitates the operational or ‘real’ load that a backup generator would use in normal operational conditions. In short, load banks are used to test, support, or protect a critical backup power source and ensure that it is fit for purpose in the event that it is called upon.

Ideally, all generators should be tested annually for real-world emergency conditions using a resistive-reactive 0.8pf load bank. Best practice dictates that all gensets (where there are multiple) should be run in a synchronised state, ideally for 8 hours but for a minimum of 3.

Where a reactive-only load bank is used, testing should be increased to 2-4 times per year at 3 hours per test. In carrying out this testing and maintenance, fuel, exhaust and cooling systems and alternator insulation resistance are effectively tested and system issues can be uncovered in a safe, controlled manner without the cost of major failure or unplanned downtime.

Secure power resilience for your facility

For more information on using a load bank to ensure power resilience for your facility, contact our team here.

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Back up generator failure

Reports of the event suggest that the power failed and the back-up generator also failed to start. The outage affected programming on both Channel 4 and Channel 5.

Jeremy Vine, who was forced off air by the power outage, to be replaced by reruns, later wrote: “Sorry to say, we didn’t make it to air today. Questions will be asked of the emergency generator, and the emergency backup generator.”

The role of load bank testing

Paul Brickman, Commercial Director at Crestchic Loadbanks, commented: “While it is unclear at this stage what the cause of the outage was, it is clear that it caused significant disruption and inconvenience to ITN. While power outages are not uncommon, being able to mitigate their potential impact – not to mention the associated financial implications – is crucial.”

For this reason, it is vital that back-up generators are tested regularly to ensure that they will operate effectively when required. The best way to undertake a complete system test is to use a load bank. These little-known machines are used to apply a load to the generator which mimics the load it would receive under real operating conditions. In doing so, the entire system can be tested to ensure it is fit for purpose.

A stark reminder of the impact of power failure

Paul continues “The failure of the back-up generator at ITN is yet to be understood, but it serves as a reminder to all businesses of the importance of using a load bank to test generators. Testing your back-up power generator is the only way to be sure that it let you down when you need it most. Load banks are the unsung heroes of back-up power – you wouldn’t want to risk being without one.”

Find out more about the risks of not testing generators here.

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Battery failures

One of the most common causes of generator problems is battery failure. In short, a failed battery won’t supply the current the generator needs to start. Battery problems can be caused by sulfation build up, which occurs when the lead sulfates in the electrolyte begin to coat the battery’s lead plates. As the sulfation builds on the plates, it inhibits the electrical conversion, preventing the battery from providing the current needed to start the generator.

Dirty and loose connections are the culprit for a host of battery problems, from a build-up of lead debris in the sedimentary trays to open cells caused by overcurrent or insufficient battery capacity. Preventative maintenance is key to overcoming these issues and overcoming potential failure before it occurs. Cleaning and tightening of cable connections and monitoring the charge rates on a regular basis will help to ensure that your backup generator works as expected in the event of a power outage.

It is also worth bearing in mind that battery failure can occur when the charger breaker is open or tripped. This is usually due to human error, when the charger has been switched off for maintenance. Ensure all testing and maintenance is carried out by a skilled professional who will follow the relevant steps and procedures to fully check a generator is working properly after maintenance or repairs.

Coolant levels and overheating in generators

Low levels of coolant in the system cause overheating, leading to a whole host of other issues, from melted bearings, warped crankshafts and overheated cylinder heads through to damage to the radiator core, exhaust valves and valve guides.

Overheating can be caused by low coolant levels, which may indicate a leak somewhere in the system, commonly the block heater hoses. To prevent issues, hoses should be checked regularly for signs of wear, bulges and cracking; clamps should be tightened to reduce the likelihood of leaks; and coolant antifreeze and additives should be maintained to prevent pitting and engine damage. However, while checking the system and keeping an eye out for puddles of coolant is important, overheating can also be caused by a build-up of dirt and debris, a broken fan or fan belt, clogged injectors or air filters, or low oil levels.

The only way to accurately test a cooling system and ensure that the thermostats are fully open is to test the generator under load. Weekly running, while vital to the overall health of the system, simply won’t cause the thermostat to open enough to test the system – making load bank testing the best way to mitigate any issues.

Leaks or “wet stacking” on generators

Very often, problems that are perceived to be oil leaks are actually caused by “wet stacking”, where thick, dark liquid drips from the engine’s exhaust and turbo chargers. Wet stacking usually happens when engines operate significantly below their rated output level (recommended levels vary between manufacturers). This kind of excessive no-load run time causes a build-up of unburned fuel deposits around the combustion chamber, injector nozzles, piston rings, turbo charger and exhaust. This, combined with condensed water results in carbon particles and moisture gathering around the exhaust system.

The potential impact of wet-stacking includes reduced power, increased emissions and increased operational costs. When this happens, the engine can be cleaned up by running it at full load to burn off excess fuel, using a load bank to place a load on the system. If the generator is used below the rated output level on a regular or consistent basis, consider pairing it with a load bank more permanently to keep it running at 70-80% of rated capacity and prevent a “wet stacking” from occurring. A load tracking load bank is ideal for this application.

Emissions Issues with generators

With emissions controls becoming increasingly stringent, the use of exhaust aftertreatment systems is becoming more commonplace. These tend to require the engine to be running at an optimum load / temperature. If the generator does not have sufficient load the performance of the aftertreatment could be compromised, in this instance a load bank can be used to ensure sufficient load is provided to allow the generator to run at its optimal performance level.

Fuel issues with generators
The increased level of bio content in fuel can exacerbate stagnating fuel issues causing microbial build-up in the fuel. Ultimately, this build-up could result in the generator being unable to run when called upon. Polishing / cleaning the fuel removes harmful sediment such as water, sludge and microbial contamination through filtration and circulation

Some generators are equipped with an auto shutdown mechanism when the fuel reaches critical levels. Running out of fuel, or problems caused by fuel stagnating in the system, can be avoided by maintaining the fuel tanks and checking them for water and contaminants which can damage the system. By the same token, high fuel level alarms can be activated by natural thermal expansion of the fuel on a hot day.

Human error

Naturally, there are times when simple human error can cause the generator not to start up when needed. The most common issues relate to switches being left in the wrong position when weekly checks are made. Control switches, battery chargers, ground fault sensors and switchgear are often switched off as part of routine checks, making it important that these are checked and reset to prevent non-start situations, ideally by a trained and experienced technician.

Alternator integrity in generators

The alternator is the part of the generator which converts the mechanical energy of the engine into electrical energy, making it vital to the effective performance of the system. Alternator housing, windings, bearings, controls and cooling system should all be included in your maintenance. A resistive-reactive load bank test will help to identify any problems and test the alternator’s capability to provide the required voltage and pinpoint any work that needs to be done to prevent the failure of the generator.

The role of load bank testing a generator and back up power supply

The reality is often that those in charge of maintaining backup power have no regular testing schedule, making an assumption that occasionally powering the generator up, testing for a minimal period, or a visual inspection, will overcome any potential issues. By not testing the system adequately, the generator is put at risk of failure – with the fuel, exhaust and cooling system untested, along with the potential for embedded moisture, putting the system in the very high-risk category.

Using a load bank overcomes this risk, by applying a load to the generator which imitates the operational or ‘real’ load that a generator would use in normal operational conditions. Properly planned and implemented, load banks can be used as part of a preventative maintenance strategy, minimising the likelihood of unscheduled breakdowns and outages and effectively negating the potential risk of downtime.

To talk to our team about your future load testing needs, please contact us.

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Members of the Crestchic team will be available throughout the event on stand D1030 to discuss Crestchic’s capabilities and product offering, including: 

• Resistive-only load banks typically up to 300kW for heat load testing
• Rack mounted server emulators for heat load- testing
• Capacitive load banks to test with the leading power factor often associated with servers
• Large multi-megawatt, medium voltage load bank packages to test and synchronise multigenset systems on a common bus with a lagging power factor
• DC load banks to test UPS systems for close battery analysis and discharge performance
• Resistive-reactive load banks for testing the whole system operation in an emergency change-over scenario

As the world’s premier datacentre conference, Data Centre World offers attendees an unrivalled line-up of world-class suppliers to the datacentre sector together with excellent networking and conference opportunities.

Paul Brickman, Group Commercial Director at Crestchic Loadbanks, explains: “Reliable power is vital for data centres and testing of facilities under real working conditions is essential to ensure that power supplies cannot be interrupted. Power outages can lead to decreases in productivity, increases in production time, and an increase in costs. Using load banks for commissioning and ongoing testing of backup power solutions, as well as for heat load testing, can mitigate this risk. We’re looking forward to meeting customers and industry colleagues to talk about power continuity in the sector.”

Building on its past success, the event will be key for anyone looking to develop their understanding of the data centre market and source solutions and services to help manage cost and risk, and deliver unparalleled continuity and sustainably.

To register for this event, please visit: www.datacentreworld.com.

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To specify the right equipment for the job, your chosen supplier is likely to ask you for the capacity rating of the generator you wish to test. This information can be found on the nameplate (or data tag) on the generator itself. The capacity rating will be specified in KVA and kW at a specified power factor and maximum output voltage.

The primary difference between kW (kilowatt) and kVA (kilovolt-ampere) is the power factor.  kW is the unit of real power and kVA is a unit of apparent power (or real power plus reactive power).  The power factor, unless it is defined and known, is therefore an approximate value (typically 0.8), and the kVA value will always be higher than the value for kW.

The nameplate will also have information on the voltage, operating phases and configuration of your generator, all of which will impact the load bank your supplier will specify. Having a photo of the nameplate on your mobile phone will mean you have all the information to hand when talking to your supplier.

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What is a load bank and why might I need one?

Where businesses rely on power to remain operational, having backup power such as a generator is crucial. Wherever there is standby power, there is also a need for a load bank – a device which is used to create an electrical load which imitates the operational or ‘real’ load that a generator would use in normal operational conditions. In short, the load bank is used to test, support, or protect a critical backup power source and ensure that it is fit for purpose in the event that it is called upon.

Should I hire or buy?

When looking at specifying a load bank, the first decision is whether to hire or buy the equipment. Consider how many generators you have on-site and how regularly you’ll need to test them. In applications such as data centres or hospitals, where power is absolutely critical, buying a load bank might be the best solution. However, for those who need to run testing at set intervals, or smaller businesses that have neither the space or the technical expertise on-site, rental can provide an ideal solution.

Generally speaking, load bank rental companies will have the expertise to help specify, transport, install and remove the machines. You’ll benefit from the experience and knowledge of their technicians and have access to a fleet of equipment which ensures that you have the right equipment for the job, all without the capital expenditure.

Tomorrow’s focus: What type of load bank do you need?

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