Efficiency is key: During the two-day conference, there was a lot of talk about efficiency in the data center sector. Many of our customers and prospects want to do testing promptly, making rental turnaround a key driver in selecting a provider. 

Labour shortages are an ongoing issue: Many data centres do not have the right labour pool to execute daily operations, let alone testing. This means that having access to trained technicians is an important factor when selecting a solution provider. 

Heat load testing is as important as genset testing: Most facilities managers and data center operators are aware of the need to test generators to keep backup power running efficiently. Speaking to customers and prospects, it would seem that there is an increased interest in using load bank solutions to heat load test server halls at the commissioning phase. 

Backup power lead times are long: In some cases, lead times for generators are up to two years. This means that data centers must invest in backup power solutions early in the planning and commissioning phase. To avoid this, some data centers rent generators. While this is a temporary solution, rental generators are often older, making it vital that load testing is completed frequently. 

De-risking data centers is high on the agenda: From my many conversations with customers, I heard them speak about de-risking their data center. Some load banked their data centers monthly; others only did it when their generator services company scheduled it. The overwhelming sentiment was that they want to test more often and efficiently to avoid the risk of outages. 

To find out more about how Crestchic can help to address these issues, speak to our rental team here. 

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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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Members of the Crestchic team will be available throughout the event at stand 1823, where they will be available to answer industry questions about power testing and continuity. 

Solutions include: 

• Large multi-megawatt, medium voltage load bank packages to test and synchronise multi-genset systems on a common bus with a lagging power factor
• Resistive-reactive load banks for testing the whole system operation in an emergency change-over scenario
• Data centre specific solutions such as Resistive-only load banks and Rack mounted server emulators for heat load- testing
• Capacitive load banks to test with the leading power factor often associated with servers

Formerly POWERGEN Asia and Asian Utility Week, the Enlit Asia event has crica 350 exhibitors showcasing technology and solutions supporting the ASEAN energy sector’s continued transition to a lower-carbon future, with an anticipated delegate count of over ten thousand people. The event is co-located with Sustainable Energy Technology Asia (SETA) & Solar+Storage Asia (SSA), making it a go-to destination for anyone interested in the power sector. 

Paul Brickman, Group Commercial Director at Crestchic Loadbanks, explains: “For industries across the globe, having reliable backup power is increasingly important, especially during times of transition. 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 can mitigate this risk. The chance to showcase in Asia gives us a huge opportunity to grow our load bank business in this part of the world. We’re looking forward to meeting customers and industry colleagues to talk about power continuity in the sector.”

Crestchic has enjoyed a busy year of major exhibitions, having attended Data Centre World London, Data Centre World Frankfurt and Middle East Energy. The company will also be attending Data Cloud USA, DC Ireland, Data Centre World Singapore and Data Centre World Paris. 

To register and find out more about this event, visit: https://www.enlit-asia.com/ 

To find out more about how to incorporate a Crestchic load testing programme 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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If you’re in the market for a load bank, you’ll undoubtedly have come across the terms resistive and reactive. To make load bank specification as simple as possible, you need to understand the difference between the different types of load testing solutions and which one is most appropriate for your application. 

What is a resistive load bank?

A resistive load bank provides a simulated electrical load for generators and backup power systems. For engine-only exercising and general engine maintenance, a resistive-only loadbank is ideal for clearing carbon build-up in the engine, it is the most common and cost-effective option for preventative maintenance.

What does a resistive load bank do? 

A resistive load bank mimics the operational load that a power source would handle during actual use. When used as a controlled system test, the load simulates real-life resistive loads, such as incandescent lighting and heating loads, as well as the resistive or unity power factor component of magnetic (motors, transformers) loads. A resistive load bank works by converting electrical energy into heat using power resistors, which then dissipate the heat using forced air cooling. 

What applications use a resistive load bank? 

Resistive load banks can be used for a broad spectrum of applications, from testing turbines, rotary UPS and generators in sectors like heavy industry, and manufacturing, as well as for maintenance in mission-critical facilities like hospitals and data centres. 

Is a resistive load bank sufficient to completely test my system? 

It is important to note that, in many applications, resistive loads make up a small proportion of power consumption. In data centres, for example, it is generally only heating and lighting systems that use a resistive-only load. Alongside this, other aspects of the operation incur reactive loads; these create a lagging power factor (pf), typically around 0.8, which is not accounted for when undertaking a solely resistive test. 

What is a reactive load bank? 

Reactive load banks do not test a system at full load. Instead, they simulate “real world” scenarios for either an inductive or capacitive load – whichever is relevant for the application. They use a 0.8 power factor with a 75% load, compared to the 1.0 power factor and 100% load of a resistive loadbank. A reactive load bank works by converting current into a magnetic field and can resist the change to voltage, which causes the circuit current to lead voltage.

What type of applications use a reactive load bank? 

Reactive load banks can be used to evaluate transient loads, as well as for load sharing and testing alternator capacity. This type of testing is suitable for equipment that is affected by electric motors or other electromagnetic devices. This could include applications like motor-driven devices, transformers and capacitors, making them a real contender for the telecommunications, solar, manufacturing and mining industries. 

What is a resistive/reactive load bank? 

These solutions combine both resistive and reactive elements in one load bank. The system can also be switched to enable resistive only, inductive or lagging power factor testing. 

The inductive loads used in resistive/reactive testing will show how a system will cope with a voltage drop in its regulator. This is particularly important in any application which requires generators to be operated in parallel (e. larger business infrastructures such as major telecoms or data centres) where a problem with one generator could prevent other system generators from working as they should. This is something which is simply not achievable with resistive-only testing. 

Why is a resistive/reactive load bank the best choice?

A resistive/reactive load bank can be used to test a generator fully at 100% nameplate kVA rating. Carrying out this type of load bank testing provides a picture of how well an entire system will withstand changes in load pattern while experiencing the level of power that would typically be encountered under real operational conditions. 

Ideally, all generators should at the very least be tested annually for real-world emergency conditions using a resistive-reactive 0.8pf loadbank. Where a resistive-only loadbank is used (1.0pf), testing should be increased in frequency to ensure that the system doesn’t encounter issues when an emergency arises. 

What is a DC load bank? 

In addition to the main categories of loadbank listed above, DC load banks can be used to provide an accurate load for the discharge of batteries, both following amps and voltage, from 24VDC to 700VDC, with power from 10kW to 664kW. 

Why use a load bank: Key benefits

Load testing a generator offers reassurance 

Crucially. testing a backup power system at full load provides reassurance that, even in a worst-case scenario, the generator is able to perform under the most demanding conditions. Regular load testing can increase the life and reliability of a generator. 

Load bank testing helps to prevent wet stacking 

Unburned fuel inside a backup generator can clog the exhaust system and result in excessive moisture in the engine – this is called wet stacking. Using a load bank to apply a full load to the generator encourages the engine to burn more fuel, preventing wet stacking. 

If wet stacking conditions are already present, the load bank testing process will burn off the excess moisture, improving engine performance and prolonging system life. 

Treatment of exhaust fumes

Using load bank testing to force a generator to operate at full load will exercise the exhaust system enough to improve peak performance.

Identify hotspots and component performance issues

Applying reactive load conditions to systems in parallel presents an ideal opportunity to assess the performance of electrical connections, cables, bus work and other components. Likewise, where possible, infrared can be used during the testing phase to identify system hotspots. 

Take the first steps towards effective backup power testing

For more specific support on choosing which loadbank is right for your application, speak to our specialist team today on 01283 531 645 or email sales@crestchic.com.

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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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For many critical industries, interruptions in power supply can have a significant impact on revenue through lost productivity and damage to equipment – in some sectors, a loss of power could even pose a significant risk to health and safety with potentially fatal results.

Backup power systems are a common way to mitigate these risks, and to make sure backup power is available when you need it most, the maintenance and testing of these reserve systems is an important process – that’s where load banks come in.

Load banks test the efficiency and performance of a backup generator by imitating the operational or ‘real’ load that a generator would use should the primary power source fail. By testing your backup power system regularly, you can rest assured that should there be a power outage, the backup supply will provide adequate protection for your facility until the problem is resolved.

Like all critical equipment, the specification of load banks should be carefully considered, and one of the key deciding factors should be whether to purchase a load bank outright or rent the equipment as and when it is required throughout the year. As you can imagine, there are pros and cons to both options, and Crestchic is here to help you make the right choice for your business.

When is load bank rental right?

Right load bank, right time, right place: Rental can be right for many reasons. If you own, or are contracted to manage or maintain, generator assets across multiple sites or need a range of voltages and power factors to complete your tests, load bank rental will be logistically and financially more viable for you. It will enable you to access the right load bank for the right tests, in the right location each and every time.

Real-estate: Space is an important consideration too – if you are tight on space, it can be easier to clear an area for a few weeks at a time, knowing that you will regain that square footage once the back up generators have been tested, rather than lose space permanently to a purchased load bank.

Power testing expertise: You should consider expertise too; do you have the right expertise in house, or would you benefit from the experience and knowledge of a dedicated technician? Renting your load back will give you access to a team of specialists that can support you in the early days.

Affordability: Lastly, rental works well for new or smaller businesses that cannot afford the initial outlay to purchase a load bank, allowing them to spread the cost of testing throughout the year.

 When is buying a load bank right?

There is a fairly easy rule of thumb that applies for most applications when it comes to purchasing a load bank rather than renting one. If you answer yes to the following questions, purchasing a load bank will be financially and logistically the right option for you:

• Will you always use it at the same voltage?
• Do you only need a load bank at one location?
• Will you use it for two or three weeks at a time?
• Will you use it multiple times per year?

There are many benefits to owning a load bank outright, including the convenience of knowing it’s always on hand should you want to run tests on your back-up generator, something which is of particular interest to mission critical environments such as data centres and hospitals. You’ll enjoy less admin and reduced OPEX costs too.

Combining the best of both worlds

Whether you want to rent or purchase your load bank equipment, choosing a provider that has a dedicated team for both can be beneficial in the longer term. Let’s say you purchase equipment in the first instance, but then open a second or third facility and would benefit from a rental option too?

Or the opposite, perhaps you want to rent for now because you cannot afford the financial outlay, but hope to buy a container load bank further down the line? Buying from the manufacturer you have rented from will mean the equipment is familiar to you and results will be consistent.

When it comes to the safety and performance of your back-up power supply, choosing a partner that can offer a combination approach, plus the expertise to support you whichever method you choose, will pay dividends.

Click the link to find out more about Crestchic’s rental load bank offering, or for help specifying a Crestchic load bank to purchase.

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