For a globally renowned manufacturer of canopy generators, headquartered in Spain, the calibration and servicing of its load banks is critical to the quality output of its production. For this reason, they call on the external expertise of Crestchic to get the job done. 

Steven Jewell, Service Engineer for Crestchic comments: 

“When load bank testing is used to ensure the performance of new generators entering the market, it is critical that those load banks work without fault. To achieve that, regular planned servicing, maintenance, and re-calibration is essential. 

“This Spanish generator manufacturer understands that no stone can be left unturned when it comes to the performance of its new products, which is why they partner with Crestchic for their annual load bank maintenance and inspection.”

A thorough investigation of performance

The Crestchic team arrived at the Spanish factory for a two-day visit, with a view to servicing two 3.3MVA 690/400V Star-Delta load banks. Even though the factory engineers were not experiencing any performance issues with their load banks, the Crestchic team identified abnormal electrical noise which was thoroughly investigated to ensure the equipment was safe and performance would not be affected. 

Steven added: “The real benefit of using a load bank expert for annual servicing is that they can often identify potential issues that the onsite engineers are not attuned to. When load bank testing is so critical to business operations, this level of detail is essential.” 

Upon investigation, the Crestchic team confirmed that the electrical noise was caused by a poorly routed control cable, which was re-routed to resolve the issue.

Additionally, two tests were carried out to improve voltage dip and the customer requested updated drawings so that a selectable internal/external voltage switch could be installed along with fuse protection. 

Demonstrating the latest software technologies 

Annual servicing provides an ideal opportunity for Crestchic to educate customers on any potential upgrades that may be required to their equipment. In this instance, the customer was introduced to the LC80 Controller that could improve user experience and reporting of tests conducted in the Spanish factory. 

Steven concludes: “Technological advancements happen all the time, and we strive to ensure customers are always well-informed about whether the equipment they are using may become obsolete, or if there are new technologies available that could improve their load bank performance.

“This puts our customers in the best position to make informed choices about future load bank investments.”

For more information on annual servicing visit services and spares on the Crestchic website.

The post CRESTCHIC MAINTAINS ANNUAL QUALITY CONTROL FOR CANOPY GENERATOR MANUFACTURER appeared first on Crestchic leading manufacturer of load banks.

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.

The post Power failure is number one culprit in spiralling datacentre costs appeared first on Crestchic leading manufacturer of load banks.

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.

Please click the relevant country If you need a solution local to you: France   Germany   Middle East    USA

The post Three reasons why factory testing your backup generator is not enough appeared first on Crestchic leading manufacturer of load banks.

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.

The post Crestchic: ITN suffers mass power outage after back-up generators fail to start appeared first on Crestchic leading manufacturer of load banks.

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.

Please click the relevant country If you need a solution local to you: France   Germany   Middle East    USA

The post Common reasons for generator failure (and how to avoid them) appeared first on Crestchic leading manufacturer of load banks.

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.

The post Load bank rental vs purchase – which option is right for you and why? appeared first on Crestchic leading manufacturer of load banks.

If you’re interested in working for Crestchic, please follow this link: Employment opportunities

The post Great progress on new manufacturing facility expansion appeared first on Crestchic leading manufacturer of load banks.

The company, which is based in Burton-on-Trent, has bucked the trend during the recent pandemic, resulting in the need to expand and recruit new talent.

Paul Brickman, Sales and Marketing Director at Crestchic, commented, “The investments we are making in our business will help to meet increased demand from our core sectors. The focus on renewables, along with growing demand from the data centre sector, means more demand for power reliability and load testing equipment.”

“We’re looking forward to getting the build underway and welcoming new people to the team in early 2022.”

For more information about Crestchic, and for current and future job opportunities, visit our recruitment page here.

The post Crestchic expands its manufacturing footprint by 60% to meet increased demand appeared first on Crestchic leading manufacturer of load banks.

The company, which is based at the Centrum 100 business park in Burton-on-Trent, has bucked the trend during the recent pandemic. As a result of an increase in demand for its load bank technology, Crestchic is expanding its current site footprint by over 60 percent, adding an additional 2000 square metres. The expansion will create around 30 new roles for local people.

Ms Griffiths was welcomed to the site by Managing Director, Chris Caldwell, and Sales and Marketing Director, Paul Brickman, before being given a private tour of the current site. In addition to the tour, those in attendance also took the opportunity to discuss Crestchic’s ongoing commitment to the local community, including training and recruitment initiatives with local schools and colleges.

As part of the visit, Ms Griffiths was also asked to break ground at the new factory site, and dig the first spadeful of earth. Work is officially due to commence in August 2021, with an anticipated 9 months build time.

Speaking about the visit, Ms Griffiths commented: “Crestchic is an important company to our local economy, employing 100 people and providing new skills and training opportunities. Choosing Burton as their business’s location of choice to grow and open a new factory is a huge boost of confidence for our local economy and the employment prospects of many residents.

“Having toured the new factory site today, it is great to see them keeping a keen focus on the importance of their apprenticeship schemes—giving local people some fantastic career opportunities right on our doorstep.”

Paul Brickman added: “We were delighted to have to the opportunity to show MP, Kate Griffiths, what we are achieving here at Crestchic. We’ve been based in Burton for around 35 years and are committed to remaining here for the foreseeable future.”

“The investments we are making in our business will help to meet increased demand from the power reliability sectors, renewables and data centres, while supporting new and existing jobs in the local area.

“We look forward to sharing news of job opportunities via our website in the coming months.”

The post MP Kate Griffiths visits Crestchic factory to learn about new investments and future job opportunities appeared first on Crestchic leading manufacturer of load banks.

Ian Casson, Crestchic Service Manager, said: ”I was randomly searching ebay and found a listing for one of our old load banks, made back in 1989. It had been used on a farm in Shropshire testing single phase generators.

“It was in a really poor condition, with beaten panels and covered in over 30 years of rust and muck.  However, testament to our precision engineering, it was still fully functional!

Ian was quick to jump in and purchase the item.

“I checked the serial number, and it was built at our original depot on Pagett Street in Burton,” continued Ian.

“The load bank was built to suit a specific requirement, so rather than refurbish it we decided to come up with another use for it.  Eventually we decided, due to the nostalgia, we would give it new life as a coffee table in our head office!

“Our team got to work repairing the panel work and making the unit look as good as new.  We added some cut-away sections and used some dynamic lighting to show the internals of the load bank. The elements and the fan were left in position, with the fan being made a feature, which is operated via a switch.”

The team ensured that any original part that could be saved would be reused, meaning minimal new items went into the project.

“The seller was very happy that it was returning to its original point of manufacture, and for us the project creates a great talking point for any visitors,” said Ian.

Crestchic has been operating for over 30 years’ in the load testing arena, garnering an incredible reputation for delivering world leading products and services, with some of the biggest industrial clients around the world.

Please click the relevant country If you need a solution local to you: France   Germany   Middle East    USA

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

The post Crestchic Service: From load testing to coffee holding appeared first on Crestchic leading manufacturer of load banks.