Importance of loadbank testing in data centre commissioning

As the world’s data centre market continues to grow, the possible repercussions of unscheduled downtime are similarly increasing for operators. With huge costs and reputation on the line, it is vital that data centre equipment is able to withstand high levels of demand amid a burgeoning appetite for data. With this in mind, Billy Durie, our Global Sector Head for Data Centres, explains the importance of comprehensive loadbank testing at the commissioning stage to avoid downtime before it happens. 

The developing needs of the working world are necessitating more frequent access to data. According to research from the Office for National Statistics, almost 50% of the UK’s population worked from home in some capacity in 2020, up from around 30% in 2019. Resultantly, there is increased impetus on data centre providers to ensure facilities can continue to function effectively when demand is high.

For operators, data centre downtime not only results in unnecessary expenses for rectifying problems and compensation, but can also be damaging to stakeholder reputation. With equipment failure cited among the most common reasons for downtime, ensuring critical power and temperature control infrastructure has been effectively tested is key to maximising uptime for operators.

Fail to plan, plan to fail

At present, data centres are expected to maintain 99.999% uptime. With such a small margin for error, even a single outage can result in these stringent targets being missed. For this reason, it is recommended that rigorous loadbank testing on infrastructure takes place early on during the construction phase, to ensure that it is capable of handling full load demand conditions. The loadbank testing process does so in five key steps, to make sure a given facility is able to operate at maximum capacity without any failures:

1. Factory acceptance testing: Determines whether equipment has been built and operates in accordance with design specifications.

2. Site acceptance testing: Ensures equipment meets specification criteria and is inspected for damage before it enters the facility.

3. Pre-functional testing: Verifies the functionality of the equipment, which includes determining whether each device is properly installed, wired, torqued and Megger tested prior to initial energisation.

4. Individual system testing: Detects hotspots or weak components in the equipment, allowing for replacement before the facility is put to work.

5. Integrated system testing: Ensures that all equipment responds appropriately to varying loads, staged machinery failures and any potential utility problems.

As a best practice measure, loadbank testing should be carried out during the initial commissioning of equipment for a new centre, then at least once a year as part of a comprehensive maintenance plan. Conducting tests in line with these five steps will unearth any potential issues early on and allow them to be dealt with ahead of time, before they develop into crises.

Testing early on delivers long-term positives

The minor costs incurred by loadbank testing greatly outweigh those of a potential outage. By undertaking five levels of thorough testing, operators are able to reduce the risk of unplanned downtime to an absolute minimum and avoid any unnecessary expenses that might otherwise occur.

Moreover, pre-emptive loadbank testing has the potential to have a considerable positive effect on overall data centre efficiency. By ensuring that all precautions have been taken to achieve the optimal performance of equipment and proper integration of systems, operations and maintenance costs are able to be reduced during the lifetime of the data centre. With potential faults raised ahead of time, operators are also able to focus on implementing effective maintenance procedures for all of the equipment in the facility, resulting in a safer data centre environment for all.

Thanks to the extensive documentation that comes from rigorous testing during the commissioning phase, data centre operators have a wealth of resources for use as a benchmark to determine the impact of any system changes or operating trends throughout the facility’s working life. Such insights could even equip them with the information to aid in anticipating future issues or guide maintenance procedures.

Take it from the experts

With loadbank testing during commissioning such a vital process to the smooth operation of data centres, contractors will want to ensure that tests are as thorough and comprehensive as possible. In recognition of this, we have recently bolstered our European loadbank fleet with an additional $5 million investment, bringing the total to 500+ units, to make certain that the unique demands of each data centre across the continent are met.

Aggreko’s fleet now includes:

• resistive-only AC loadbanks
• combined resistive and reactive loadbanks in single or multiple units
• DC loadbanks

Each type of loadbank unit can be used on single or three phase and can be accurately controlled, measured and recorded remotely from a handheld device or laptop, to afford the operator greater flexibility in the testing process.

Because data centres vary so greatly in usage, size, location and equipment level, operators and providers may find it useful to approach companies such as ourselves for their consultancy and specialised equipment to harness the benefits of loadbank testing.

With multiple years’ experience delivering loadbank solutions across the continent, we are able to pinpoint the necessary testing required for individual facilities. This also ensures that the correct safety measures have been undertaken, and that disruption of the process remains at a minimum. For all stakeholders, utilising an external consultant and rental equipment can generate even greater savings, by circumventing the need for capital expenditure.

Though loadbank testing can be considered a worthy investment simply for the time and money saved by avoiding unplanned downtime, the added streamlining and overall increased efficiency of operations render loadbank testing an invaluable process to any data centre. With the potential repercussions of outages far exceeding the minor costs of loadbank testing, it’s better not left to chance.

For more information on Aggreko’s loadbank services click below.

Aggreko Loadbank Testing