POWER
alongside surge suppression devices to improve overall system resilience. By absorbing excess energy, they reduce the load on primary protection components and help manage voltage levels more effectively.
This is particularly beneficial in high-energy applications, where frequent transient events can accelerate wear on protection devices. Incorporating resistive elements enhances durability and contributes to more stable system performance over time.
PRACTICAL IMPLEMENTATION IN INDUSTRIAL ENVIRONMENTS Integrating surge protection into a broader electrical strategy is essential for achieving optimal results. In motor control centres and VSD installations, coordinated protection can isolate disturbances at their source while preventing disruption elsewhere in the system. For sensitive electronics, including control systems and data acquisition equipment, fast-acting suppression is critical. Even microsecond-scale voltage spikes can lead to data errors or hardware damage. By addressing these risks proactively, facilities can significantly improve reliability and reduce unplanned downtime. Additionally, well-designed protection systems can lower maintenance demands by minimising component stress and enabling more predictable service schedules.
TAILORED SOLUTIONS FOR COMPLEX SYSTEMS
Selecting the right surge protection approach requires a detailed understanding of the application. Factors such as transient amplitude, environmental conditions and system configuration all influence component choice. Custom-engineered solutions that combine surge suppression with resistive technologies offer a flexible and effective way to address site-specific challenges. Emphasising thermal performance, longevity and ease of maintenance ensures that protection systems remain effective throughout their operational life.
SUPPORTING LONG-TERM RELIABILITY As industrial systems continue to evolve and incorporate more advanced power electronics, the importance of managing hidden transients will only increase. Facilities that prioritise robust surge protection strategies can reduce operational risk, extend equipment lifespan and maintain consistent performance. By adopting a comprehensive and engineered approach to power quality, operators can safeguard critical assets and ensure reliable operation in increasingly demanding electrical environments.
Cressall
www.cressall.com
UKManufacturing Spring 2026 FIVE LOAD BANK TEST DATA R
esilience in backup power systems is no longer optional. According to the Uptime Institute Annual Outage Analysis 2025, power issues remain the leading cause of impactful data centre outages. More than half of operators reported that their most recent outage cost over $100,000 (£74,600), with around one in five reporting losses exceeding $1 million. Importantly, roughly 80 per cent of operators believe their outages could have been prevented with better operational monitoring and operational processes.
When a facility loses power, the impact can be immediate and severe. Facilities managers commissioning engineers and critical power operations teams need to go beyond whether equipment simply started under load and instead understand what the data tells them about stability control and readiness.
PASS/FAIL IS NOT THE POINT
Uptime Institute Annual Outage Analysis 2025 notes that “power issues remain the most common cause of serious and severe data centre outages and many of these incidents could have been mitigated through better operational monitoring and testing practices.” A generator or UPS system that runs during a load test may superficially appear ready for service. But what really matters for operational resilience is how the system behaves under changing load conditions and whether it does so consistently across repeated tests.
VOLTAGE DROOP OR INSTABILITY DURING LOAD STEPS
What you see during a test may include voltage dipping as load is applied and then slow or erratic recovery occurs before stabilising. This pattern signals that the automatic voltage regulator or governor control is not tuned optimally. It could also indicate weak regulation poor connections or degraded cabling that cannot support rapid load transitions. The correct next step is to repeat the test with controlled incremental loads check and recalibrate regulation components and inspect all terminations to confirm they meet design tolerances. Addressing these issues early prevents instability when the system must handle real facility loads.
FREQUENCY DRIFT OR SLUGGISH RECOVERY
Load bank data often reveals frequency behaviour that is not obvious during simple pass/fail tests. If the frequency drops under load and takes longer than expected to recover, engineers should suspect problems with governor response or fuel delivery control loops. A generator that cannot maintain stable frequency under varying load may
LOAD SHARING IMBALANCE IN PARALLEL SYSTEMS
In systems with multiple generators sets, data often reveals one unit taking a disproportionate share of the load while others lag. This imbalance affects overall system stability and can shorten equipment life. The likely causes are mismatched synchronisation settings instrumentation errors or control incompatibilities. After identifying this pattern engineers should calibrate load sharing control parameters confirm instrumentation accuracy and then execute a structured parallel load test protocol to validate balanced distribution across units.
HARMONICS AND POOR POWER QUALITY UNDER LOAD
Backup systems that show high total harmonic distortion or unstable interactions with UPS systems during load bank testing suggest power quality issues. These often arise from nonlinear loads control incompatibilities or test scenarios that do not reflect actual operational conditions.
The next step is to test with representative loads to review compatibility between power system components and adjust the test design, so it reveals realistic behaviour.
Interpreting load bank test data as a diagnostic tool rather than a compliance requirement helps maintenance teams catch hidden issues before they cause downtime. Understanding the signals hidden in load bank test data requires both the right equipment and the right expertise. Most failures are completely predictable – as long as engineers treat testing as a tool, and not a tick of a box.
Power Prove
www.powerprove.com
15
SIGNALS YOU NEED TO LISTEN TO By Andrew Keith, division director of Power Prove
experience similar behaviour in real operation under stress leading to outages or protective trips. The recommended action here is to verify control settings conduct service checks on fuel and governor systems and repeat the test with carefully staged load increments to confirm performance improvements.
UNEXPECTED TEMPERATURE RISE OR UNEVEN THERMAL PROFILE Unexpected spikes in coolant exhaust or local component temperatures during testing can be the first indication of cooling restrictions or thermal stress. A hot spot on a radiator a blocked airflow path or a failing fan can all cause rapid temperature increases that the test data will show before a real-world failure occurs. When teams see this signal, they should conduct cooling system inspections verify airflow paths and if necessary, consider supplemental cooling solutions. Early thermal issue detection helps avoid overheating during extended runs during actual outages.
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