Six years ago one of our major colocation Data Centre customers moth-balled one of their UPS supply streams as part of a cost saving exercise. The system has been dormant since, but with increased Data Centre usage due to Covid, the system needed to be put back into service. With such a long period of downtime, a full sequence of testing was needed to ensure that the system was still fit for purpose.
A major service of the two 500 kVA UPS modules was completed by the OEM and they worked alongside us to put the system through its paces. Load banks were connected to the output panels and a programme of intensive Power Quality assessment, Ultrasonic Analysis and Infrared Imaging was initiated.
With the system running for the first time in years, the entire supply path from incoming transformers to the recently-replaced batteries was analysed using our TEGG process. A total of five Dranetz PX5 monitors were connected to the upstream and output supplies to measure voltage and load levels along with distortion and waveform deviation during the multiple transfers needed to ensure compliance. Ultrasonic sound files and Infrared Images were recorded from each of the energised panels and Circuit Breakers and the incoming cast resin transformer.
Autonomy tests were also completed on the battery systems which allowed us to identify any potential connection or cell issues while the strings were loaded.
After three days of comprehensive and exhaustive testing a full report on the condition of the system was delivered. This included data from the UPS OEM, Power Quality waveform snapshots, Ultrasonic sound files and analysis and the results of our extensive Infrared Imaging.
Several issues were identified with supply quality, incoming transformer cabling and battery connections, all of which would have affected the integrity of the system once in service. Plans were put in place to rectify these anomalies and after a further round of confirmatory tests the system is now back in service adding confidence, resilience and reliability for many years to come.
Although the testing was time consuming and logistically challenging, the customer estimated that servicing, testing and utilising the existing modules was by far the most economical way of achieving their objectives, saving over £120,000 compared to full module replacement.