Studies show that 70% of data centre downtime is caused by electrical failures. But the good news? Almost all of them can be prevented with proper Testing & Commissioning (T&C).
Here are the most common electrical issues, why they happen, and how T&C stops them before they cause damage.
Failure 1: UPS Breakdown During Power Outage
Why it happens:
- Weak batteries
- Incorrect wiring
- Overloaded circuits
- Poor maintenance
How T&C prevents it:
- Battery discharge test
- Load simulation
- Failover time measurement
- Internal wiring verification
Failure 2: Generator Fails to Start Automatically
Why it happens:
- Faulty auto-start panel
- Low fuel pressure
- Control panel wiring faults
T&C Solution:
- Auto-start simulation
- Fuel line inspection
- Generator synchronization test
Failure 3: Overheating in Cables or Panels
Why it happens:
- High load
- Loose connections
- Undersized cables
T&C Solution:
- Infrared thermal scanning
- Load balancing
- Torque tightening
Failure 4: Switchgear Malfunction
Why it happens:
- Wrong breaker settings
- Control wiring errors
- Mechanical failure
T&C Solution:
- Interlock test
- Breaker trip verification
- Inspection of mechanical components
Failure 5: Backup Failover Delay
Why it happens:
- Misconfigured UPS
- Slow generator response
- Faulty ATS (Automatic Transfer Switch)
T&C Solution:
- ATS response test
- UPS-to-generator sync test
- Full blackout simulation
Failure 6: Incorrect Load Distribution
Why it happens:
- Improper PDU installation
- Poor load planning
- No balancing checks
T&C Solution:
- PDU test
- Phase balancing
- Energy monitoring validation
Conclusion
Electrical failures are expensive—but preventable. A strong Testing & Commissioning process identifies faults before the data centre goes live, ensuring reliability and safety from day one.
