Daryl explains the decision to persuade Isabella to join the sales team; “In her previous engineering role, Isabella was involved in all stages of the lifecycle of a load bank – from analysing technical documentation and specifications, undertaking electrical calculations of cable, power and fuse sizing and producing electrical schematics, controller coding and build instructions, through to making recommendations for product improvement and development. As such, she knows the product inside and out, and has a level of understanding that makes her a huge asset to the sales team.”

So how have the first three months in the role gone? Isabella’s first week was spent with five Indonesian customers and a London-based consultant, who wanted to witness a Crestchic 3MVA resistive reactive containerised load bank on full load, using the power from Aggreko Gensets. All went really well, and the load bank was air freighted to Jakarta 2 weeks later.

Two weeks later, Isabella was an integral part of the team hosting the Crestchic stand and meeting customers and prospects at the Middle East Energy exhibition, in Dubai. This was the true baptism of fire for Isabella! 

Daryl explains: “The show is always a busy one, so Isabella was unsure what to expect! 

As soon as the team arrived at the exhibition stand we were overwhelmed with visitors and it was all hands on deck chatting to customers. The expo was the busiest I had ever attended, with nearly 140 enquiries received on the stand. Isabella had no time for doubts and got on with the talking!”

Back in the office Isabella is quoting load banks from 100kW up to multi-MVA projects around the world and says she has never had so many emails! She is also looking forward to the Enlit exhibition, which takes place in November in Jakarta. 

Well done Isabella, it sounds like you have really hit the ground running!

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The event was attended by more than 100 customers, suppliers, and senior staff, who were invited to the opening ceremony, a tour of the Crestchic site, and lunch. A ceremonial ribbon-cutting and speech were carried out by former BBC journalist and Times Radio Presenter John Pienaar, and a plaque unveiled by Councillor Philip Hudson, the Mayor of East Staffordshire.

Despite the economic pressures of the pandemic and global political events, Crestchic has seen strong growth in demand for its products. Data centre and energy transition markets are growing rapidly, and demand continues from well-established, traditional sectors, such as critical infrastructure, marine engineering, and extractive industries. The new factory will allow the company to increase manufacturing capacity to respond to the growing demand for sales and rental of load testing equipment in the UK and beyond.

Peter Harris, Executive Chairman at Crestchic, commented, “As well as responding to customer demand, the investment in both our new and existing factories is part of our commitment to continuous improvement. Our vision is to be world-class manufacturers in every sense of the word – in our commitment to innovation, design excellence, product build quality, meeting delivery times and exceeding customer expectations. We’re continuing to invest in our people and technology – bringing on board new expertise and investing in R&D to ensure that Crestchic continues to lead the market.”

Paul Brickman, Commercial Director added, “Power resilience is becoming increasingly important across all industries. Load testing is no longer a nice-to-have, it’s an absolute necessity for any modern business that needs power to operate effectively. We’re undoubtedly seeing this reflected in our order books. The factory will allow us to fulfil demand across all of our existing locations, as well as our new depots in Antwerp and Texas. As we ramp up our production, we hope to open more depots to serve our rapidly growing global market.”

The senior team also thanked everyone who had been involved in the delivery of the new building, including architects and structural engineers AJS Structural Design; project manager/quantity surveyor Amsons-Barlow; main contractors BFG; electrical contractors SCI; planning advisor JMI Planning and everyone at Crestchic who had played a part. Everyone who works across the three Crestchic manufacturing and office sites was also invited to enjoy a celebratory lunch.

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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.

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We called on staff around the business to show their support for breaking the bias in the workplace and beyond. It’s no secret that Engineering has long been a male-dominated industry. However, while there is still a long way to go, since 2010 both the percentage and number of women in engineering roles has increased. In 2010, just over 1 in 10 (10.5%) of those working in engineering roles were women. By 2021, this had risen to 16.5% – representing an increase from 562,000 in 2010 to 936,000 in 2021 (source: Engineering UK, Women In Engineering Report, March 2022)  

We caught up with some of our female engineers to find out their thoughts on the need to #BreakTheBias in the world of engineering. 

Sharon, Production Manager 

“I knew that I wanted to be an engineer from an early age. As the eldest of five kids, and the only girl, I spent my teenage years taking motorbikes and banger cars to bits and putting them back together. In those days though, I was definitely a woman in a man’s world. 

In fact, at one point, I worked for an Engineering company that supplied to the MOD. I had the pleasure of going on a type 45 submarine in dry dock to carry out an isolation. They took one look at me as a woman and asked if they could carry my toolbox for me!

Things have definitely changed over the years. When I first started at Crestchic, I was the only woman in a team of men. I’m pleased to say they treated me as an equal and we’re now evening up the numbers!” 

Isabella, Electrical and Mechanical Design Engineer 

“When I chose what to study at university, my dad and mum suggested I should do teaching, medicine, or accounting. They felt that they were more suitable subjects for a woman, but I wanted to change the world in a different way, by designing and building equipment and delivering engineering projects which can make the world a better place.

When I was looking for my first job after graduation, I was asked to take less salary compared to male graduates. I asked why, the interviewer explained that, as an engineer, site visits may require heavy lifting, that some of the sites may not be safe for women, and that some of them don’t even have a female toilet.

After almost ten years in the industry, I can tell the atmosphere is changing. It’s easier for women engineers now, but there is still bias, and we can do more to improve.”

Female engineers who changed the world 

• Hertha Marks Ayrton was a leading suffragette, physicist, mathematician, and inventor who patented 26 inventions during her lifetime. Amongst them was  the ‘Ayrton anti-gas fan’, which was used in the WWI trenches to disperse gas. In 1899 she was the first elected female member of the Institution of Electrical Engineers (IEE).
• In the late 1800s, Alice H. Parker designed the first gas furnace powered by natural gas, and the first heating system which allowed temperature control in different areas through independently monitored burners. 
• Dr Margaret Fishenden (1889-1977) carried out pioneering work in Combustion and Heat Transfer contributed to the understanding of aircraft gas turbines, flamethrowers, and airfield gas-burners. 
• Ada Lovelace is considered the first computer programmer. She collabprated with mathematician Charles Babbage to work on the Analytical Engine. Decades before the first computers, she worked out how to use the Analytical Engine to perform calculations – the first ever algorithms.
• Stephanie Kwolek accidentally discovered bulletproof fibre Kevlar in the 1960s while looking for a lightweight but strong material for car tires. Following extensive research into polymers, Kwolek discovered that Kevlar is five times stronger by weight than steel. It is now used in bulletproof vests and mobile phone cases.
• Mary Anderson invented the first hand operated windscreen wiper in 1902. It consisted of a lever inside the vehicle connected to a rubber blade outside. Few car makers were interested until years later, when they became a standard feature. In 1917 another woman, Charlotte Bridgwood, patented the first automatic windscreen wiper.
• In her spare time, 1930s film star Hedy Lamarr developed a technique called ‘frequency hopping’ that was used by the US military to control weapons and other devices remotely, without the worry of jamming.

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Equally important is whether the load bank will be used indoors or outdoors. Load banks work by dissipating energy as heat, making it vital that there is space around the equipment for proper airflow, or that the correct type of equipment, such as a vertical blow machine, is used. When used indoors, it is critical that temperatures are monitored to prevent accidental activation of sprinkler systems, overheating or damage to the load bank.

Finally, it helps your supplier if you let them know if the load bank will need to be installed or delivered above ground level, as well as the distance it will be located from the generator. This will ensure that your supplier provides adequate manpower and cabling to successfully carry out testing.

Tomorrow’s focus: Working from generator nameplates and data tags

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What is a load bank and why might I need one?

Where businesses rely on power to remain operational, having backup power such as a generator is crucial. Wherever there is standby power, there is also a need for a load bank – a device which is used to create an electrical load which imitates the operational or ‘real’ load that a generator would use in normal operational conditions. In short, the load bank is 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.

Should I hire or buy?

When looking at specifying a load bank, the first decision is whether to hire or buy the equipment. Consider how many generators you have on-site and how regularly you’ll need to test them. In applications such as data centres or hospitals, where power is absolutely critical, buying a load bank might be the best solution. However, for those who need to run testing at set intervals, or smaller businesses that have neither the space or the technical expertise on-site, rental can provide an ideal solution.

Generally speaking, load bank rental companies will have the expertise to help specify, transport, install and remove the machines. You’ll benefit from the experience and knowledge of their technicians and have access to a fleet of equipment which ensures that you have the right equipment for the job, all without the capital expenditure.

Tomorrow’s focus: What type of load bank do you need?

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Jon joins the team from Rolls Royce, where he was Chief of Manufacturing Engineering. During his eight years with the company, Jon managed the production of flight test and compliance engines from initial development into volume production, as well as overseeing the company’s global assembly facilities in the UK and New Product Introduction in Singapore and Germany. 

Prior to Rolls Royce, Jon spent 14 years at Siemens Oil Gas, holding a number of engineering management positions including production quality, logistics and operations.

Jon’s appointment comes at a time when Crestchic is expanding its manufacturing footprint by over 60%, adding an additional 2000 square meters to its current site. The new flagship factory will help to meet increased demand from the power reliability, renewables and data centre sectors. 

Speaking about his appointment, Jon commented “I’ve got a real passion for engineering. My Dad was an Engineer, and my Grandpa before him. I’m really excited to bring that passion to the role at Crestchic – especially in light of the forthcoming expansion of our manufacturing facilities. I’m really enjoying meeting the teams and working with them to build on their current successes by identifying incremental improvements that will allow us to be best in class when it comes to product safety, integrity and quality, as well as meeting customer expectations in terms of lead times.” 

Chris Caldwell, Managing Director at Crestchic added, “We are delighted to welcome Jon to the business and see tremendous value in his world class experience in managing production facilities for large blue chip companies. Jon will strengthen our engineering and production capabilities at an exciting time for the business, allowing us to upscale and meet growing customer demand.”

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Steven Bacon will undertake market positioning research and look to further establish our data centre focused load testing business in Texas, over the coming year.

Chris Caldwell, Managing Director at Crestchic, said: “We’re delighted with the appointment of Steven to this role. His in-depth sector knowledge comes from many years within power generation companies. He has already displayed an insatiable appetite to push Crestchic’s market leading load testing products into the hands of potential clients; desperate for a solution that meets their exacting needs.”

Steven, who refers to himself as a life-loving family-man, has always had a passion for helping people get where they want to go in life.

Steven added: “My career has seen me in many sales leadership roles, and I am incredibly excited to move forward with Crestchic.   Their reputation and market share are growing rapidly across the US, and this fact alone gives me the confidence to know that I am promoting a company who understands their client’s needs, and has tried and tested solutions that address them.”

Crestchic’s US office can be contacted on +1 (610) 458-8182 or via the website at www.crestchic-usa.com

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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.

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A Modbus interface module, STAR-DELTA and 400Hz operation are all imminent releases for NOVA. Foreign language versions will become available in 2021.

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