Overcoming Grid Constraints in the Era of AI

The new era of AI is fueling the rapid construction and energy demands of mission-critical data centers, which is straining the existing power grid. To ensure "five-nines" uptime (99.999% availability), operators are prioritizing robust backup power solutions. Providers like Rehlko offer premium, rigorously tested generators. Key selection considerations for these generators include power output, fuel type (such as renewable HVO), noise level, and a compact, robust design for long-term reliability.

Data centers are mission-critical infrastructure in the new era of AI. These enormous facilities – often measuring up to 100,000 square feet – provide the compute resources for AI model training and deployment, acting as the backbone of the digital economy. No wonder data centers are being constructed at a rapid rate. In the US, for instance, in 2025 there are now 5,427 data centers in operation, with the numbers expected to rise.

However, data centers consume an incredible amount of grid-based energy. Servers, storage systems, networking equipment, and other infrastructure, such as lighting, require round-the-clock electricity – and copious amounts of it. According to the International Energy Agency, global electricity consumption for data centers is projected to double, reaching around 945 TWh by 2030, representing just under 3% of total global electricity consumption in 2030. To put that into a broader context, from 2024 to 2030, data center electricity consumption is expected to grow by around 15% per year, more than four times faster than the growth of total electricity consumption from all other sectors.

These increasing energy demands are a challenge to US energy providers. Global research and consultancy group Wood Mackenzie says the scale of this new demand exceeds the industry’s supply capacity. It says that grid constraints are being exacerbated by procurement bottlenecks for critical supply-side equipment, the retirement of substantial amounts of coal-fired generation, tariffs and energy policy changes that make renewables development more challenging. Consequently, there are long lead times on new projects, and wait times for grid connection have increased.

The Critical Role of Backup Generation

The twin challenge of increasing demand and supply-side bottlenecks hold the potential to undermine grid reliability at precisely the moment data centers and other mission-critical infrastructure need it most. With the grid under unprecedented strain, power interruptions are becoming more frequent and are lasting for longer. For data centers, where uptime is measured in the “five-nines” metric (99.999% availability), grid unreliability is seen as an unacceptable risk. That explains why intense focus is put on how the industry approaches backup power.

Increasingly, data center operators are looking to install best-in-class generators to protect themselves against any outages. Rehlko is renowned for its focus on premium quality and longevity, rigorously testing every generator for performance and efficiency. These thorough processes result in generators that are reliable to operate immediately, every time, when they are needed. The excellent build quality also helps reduce maintenance and operating costs over the long term.

However, the generator itself is only one part of the story. Rehlko and its authorized distributors work closely with data center operators to make the selection process as straightforward as possible. These enduring relationships mean end users choose the most suitable generator for their specific environment.

Key Considerations for Generator Selection

• Power output: The required power output is an important factor. Industrial generators come in a wide range of power options.

• Fuel type: The choice of fuel type is significant, with options including diesel, natural gas, and liquid propane. Increasingly, many data center users are running backup generators on renewable diesel fuels, such as Hydrotreated Vegetable Oil (HVO), which reduces lifecycle emissions by up to 90% compared to diesel fuel.

• Noise level: Noise pollution is problematic, particularly in metropolitan areas. To lower noise emissions, generators can be housed in walk-in acoustic enclosures equipped with the latest soundproofing.

• Footprint: Generators are often installed in space-constrained sites. Careful consideration is given to design for compactness by utilizing efficient engine and component placement, optimizing cooling solutions, and offering modular options.

• Robustness: High-quality materials are crucial for achieving low through-life costs, particularly when generators are installed outdoors – as is often the case for data center applications. Generators are made robust through a combination of durable materials, such as steel with enhanced corrosion resistance. They can be housed in enclosures that cover and protect them from outside weather elements, animal intrusion, and unwanted entry.

• Maintenance and warranties: Easy maintenance and comprehensive warranties are also important aspects of the story. Smart maintenance programs enable operators to perform no-load generator exercises every four months, extending maintenance intervals. Extended warranties are also available to provide additional peace of mind.

In conclusion, AI is transforming the data center sector. Surging demand for electricity is acting as a powerful new force straining a grid that simply was not designed for this type of concentrated, massive, and rapidly growing load. As utilities grapple with the challenges and opportunities of this AI-inspired environment, grid constraints remain an ongoing concern. To address this, data centers must deploy rigorous backup strategies to enhance operational continuity.

Rehlko is proud to support the data center industry during this period of exciting growth. Working together, we can ensure that the infrastructure powering AI's future remains resilient, reliable, and ready for whatever challenges lie ahead.