What is Generator Load Bank Testing?
A generator load bank test involves an assessment of a generator set by applying an artificial power load to the back-up power system bringing the engine to an appropriate operating temperature and pressure level. Because many generators do not regularly operate at their full kW rating, it's especially important that you verify your generator can actually produce the highest possible horsepower that may be required - while at the same time maintaining adequate temperature and pressure levels that will allow it to run as long as necessary. This allows verification that all primary components of the generator set are in proper working condition. This is especially important for standby and emergency generator sets that do not run very often and/or may not be exposed to carrying heavy loads on a frequent basis. The general rule is - if your generator is not exposed to higher than 30% of its rated kW load then you should be considering a load test.
Furthermore, when a diesel engine powered generator is not used frequently or only run on light loads, it can be prone to experiencing unburned fuel and soot buildup in the exhaust system. This is called 'wet-stacking.' When wet-stacking occurs, the generator set is likely to perform poorly, to endure damage, can become a fire hazard, and can even lead to complete failure. During a load bank test, the generator is allowed to run at full power and full temperature. This will cause any wet-stacking to burn off. This is yet another reason Load Bank Testing is so important for your generator set.
A load bank test ensures that your generator will run properly when it’s needed so that you can have peace of mind during an emergency situation.
How does a Load Bank Test Work?
When a load bank test is implemented, an artificial load is placed on the generator that mimics the load level your company places on your power system today. The test is performed at percentages of your current load to access how the system will perform at each level. These levels will be properly set based on our partnership with the customer.
The test is timed and we gradually increase the kW load in specific increments. Each time the kW load is increased, the test measures and records critical engine parameters, the generator's ability to handle the boost, and its ability to continue functioning at the highest possible level for a sustained period of time. The equipment needed to complete the test includes a load bank (machine with kW rated sizes and battery like cables).
Sluder Emergency Power Services provides full end-to-end Resistive/Reactive Load Bank Testing from coordination and scheduling of the test with all those involved at your company, planning the load levels to be tested, the order of the load bank equipment, delivery and set-up of the equipment, full on-site execution and monitoring of the test by one of our expert technicians, pick up and removal of testing equipment, and clean-up of the site back to its original condition. Safety of your staff and our employees is of the utmost importance and we go above and beyond to ensure safety for everyone involved during testing.
Once the test is completed, the client will be provided with a detailed report showing how the equipment performed at each testing level and will outline any recommended changes or issues that arose during testing. Upon approval by the client, Sluder Emergency Power Services will perform all necessary repairs to ensure your system is ready when you need it most.
Benefits of Load Bank Testing:
While some industries, such as hospitals, are required to perform Load Bank Testing as part of the regulations governing their industry, it cannot be stressed enough that all industries should consider Load Bank Testing as part of their Preventative Maintenace plan. The benefits of Load Bank testing far outway the cost associated with the testing, along with giving you the priceless reassurance and peace of mind that your system will be ready to perform during an emergency. Some of these benefits include:
- Verification of the generator sets' performance and capabilities opposed to just a routine start it up
- Identification of problems discovered early will be significantly less expensive to fix now and will prevents future major issues
- Helps to avoid wet-stacking and cleans out carbon deposits
- Verifies the engine cooling systems will perform while under load
- Provides assurance that the generator set will work properly when you need it most
This is precisely the reason generator load bank testing is an essential piece of a comprehensive Preventative Maintenance plan, which you should ideally have conducted on your generator sets each year.