When the lights go out, and there is a power outage emergency, your backup power source will kick into action. But there’s a chance it may not function as expected. What does that mean for your company? It often means it can be costly and sometimes catastrophe, and why a preventative generator maintenance plan is important.
Generator load bank testing is an essential piece of a comprehensive preventative generator maintenance plan, which you should ideally have conducted an examination and assessment of a gen-set (s) each year. The purpose of most generator sets is to provide a reliable source of power during an emergency situation.
Load bank testing helps to ensure that your generator will be fully dependable and operational, as well as completely capable of the highest possible load it may be required to handle at any critical point in time.
What is Generator Load Bank Testing?
A generator load bank test involves an examination and assessment of a gen-set. It verifies that all primary components of the generator set are in proper working condition. The equipment used to conduct a load bank test produces artificial loads on the generator by bringing the engine to an appropriate operating temperature and pressure level. 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.
The key to a proper load bank test is that it tests your generator at its full kilowatt (kW) output rating. 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.
How does a Load Bank Test Work?
When a load bank test is implemented, an artificial load is placed on the generator. The test is timed and gradually increases 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).
Wet-Stacking
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 gen-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. Hence, a load bank test actually serves two purposes: 1) it tests the generator to determine whether it will function properly and efficiently on all levels; and 2) it eliminates any wet-stacking that may have built up within the generator.
Benefits
There are multiple reasons gen-sets should undergo a load bank test on an annual basis, including the following:
- Verifies the gen-sets capabilities opposed to just routinely starting it up
- Problems discovered early can be significantly less expensive and 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 gen-set should work properly when you need it most
What’s Included in Load Bank Testing?
Odyssey Power Corporation runs a resistive load bank test on every generator we own and sell. Upon completion of a successful load bank test, which is timed out with increasing intervals until it is stepped up to a full load. In addition we provide our customers with a Load Bank Report that contains thorough, comprehensive test results, which are available on all of our name brand commercial and industrial gensets.
Contact us today to find a solution that suits your business.