At SR Power , we can provide the highest quality diesel generators for primary or backup power for a wide range of uses and industries, from data centers to farms and everything in between. SR Power also strives to ensure that our customers receive the best value for money. This not only means ensuring that SR Power can provide quality diesel generators at the best price, but also means ensuring that anyone who uses an SR Power diesel generator can use the generator as effectively, efficiently (and of course, safely) as possible.
Reliable operation in emergency situations
In an emergency, the last thing you want is to know that the backup generator is not able to provide all the power required. load testing allows the backup diesel generator to be tested and exercised to verify its overall reliability and its ability to operate at full rated kW output.
During a diesel generator load test, critical engine parameters should be monitored such as: oil pressure, engine temperature, fuel pressure, etc. These readings should be recorded to show that once the unit reaches full rated load, it is operating at normal operating temperature .
Weekly no-load testing is the best way for most generator owners to maintain their standby diesel generators. The problem with this practice is that underloading the generator can lead to “carbon deposits” – when unburned fuel and soot accumulate in the engine exhaust. Carbon deposits appear as black exhaust and in the fuel mixture, and it can damage the efficiency and life of the engine. Carbon deposits are also a fire hazard.
Annual generator load testing allows the engine to reach its full operating temperature so it can burn off accumulated fuel and prevent carbon deposits, which ensures a cleaner, more efficient engine operation.
Whether running lightly loaded or not loaded at all, most manufacturers agree that annual generator load testing is a must to extend engine life. In fact, it’s more than just a suggestion, it’s the key to extending the life of your diesel generator.
So what is load testing?
Running your diesel generator efficiently is key to ensuring its longevity and avoiding unnecessary downtime. Things like underloading your diesel generator or neglecting scheduled diesel generator maintenance can result in unexpected diesel generator operating costs, excessive wear and increased emissions. load testing is especially important for mains power, diesel generators.
Most importantly, regular maintenance will help ensure your diesel generators are ready when you need them. For some industries, such as data centers, blood banks, and hospitals, emergency diesel generators simply cannot afford to fail. That’s why preventive maintenance techniques like load testing are critical.
So, what is load testing and why should you do it?
What is load testing?
A load test involves starting a standby or common diesel generator and running it at maximum capacity under artificial load for a specified period of time. During a load test, data can be logged, giving a more complete picture of the overall health of the diesel generator set. The test verifies that the diesel generator is able to handle gradually increasing kW loads, that it is still able to accommodate its maximum specified load, and that it can work for an extended period of time. So, in its simplest form, a load test is a way to verify that a standby or common diesel generator is still able to start and run at maximum kW output.
But there is more to load testing than that, and one of the most important reasons to perform a load test has to do with the issue of carbon deposits caused by light loads. We will briefly cover light loads here, but for a more comprehensive understanding of the phenomenon, please contact us.
Underloading refers to the practice of running a diesel generator at less than its possible maximum output capacity. Since every diesel generator has an optimal balance of operating load and fuel consumption, underloading results in reduced efficiency and can cause a buildup of unburned fuel in the engine exhaust. This potentially dangerous buildup is known as carbon deposits. Carbon deposits can reduce a diesel generator’s maximum power output, increase its emissions, make the diesel generator a fire hazard, and require more maintenance than a healthy diesel generator.
In addition to simply ensuring that the diesel generator will operate to specification, load testing helps prevent carbon deposits. When operating at maximum kW output, the temperature and pressure within the engine rise to levels that cannot be reached when operating at lighter loads. These extreme conditions help burn off fuel and soot deposits that accumulate in the engine exhaust chamber due to light loading, effectively curing a diesel generator that has been damaged by light loading.
This includes ensuring our customers know what tests should be performed on diesel generators, why generator load testing is important and how to perform the test. Generally speaking, load testing ensures the efficiency of your diesel generator set.
Diesel generator load testing involves a series of checks and assessments of the diesel generator to ensure it functions optimally when it is most needed. It ensures capacity and battery autonomy and ensures all the main components of the generator are in working order under load conditions.
The load test uses a special device (the load) to create an artificial load on the generator by bringing the engine to the correct operating temperature and pressure.
We need to consider the expected functionality of the diesel generator. When the main power fails, the diesel generator needs to be able to start immediately to prevent the business from potentially catastrophic loss of functionality and data. Because diesel generators are likely to be used rarely by their nature, you need to ensure that the generator can start without any problems even if it is dormant for a long time.
This is particularly important if the generator may be required to carry heavy loads on a regular basis. As a rule of thumb, if the generator is not subjected to loads above 30% of its rated kW, a load test should be performed.
load testing is necessary to prevent problems that can cause slow or loss of generator function. One of the most common is wet stacking. This occurs when a diesel generator is not running often or is only under light load. Over time, deposits of soot and unburned fuel can begin to collect in the exhaust system, causing wet stacking. This can cause the diesel generator to operate improperly and can even damage the internal workings of the generator. load testing can burn off these fuel and soot deposits and reduce the risk of wet stacking.
To be most effective, load testing should be performed annually. When it is implemented regularly, generator owners can enjoy the following benefits:
Verify diesel generator functionality without routine startup.
Issues that could impact performance can be identified earlier, preventing lost productivity and significantly saving on repair costs.
The generator is free from carbon (soot) deposits and has a reduced risk of wet build-up.
The engine cooling system will perform well under the required load.
Provides a more reliable indicator of performance than simply starting it. Just because a generator starts properly does not mean it can handle the load.
The generators will support them when they really need it.
The load test is designed to provide peace of mind to the generator user and therefore checks all factors that are critical to efficient and reliable operation and the life of the diesel generator. Factors checked include: Oil pressure , Hertz , kW load , AC voltage , rated current , voltage test
So, now that we have discussed the importance and benefits of load testing and what to check during the process, let’s take a look at how it is performed.
Whatever electrical equipment is feeding the load, it should be provided with appropriately rated cables. These enable it to be placed up to 20 meters from the diesel generator terminals or power distribution units (PDUs).
The loads are cooled with heavy duty heating elements and fans, so heat dissipation and noise reduction should be considered when conducting the test. Ensure the test is conducted in an appropriate location without sensitive alarms, sprinkler systems, and of course nearby personnel.
Measurements are taken during discharge to determine battery life and overall system performance. load testing will also identify any issues with the generator and uninterruptible power supply in real time, indicating what actions should be taken to resolve the issue.
For standby diesel generators, a load test is particularly useful because it not only indicates the engine’s ability to provide adequate power, it also ensures the alternator has the ability to provide the required voltage stability. It also ensures that all components are working together to produce a stable frequency and efficient performance at the correct oil and fuel pressures. Since the testing process is performed by a load, carbon deposits will be burned off the exhaust, engine cases, and pistons.
load testing is highly recommended to be performed regularly as it is so important and, more importantly, it also reduces system resilience, discharges the battery and represents a risk to the connected loads. This will minimize disruption caused by the testing while ensuring peace of mind.