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Why We Load Test Each Individual Generator

Here at Constant Power Solutions, we know that batch testing generators is simply not a viable option in this industry.

All our sets are built in uniform and will be on our production line side by side, our engineers will perform the same steps when building our UK Sets. However, as we build the majority of our sets to order, sometimes our sets can go out bespoke as opposed to the ‘standard’ stock, meaning that they all need to be individually tested.

There are many factors why two generators-built side by side, by the same engineers will still perform differently on load test. The major one is human error – we are all human and as a human you can do the same task 100 times, but there is still that one time, when a bolt may not be as tight, a wiring loom may be slightly loose. This is why we test all our units up to 1 hour at 110% load. Our new engines and alternators we usually test longer than the standard 1 hour to triple check it passes all our quality control checks.

How do we test our units?

We have several load banks here at Constant Power Solutions that suit all our generator ranges.

What is a load bank?

A load bank is a piece of electrical test equipment used to simulate an electrical load, to test an electric power source without connecting it to its normal operating load. This application will allow us to simulate an electrical load to ensure that the generator can not only take the load, it can also power the load at certain load increments such as 25%, 50%, 75% and even 100% and 110% without affecting the frequency or voltage.

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Why is it important to be able to withstand certain incremented loads?

Most industrial equipment will not always be a steady load. Due to different equipment’s factory, hospital and hotels application require, loads can fluctuate, time of day also differs the required load as well. At night a hotel may only require a lighter load due to less power demand from lights, computers and heaters / air con. Whereas during the day when the kitchens are open the load demand will be a lot higher.

Why will we test newer engine or alternator models longer than others?

In short, familiarity. Using engines such as Perkins, Cummins, Scania, Lister Petter and Volvo. We know a lot more about these engines, our engineers know what to look out for and what to expect. When Perkins introduced the new 1206A-E70TTAG2 and 1206A-E70TTAG3, as well as CPS bringing in the Deutz ranges from 13kva to 500kva we tested the first built sets more robustly. The major reason was that the 1206A Engines set up was completely different to the 1506A Engines, and the Deutz engines 60kVA and below is all oil cooled.

We tested these gensets for a longer period than our standard, as well pre checks on temperature, pressure, viewing all the parameters and signals of the Deepsea controller. We invited both Perkins (Diperk) engineers to our factory as well as Deutz engineers for their guidance, support and advise. The first Deutz set we built was the TCD2013L06 4v 250kva Prime rated set, followed by a few of the F2M2011 and F4M2011 engines. We didn’t let the gensets leave the factory until Perkins and Deutz were completely happy with performance, airflow within the canopies and overall load acceptance and simulation.

As we introduce more engine brands, models and ranges, here at CPS we will continue to load bank every set before it leaves and ensure nothing leaves our factory until all department heads are agreed and signed each individual set out.

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