Load bank testing procedure

I. General

A. Provide all equipment, labour, materials and supervision necessary to test the generator set specified. Tests shall be performed prior to acceptance or as installed on-site.

B. Acceptance testing of the installed generator set shall be conducted by a factory trained representative of Powercity. An authorized representative of the customer will also witness the acceptance tests. The test results shall be submitted to and approved by the customer before the generator set is accepted. Powercity shall furnish all testing equipment, materials, fuel*, etc., needed to demonstrate the set is in compliance with the specification. Any deficiencies brought to the attention of Powercity shall be corrected and if warranted or requested by the customer, the test shall be re-performed prior to acceptance. Final Operations & Maintenance (O&M) manuals shall be submitted before the acceptance tests commence.

C. The acceptance tests shall be performed during a field test during which Powercity’s representative shall demonstrate that the system performs in complete compliance with the specifications. As a minimum, a load bank test performed in accordance with the Philippine Electrical Code (PEC) and the National Fire Protection Association 110 (NFPA 110) section 7.13.4.2 to 7.13.4.3.2 (copy of which is included at the end of this section) shall be conducted. The load test shall use resistive type load banks specifically utilized for this purpose. The load bank will be capable of definite and precise incremental loading and shall not be dependent on the generator control instrumentation to read voltage and amperage of each phase. The test instrumentation will serve as a check of the generator set meters. Salt water brine tank load banks are not acceptable for this purpose and are disallowed and will not be utilized for this test.

D. Witnessed by a customer representative, load bank testing shall be performed for a period of two (2) hours which is initiated as follows:

*Note: Fuel for the purpose of this testing shall be at the expense of the customer if testing is more than the two (2) hour limit.

II. Generator and Load Bank Testing Outline

1.Prechecks

Check proper generator position. Is the generator on a firm, dry and level ground?
Check generator physical appearance for any damages.
Check engine oil level, engine coolant level, and battery solution if non-maintenance free battery is used. Also check for leaks.
Check all electrical connections at terminal panel of the generator set to the load bank if properly connected. If they are wired and tightened correctly?
Check that the generator is properly grounded to a good earthen ground per local and PEC regulations.
Verify required load voltage, phase and frequency.
Check engine drive belt tension and condition.
Locate the battery switch and turn it ON.

2. Run the generator without load to warm up the engine for at least 5 minutes.

3. Switch on the generator main circuit breaker.

4. In lieu of PEC and NFPA 110, perform a stepped load test on the generator at 30% for 30 minutes. This is the first 30 minutes of load test. Record the results of the following parameters:

Line voltages

Current

Battery voltage

Frequency Engine speed

Engine temperature

Oil pressure

Test duration time

Also, take note of exhaust colour (black, gray, white, or clear), abnormal noise and fluid leaks if there is any.

5. Increase the stepped load on the generator at 50% for 30 minutes. This is the second 30 minutes of load test. Record again the results of the above parameters.

6. Increase the stepped load on the generator at 100% for 60 minutes. Record again the results of the above parameters.

7. Gradually switch off all step loads and allow the generator to cool down for at least 5 minutes.

8. Switch of the generator main circuit breaker and stop the generator.

III. Documentation

The following documentation is to be submitted to the customer prior to acceptance:

1. Installation certificates, if any.

2. A final on-site performance and inspection report summarizing load bank test results, engine controls testing, observations and other information relative to generator testing. This data is to be included as part of the product manual. All problems, findings or any corrective actions necessary to bring generators into compliance shall also be well documented.

3. Shop drawings.

APPENDIX A – The Philippine Electrical Code