Load Testing is a common phrase that is used a lot in the generator industry. People quite often ask us the question; “What’s the point in that? I hardly ever run my generator?”. When winter comes round, more power is demanded from the grid which could lead to more “power-cuts”.
Have you load tested your generator?
Testing your standby generator is imperative, even if your generator only runs once a year, weekly or daily it is important to test your stand by generator. Did you know that even on a regular test with a light load leaves the generator prone to faults incurred through under use or neglect?
Bellwood Rewinds recently received a 45kVA perkins set for refurbishment, and although this set had been running prime for the last 4 years on site, after we had stripped it down there was an astonishing amount of carbon build up within the engine. This happened because of a light load and the generator not being maintained at regular intervals.
Load testing ensures that, when needed, your standby generator is in peak condition to bear the load of your power requirements. Diesel standby generators that aren’t ran often can build up fuel deposits in parts of the engine which may leave your standby generator with reduced output when it is needed in an emergency.
What to do next?
If you your generator hasn’t been load tested before, you should consider having it tested. Bellwood Generators can load test your generator for you.
Contact us today to find out more about load bank testing. We can provide you with more answers and help you moving forward.
When a glass manufacturing plant on Merseyside had their main power source a 700KVA FG Wilson generator break down recently, they called Bellwood Rewinds Limited’s generator division for help. The main stator on the alternator had blown up and they were left with an expensive hire generator in its place costing them £2K per week. They tried many companies but settled on Bellwood Rewinds due to the very competitive price but mainly the 3 week turnaround guarantee.
The generator arrived and underwent an initial inspection, it was in a bit of an uncared for state.
Our engineers got to work straight away and carefully detailed the list of problems the generator had, these included:
- Alternator main stator and exciter stator blown
- Both front and rear crank shaft oil seals failed on engine
- Radiator and intercoolers totally blocked with oil due to above
- Fuel lift pump weakening
Once the customer had inspected the damage they gave us the green light to proceed, still on the 3 week turnaround time, we got to work.
Firstly the roof came off the canopy and the alternator and radiator/ intercooler unit were removed:
We then dismantled the alternator to find the damage that we have previously noted during static testing, the main stator had blasted to earth:
The radiator core and intercooler were totally blocked with oil due to the failed crank shaft seals:
The alternator underwent a full main stator and exciter stator rewind, the remainder of the alternator was fully overhauled.
The radiator/ intercooler unit was dismantled into its 4 separate components and they were each cleaned in an ultrasonic cleaning bath for 48 hours to release the oil debris. Once they were clean they were all pressure tested and then reassembled:
The crank shaft seals were both replaced:
Then the unit was reassembled, refitting the alternator and radiator. Once all refitted the engine was fully serviced and with a new lift pump fitted was back to perfect working order. We carried out a load test over 4 hours to determine the set up was correct and the customer was advised he could collect the unit, all this work carried out in 2 weeks and 4 days.