Here, we explore why this is not the case, and offer best practice advice for ensuring power resilience through regular testing of your backup generator power system.

1. The impact of onsite conditions

Factory conditions do not replicate the environment found onsite. It is, therefore, vital to consider variables such as climate, humidity and temperature differences, and how these will affect the performance of your UPS and backup power system once in-situ.

Even simple fluctuations in temperature can affect run time performance, battery capacity, cut off voltage, gassing and thermal runaway in UPS systems. Humidity and climate fluctuations can also cause longer-term performance issues including corrosion and condensation.

2. Factory conditions are rarely replicable

When tested at the factory, your backup generator will undoubtedly have been put through rigorous testing. However, even with the very best of testing, the fuel supply system, exhaust system, and cooling will differ from the system used in operational conditions. Equally, it won’t have been connected to your specific electrical system, with its own array of circuit breakers, instrumentation, and automatic changeover switches. The fact that the genset now has to operate to capacity with all these different supplying factors is reason enough to test at commissioning regardless of how recent a factory test was performed.

3. The impact of transportation and installation

At the point of factory testing, your equipment has been subjected to very little movement or human intervention. It has been constructed in a carefully controlled environment and handled with the utmost care. But by the time it reaches the point of installation, this sensitive equipment has been lifted, transported, installed, commissioned, and adjusted by human hands. Any one of these processes may throw performance off kilter. Again, the impact may not be visible straight away. For this reason, it is critical that power systems are tested in-situ, regularly and for backup power, this means using a load bank.

Testing backup power using a load bank

A load bank is used to create an electrical load that imitates the operational or ‘real’ load that a backup generator would use in normal operational conditions. In short, load banks are used to test, support, or protect a critical backup power source and ensure that it is fit for purpose in the event that it is called upon.

Ideally, all generators should be tested annually for real-world emergency conditions using a resistive-reactive 0.8pf load bank. Best practice dictates that all gensets (where there are multiple) should be run in a synchronised state, ideally for 8 hours but for a minimum of 3.

Where a reactive-only load bank is used, testing should be increased to 2-4 times per year at 3 hours per test. In carrying out this testing and maintenance, fuel, exhaust and cooling systems and alternator insulation resistance are effectively tested and system issues can be uncovered in a safe, controlled manner without the cost of major failure or unplanned downtime.

Secure power resilience for your facility

For more information on using a load bank to ensure power resilience for your facility, contact our team here.

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Battery failures

One of the most common causes of generator problems is battery failure. In short, a failed battery won’t supply the current the generator needs to start. Battery problems can be caused by sulfation build up, which occurs when the lead sulfates in the electrolyte begin to coat the battery’s lead plates. As the sulfation builds on the plates, it inhibits the electrical conversion, preventing the battery from providing the current needed to start the generator.

Dirty and loose connections are the culprit for a host of battery problems, from a build-up of lead debris in the sedimentary trays to open cells caused by overcurrent or insufficient battery capacity. Preventative maintenance is key to overcoming these issues and overcoming potential failure before it occurs. Cleaning and tightening of cable connections and monitoring the charge rates on a regular basis will help to ensure that your backup generator works as expected in the event of a power outage.

It is also worth bearing in mind that battery failure can occur when the charger breaker is open or tripped. This is usually due to human error, when the charger has been switched off for maintenance. Ensure all testing and maintenance is carried out by a skilled professional who will follow the relevant steps and procedures to fully check a generator is working properly after maintenance or repairs.

Coolant levels and overheating in generators

Low levels of coolant in the system cause overheating, leading to a whole host of other issues, from melted bearings, warped crankshafts and overheated cylinder heads through to damage to the radiator core, exhaust valves and valve guides.

Overheating can be caused by low coolant levels, which may indicate a leak somewhere in the system, commonly the block heater hoses. To prevent issues, hoses should be checked regularly for signs of wear, bulges and cracking; clamps should be tightened to reduce the likelihood of leaks; and coolant antifreeze and additives should be maintained to prevent pitting and engine damage. However, while checking the system and keeping an eye out for puddles of coolant is important, overheating can also be caused by a build-up of dirt and debris, a broken fan or fan belt, clogged injectors or air filters, or low oil levels.

The only way to accurately test a cooling system and ensure that the thermostats are fully open is to test the generator under load. Weekly running, while vital to the overall health of the system, simply won’t cause the thermostat to open enough to test the system – making load bank testing the best way to mitigate any issues.

Leaks or “wet stacking” on generators

Very often, problems that are perceived to be oil leaks are actually caused by “wet stacking”, where thick, dark liquid drips from the engine’s exhaust and turbo chargers. Wet stacking usually happens when engines operate significantly below their rated output level (recommended levels vary between manufacturers). This kind of excessive no-load run time causes a build-up of unburned fuel deposits around the combustion chamber, injector nozzles, piston rings, turbo charger and exhaust. This, combined with condensed water results in carbon particles and moisture gathering around the exhaust system.

The potential impact of wet-stacking includes reduced power, increased emissions and increased operational costs. When this happens, the engine can be cleaned up by running it at full load to burn off excess fuel, using a load bank to place a load on the system. If the generator is used below the rated output level on a regular or consistent basis, consider pairing it with a load bank more permanently to keep it running at 70-80% of rated capacity and prevent a “wet stacking” from occurring. A load tracking load bank is ideal for this application.

Emissions Issues with generators

With emissions controls becoming increasingly stringent, the use of exhaust aftertreatment systems is becoming more commonplace. These tend to require the engine to be running at an optimum load / temperature. If the generator does not have sufficient load the performance of the aftertreatment could be compromised, in this instance a load bank can be used to ensure sufficient load is provided to allow the generator to run at its optimal performance level.

Fuel issues with generators
The increased level of bio content in fuel can exacerbate stagnating fuel issues causing microbial build-up in the fuel. Ultimately, this build-up could result in the generator being unable to run when called upon. Polishing / cleaning the fuel removes harmful sediment such as water, sludge and microbial contamination through filtration and circulation

Some generators are equipped with an auto shutdown mechanism when the fuel reaches critical levels. Running out of fuel, or problems caused by fuel stagnating in the system, can be avoided by maintaining the fuel tanks and checking them for water and contaminants which can damage the system. By the same token, high fuel level alarms can be activated by natural thermal expansion of the fuel on a hot day.

Human error

Naturally, there are times when simple human error can cause the generator not to start up when needed. The most common issues relate to switches being left in the wrong position when weekly checks are made. Control switches, battery chargers, ground fault sensors and switchgear are often switched off as part of routine checks, making it important that these are checked and reset to prevent non-start situations, ideally by a trained and experienced technician.

Alternator integrity in generators

The alternator is the part of the generator which converts the mechanical energy of the engine into electrical energy, making it vital to the effective performance of the system. Alternator housing, windings, bearings, controls and cooling system should all be included in your maintenance. A resistive-reactive load bank test will help to identify any problems and test the alternator’s capability to provide the required voltage and pinpoint any work that needs to be done to prevent the failure of the generator.

The role of load bank testing a generator and back up power supply

The reality is often that those in charge of maintaining backup power have no regular testing schedule, making an assumption that occasionally powering the generator up, testing for a minimal period, or a visual inspection, will overcome any potential issues. By not testing the system adequately, the generator is put at risk of failure – with the fuel, exhaust and cooling system untested, along with the potential for embedded moisture, putting the system in the very high-risk category.

Using a load bank overcomes this risk, by applying a load to the generator which imitates the operational or ‘real’ load that a generator would use in normal operational conditions. Properly planned and implemented, load banks can be used as part of a preventative maintenance strategy, minimising the likelihood of unscheduled breakdowns and outages and effectively negating the potential risk of downtime.

To talk to our team about your future load testing needs, please contact us.

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When dealing with your chosen supplier, ensure that you know how much involvement you need from them and get them to quote accordingly. Choose a supplier that offers flexibility – packages vary from supply-only, short-term rental right through to larger multi-megawatt, high voltage projects which are fully managed by a team of engineers. They can also include site surveys, risk assessments and method statements as well as full project management. Equally, understand what peripherals are included, from step-up/step-down transformers and cabling, extension reels, junction boxes, through to control and data collection equipment and load bank fans.

 Check lead-times meet your requirements

When time is critical, ensure your suppliers can meet your needs. The COVID pandemic has seen an increase in companies wanting rental equipment to be supplied with a very fast turnaround. Using a supplier with its own fleet of loadbanks and dedicated delivery vehicles can help to reduce reliance on outside suppliers and ensure adherence to strict lead times.

COVID-ready

With the COVID pandemic set to impact the way we live and do business for the foreseeable future, it pays to check that your supplier meets the standards set by your business. At Crestchic, we’re doing all we can to protect our staff and our customers and minimise risks. If more than one technician is needed for a job, they will travel separately to ensure social distancing. All staff are also provided with PPE including goggles, masks and sanitiser and we’ll undertake risk assessments to ensure your site is safe.

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Equally important is whether the load bank will be used indoors or outdoors. Load banks work by dissipating energy as heat, making it vital that there is space around the equipment for proper airflow, or that the correct type of equipment, such as a vertical blow machine, is used. When used indoors, it is critical that temperatures are monitored to prevent accidental activation of sprinkler systems, overheating or damage to the load bank.

Finally, it helps your supplier if you let them know if the load bank will need to be installed or delivered above ground level, as well as the distance it will be located from the generator. This will ensure that your supplier provides adequate manpower and cabling to successfully carry out testing.

Tomorrow’s focus: Working from generator nameplates and data tags

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What is a load bank and why might I need one?

Where businesses rely on power to remain operational, having backup power such as a generator is crucial. Wherever there is standby power, there is also a need for a load bank – a device which is used to create an electrical load which imitates the operational or ‘real’ load that a generator would use in normal operational conditions. In short, the load bank is used to test, support, or protect a critical backup power source and ensure that it is fit for purpose in the event that it is called upon.

Should I hire or buy?

When looking at specifying a load bank, the first decision is whether to hire or buy the equipment. Consider how many generators you have on-site and how regularly you’ll need to test them. In applications such as data centres or hospitals, where power is absolutely critical, buying a load bank might be the best solution. However, for those who need to run testing at set intervals, or smaller businesses that have neither the space or the technical expertise on-site, rental can provide an ideal solution.

Generally speaking, load bank rental companies will have the expertise to help specify, transport, install and remove the machines. You’ll benefit from the experience and knowledge of their technicians and have access to a fleet of equipment which ensures that you have the right equipment for the job, all without the capital expenditure.

Tomorrow’s focus: What type of load bank do you need?

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Chris Caldwell, Managing Director at Crestchic, said: “Wodan has an incredible track record of sales success across a multitude of industrial sectors. I’m therefore delighted to welcome him to our team and know that this is yet another positive step forward for the company’s ambitious expansion strategies.”

Wodan’s appointment follows news about the 2000 square metre expansion of Crestchic’s factory in Burton on Trent, allowing the company to meet and exceed the increased demand from the market.

Wodan de Quick added: “It’s an exciting time to be working at Crestchic and I’m already feeling the incredible buzz surrounding the future of the company. I have held management positions within Aggreko and Atlas Copco, especially in operations, production, maintenance, service, rental business and QHSE. I’m keen to bring all my experiences and knowledge to Crestchic, and as a forward thinking result orientated person, I love to exceed expectations through teamwork and collaboration. I truly believe nothing is impossible.”

Crestchic has been operating for over 30 years’ in the load testing arena, garnering an incredible reputation for delivering world leading products and services to some of the biggest industrial clients around the world.

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The company, which is based in Burton-on-Trent, has bucked the trend during the recent pandemic, resulting in the need to expand and recruit new talent.

Paul Brickman, Sales and Marketing Director at Crestchic, commented, “The investments we are making in our business will help to meet increased demand from our core sectors. The focus on renewables, along with growing demand from the data centre sector, means more demand for power reliability and load testing equipment.”

“We’re looking forward to getting the build underway and welcoming new people to the team in early 2022.”

For more information about Crestchic, and for current and future job opportunities, visit our recruitment page here.

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Crestchic has remained at the forefront of the demand for load bank testing solutions, and as a direct response to that, Crestchic is pleased to announce it has recruited Paul Cotton, an experienced Sales Manager, to further grow its rental division.

Paul, who hails from the south coast, brings with him over 11 years engineering, project management and sales experience to this role.

“Crestchic is a highly respected company within the load testing sector and I’m proud to be working within their rental team,” said Paul.

“I’ve studied engineering to a HND level and have always enjoyed working within a sales environment, so I’m confident this opportunity is a perfect fit for me.”

Chris Caldwell, Managing Director at Crestchic, said: “I’m really looking forward to seeing Paul as Rental Sales Manager excel in this position. We all wish him every success and happiness within our family.”

Paul is keen to put his experience to work. “I’ve been training here for a few weeks now and the people I’ve met are extremely helpful and dedicated to helping maintain Crestchic’s position as a world leader in load bank manufacture and sales.”

Paul says his chosen career path has always been enjoyable, but it did get even more interesting when a previous job required him to visit a prison. Identities were mistaken and he found himself one step away from unexpectedly interviewing a prisoner.

“It made for an odd situation, but the prison thought I was another ‘Paul’ they were expecting as a parole officer for one of their inmates. I was literally seconds away from sitting down with a prisoner!”

“Definitely not a career move I was expecting to make,” laughs Paul.

Crestchic has been operating for over 30 years’ in the load testing arena, garnering an incredible reputation for delivering world leading products and services, with some of the biggest industrial clients around the world.

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If you require a quote for a load bank package, please contact us here: Contact Form

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NOVA uses fibre-optic communication as standard, the benefits being that we can run long distances without the need to boost signals and there is zero chance of electrical interference from the main load cables. The feedback from our rental department is of highly stable communications providing rapid command implementation and data readings from the system instrumentation. Customer feedback has been equally good, and the first update of the ORION software since its initial release is imminent.

We intend to roll-out the NOVA control system to most containerised fleet load banks over the next 18 months.

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If you require a quote for a load bank controls package, please contact us here: Contact Form

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Electricity under lockdown
Life under lockdown has led to a shift in the daily routines of millions of people. Offices with banks of computers and power-hungry air conditioning are closed, factories are operating on a skeleton staff or are temporarily shut, shops and commercial centres are on lockdown. The electrical demands of commercial and industrial settings have lessened significantly. At the same time, the lockdown has shifted the demands of consumers. Data suggests we’re getting up and staying up later, shifting our patterns of energy consumption along with our body clocks, while the massive increase in subscriptions to the likes of Netflix and Disney Plus is also evidence of the trend towards increased power consumption during the evening.

This pattern is being borne out by electricity networks across the globe. In New York, power consumption during the morning rush hour has fallen by as much as 18%, while Japan has recorded a 5% drop in power use during weekdays. In the UK, the National Grid has warned that record low demand for electricity during the coronavirus lockdown could see supply outstrip demand which, in turn, could lead to blackouts.

Why is fluctuating demand an issue?
It stands to reason that blackouts are likely to occur when the demand for electricity exceeds supply. Conversely, too much electricity can also be a problem, causing the frequency on the grid to rise and potentially causing damage to infrastructure as well as problems on local energy grids. The combination of high levels of power generation and low demand can also reduce the energy system’s resilience to sudden changes in frequency, which can lead to temporary blackouts.
In April 2020, just as the UK government announced the extension of lockdown plans, National Grid published a statement which suggested that demand for electricity could fall 20% below normal levels, potentially leading to an oversupply of electricity and subsequent issues with continuity of power. Put simply, the UK may experience blackouts.

Balancing supply and demand
Historically, power in the UK has been supplied by a small number of large power stations, such as coal or nuclear. These huge power generation plants are inflexible, taking hours to shut down safely, reducing their ability to make any fast changes to supply. As supply evolves and the world switches towards greener and more sustainable sources of power, there is even more variability in supply – bringing with it further fluctuations along with an ability to be more responsive to change.

Flexible windfarms can power down quickly, switching off at short notice to avoid overwhelming the grid. Hydropower also offers a solution, harnessing excess energy to pump water into lakes into order to effectively stem the flow of power to the grid. While battery storage is seeing increased investment, further work is needed before it provides a viable solution to storing sufficient energy to balance grid fluctuations. Yet, despite these measures and their ability to be more responsive to changing demand, there’s no denying that the increased prevalence of smaller, intermittent sources can themselves result in varying power outputs and instability in supply. The high frequencies caused by high supply coupled with low demand can be very damaging to the transmission and distribution infrastructure, making HV cables bulge and putting transformers and switchgear under greater strain, as power becomes greater than original directional flow design. This was already an issue in areas of major solar generation, such as the South West.
In ‘normal’ circumstances, the grid’s frequency control demand management programme would help to mitigate these fluctuations. Major commercial and industrial consumers are incentivised to scale back or rapidly ramp-up their consumption of power to balance peaks and troughs. While pre-agreeing this pattern is a plausible option, using it as a way to mitigate risk in times of crisis isn’t something that can easily be achieved. Very few businesses have processes that they can turn up quickly to increase demand to the grid and, with many of the UK’s high-intensity power consumers currently inactive due to shutdown, there’s a declining pool of candidates willing and able to do so.

The role of load banks
A load bank offers the perfect power consumption solution to the issue of oversupply, providing a fast-acting, safe, major energy user that can be easily “plugged” into the grid. In simple terms, they can be used to manage and shed power overloads in order to prevent damage. Excess energy can be diverted from the energy network and power lines into load banks, which can then be safely dissipated as hot air.

Load banks are designed to replicate, prove and verify the real-life demands on critical power systems. As such, they are most often used to test back-up power generators and back up power systems. With modern life absolutely reliant on electricity to power everything from our personal lives to our transport, our businesses to our hospitals, load banks have a critical role to play in ensuring continuity of supply. Their role in shedding and dissipating overloads is lesser-known. Yet, in testing times, none the less valid in terms of ensuring the UK has the power it needs – especially with critical infrastructure such as hospitals reliant on uninterrupted supplies.

Whilst load banks have only recently played a small part for balancing the grid, load bank rental offers a viable, immediate and temporary solution to the issue of oversupply. With stability of supply reliant on the grid keeping the frequency at 50hz, load banks can act as a pressure relief valve, making a discernible, safe and immediate difference in an emergency situation, mitigating the risks caused by oversupply and reducing the likelihood of the UK being left without power.

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