Load Bank Testing Guide: Extend Generator Lifespan | PSTC

Introduction

For any facility in Saudi Arabia that relies on backup or prime power generators, from data centers and hospitals to remote industrial sites, the expectation is simple. When the power goes out, the generator must start and perform flawlessly. However, a generator that sits idle or only runs on very light loads is at risk of a condition known as “wet-stacking,” which can severely degrade its performance and shorten its lifespan.

How do you ensure your high-value generator is ready to perform at 100% capacity when you need it most? The answer is regular load bank testing.

The Idle Trap

What is Wet-Stacking?

Diesel generators are designed to operate at or near their rated power output. When a generator runs for extended periods on a light load (typically less than 30% of its capacity), the engine doesn’t reach its optimal operating temperature.

This leads to incomplete combustion of the diesel fuel. The unburned fuel and carbon soot can then enter the exhaust system, where they mix with moisture to form a thick, black, oily liquid—a condition known as wet-stacking.

The Dangers of Wet-Stacking:

• Reduced Capacity: The buildup of carbon can foul injectors, piston rings, and exhaust valves, reducing the generator’s ability to produce its full rated power.
• Increased Emissions: The generator will produce more smoke and harmful emissions.
• Engine Damage: Over time, this buildup can cause serious engine damage, leading to costly repairs or even complete failure.
• Fire Hazard: The accumulation of unburned fuel in the exhaust system creates a significant fire risk.

The Solution: Load Bank Testing

A load bank is essentially a device that creates an artificial electrical load, allowing you to run a generator at its full capacity in a controlled, measurable way. By connecting a load bank, such as a high-quality unit from Avtron or Froment, you can simulate the demand of your entire facility without interrupting your actual operations.

How Load Bank Testing Helps:

1. Prevents Wet-Stacking: Running the generator under a full load brings the engine up to its correct operating temperature. This burns off the carbon deposits that have accumulated in the engine and exhaust system, effectively cleaning it out and preventing wet-stacking.
2. Verifies Full Capacity: A load bank test is the only way to prove that your generator can actually handle its full nameplate kilowatt (kW) rating. This verifies that it will perform as expected during a real power outage.
3. Identifies Problems Early: Pushing the generator and its cooling system to their limits can reveal hidden issues like leaks, weaknesses in hoses, or cooling inefficiencies that would not be apparent during a simple idle test.
4. Exercises the Entire System: A load test exercises not just the engine but the entire power system, including the alternator, voltage regulator, control systems, and cabling.
   

Our load bank solutions cover:

• Resistive & Reactive Testing

• Low Voltage to High Voltage (LV/HV)

• Portable units for remote sites

Implementing a Load Bank Testing Schedule

For critical backup generators, industry standards often recommend performing a load bank test annually. A typical test involves running the generator at its full rated load for a set period, usually several hours, while monitoring critical parameters like temperature, pressure, and frequency.

At Pressure Systems KSA, we provide state-of-the-art Avtron and Froment load banks for sale or rental, giving you the tools you need to implement a robust generator maintenance program. Our team can help you select the correct size and type of load bank for your specific generator set.

A generator failure during an outage costs more than a test. Schedule your load bank rental with PSTC today to certify your power readiness.