HIERSUN POWER GENSET LOAD TEST PROCEDURES

GENSET

A common base frame skid mounted genset comes with radiator cooled diesel engine coupled to industrial brushless alternator.

1.   OBJETIVES

1.1.      To ensure that the diesel engine is operating satisfactorily without undue vibration and overheating.

1.2.      To ensure that the diesel engine is able to sustain prolong running on full load without any sign of straining and abnormalities.

1.3.      To ensure that the safety shutdown devices are operative.

1.4.      To check on any other operating characteristic (not standard) if required by the client.

1.5.      To verify the fuel consumption against specification data of diesel engine.

2.   MEASURING AND RECORDING INSTRUMENT

All electrical recording such as voltmeters, ammeters, frequency meters, hour run meters, factor meters including volts, amperes and frequency are installed in the control panel in the control room.

3.   DUMMY LOADS

The diesel engine is coupled to an alternator and the power supply terminals are connected to dummy loads by either one or combination or both of the two special designed industrial ‘grid type’ resistance banks.

4.    TEST PROCEDURE

The Load Test consists of three stages:

4.1   No load To Full Load Test- Using Dummy Loads

The generating set is started up with no load gradually Increased with resistive loads in steps to Full Load.

                 To duration for standard test is as follow:-

                 Dummy load            Testing Time

                 No Load                   5 minutes

                 25% full load current          15 minutes

                 50% full load current          15 minutes

                 75% full load current          30 minutes

                 100% full load current       60 minutes

                 110% full load current       60 minutes

                                  TOTAL    3 hours

           4.2     Safety Devices Shutdown Test

4.2.1           Low engine oil pressure fault is simulated by short circuiting its sensing device to earth which would signal the emergency relay to shutdown the engine.

4.2.2          Similarly, when the high water temperature fault is simulated, the engine should down automatically.

4.2.3           The engine speed is adjusted to run above 1500 rpm and when it exceeds 15% of the rated speed, the speed governor switch should signal the emergency relay to shutdown the engine.

5.    TEST RECORD AND REPORT 

Before commencement of load test, all relevant information for the diesel engine is entered into standard ‘Test Report Sheet’ (please refer to sample attached). The test results obtained during the various stage of the test are recorded in the standard format.

 6.     CRITERIA OF TEST MEASUREMENT

6.1    Fuel consumption reading for respective loads will be recorded.

6.2    The engine speed in (RPM) is read off from the engine tachometer.

6.3    Cooling water temperature (in ⁰C) is taken at the engine water outlet pipe using the engine tachometer.

6.4    Lube oil pressures (in psi) is read from engine pressure gauge.