Generator Load Testing

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We offer Comprehensive Generator Load Testing

Reactive Generators offers comprehensive generator load testing, personally tailored to suit your needs from 1kW all the way up to 3000kW. Our team of qualified and experienced professionals only use quality equipment, calibrated load banks and proven testing procedures to provide an all-inclusive and guaranteed independent load testing service. We recommend annual testing for most standby/emergency generators and after any low loading situations for prime power generators. 

Why do you need to Perform Generator Load Testing?

Maintaining the efficiency and performance of a generator is the key to ensuring its longevity, enhancing its reliability and increasing the machine’s capabilities during a power outage. Standby or prime power generators that are rarely used or only operated on a light load can incur glazing of the piston bores and or get a build up of fuel deposits in the engine overtime. 

This results in reduced output or failure to work at all when the situation arises as well as increased oil consumption and a poor fuel rating. Neglecting a generator for an extended period of time can also lead to unexpected operating costs, excessive wear and increased exhaust emissions. The most effective performance assessment of a generator is to conduct independent load testing. This aspect of the maintenance regimen requires putting a 100% capacity load on the machine and allowing it to run for a set period of time. Regularly scheduled maintenance will ensure your generator is able to manage the demanded load when needed, and is a compulsory requirement for many insurance companies.

Generator Load Testing

The Process to perform Generator Load Testing

When an independent load bank test is implemented, an artificial load is placed on the generator. The experienced and professional team at Reactive Generators uses a controlled environment to time and incrementally elevate the kW load in specific measures. Each time the load is increased, the team member measures and records the generator’s ability to handle the boost and continue functioning at the highest possible standard over time and if required, specific dump loads as well. 

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A Breakdown of the Process is as Follows

Step One:

Reactive Generators will firstly check all fluid levels in the generator. After ensuring the fuel tank is at maximum capacity, the oil levels are correct, the radiator is also full (applicable for water-cooled generators) and all critical shutdowns are operational, the startup testing process can begin. 

Step Two:

One of our knowledge team members will start the generator and allow the machine to run until it has reached nominal operating temperature and monitor data parameters. This process will identify any initial problems with the engine, alternator and or control system, which must be rectified before the load testing can commence.

Step Three:

We will then begin incrementing load upon the generator, generally starting with 25% of the generators specified capacity and continuing until 100% load is achieved. At each step data is collected and recorded, including for the duration of a continued load period at 100%, to assure consistency in performance is maintained.  

Step Four:

Over the continued load period at 100%, we will continue to observe the generator, watching for overheating, listening for unusual noises and monitoring the outputs. The length of this process is dependent on each individual generator and or any inhouse requirements you may need met. If any issues are identified, the generator is immediately shut down to minimise the damage and submitted for repairs before being returned to service. 

Step Five:

After the conclusion of testing, the generator is run under a light load for cooling, before all loads are removed and the generator is shut down. 

Generator Load Testing FAQ

What happens if there are issues identified during the load testing?

With a team of skilled engineers and technicians, Reactive Generators can address any issues on-site. We have replacement parts in stock at all times to ensure we can efficiently and comprehensively solve our customer’s problems. We stock most brands including the following:

  • Perkins (FG Wilson, Sabre, Lister Petter, Dorman)
  • Caterpillar (Olympian)
  • Cummins (DCEC)
  • Pramac
  • Denyo
  • Kubota
  • Atlas Copco and more.

How often should my generator undergo load testing?

Reactive Generators recommends annual testing for most generators, but this depends on how often and to what capacity your generator is usually used. Get in touch with our friendly team to discuss the options and create a personalised strategy for your needs.

Where are Reactive Generators based?

Reactive Generators is based in Queensland and Northern New South Wales, we have a number of teams spread across Brisbane, the Gold Coast, the Sunshine Coast and Ipswich. Visit the locations page in our menu bar to find your closest Reactive Generators site.

Why should I trust Reactive Generators for my generator load testing?

With a wealth of experience and a commitment to customer satisfaction, Reactive Generators boasts a culture of collaboration, transparency and efficiency. We aren’t just experts in load testing, but we’re dedicated to providing every client with long-lasting value. We have a number of crews across Queensland so you can count on our reliable team to get the job done, regardless of where you are located.

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