How can load bank testing your genset reduce the cost of ownership?
Commercial and Industrial generators are usually diesel powered and are built to be a back up power solution if the power goes down. They are designed to be used for long periods of time should repairs to the mains be substantial.
Costs for a commercial genset typically range between:
| Power Output | Cost Range |
|---|---|
|
50 – 500kVA |
$15,000 – $70,000 |
|
500 – 1,000+ kVA |
$70,000 – $120,000+ |
DPF Regeneration
Diesel engines produce soot that accumulates in the DPF. To clean the DPF, the soot must be burnt off—a process called regeneration. Regeneration typically requires exhaust temperatures of 250–600°C. On a dynamometer, the engine can be run at specific speeds and loads to intentionally raise exhaust temperatures and trigger regeneration.
Most experts recommend annual load testing using a load bank as part of a comprehensive maintenance plan.
The Benefits of Load Testing Include:
Improving Fuel Combustion
By simulating full load conditions, the genset’s fuel system is calibrated more accurately, leading to cleaner combustion and less residue inside the engine.
Preventing Wet Stacking
Running a diesel genset at low loads can cause unburned fuel and soot to build up in the exhaust system—a condition known as wet stacking. Load testing burns off these deposits, keeping the engine clean and efficient.
For more information on preventing wet stacking click here.
Reducing Engine Stress
Regular load testing helps the genset operate under controlled conditions, avoiding sudden stress during real emergencies. This reduces wear and tear on critical components.
Identifying Early Faults
Load testing reveals hidden issues like overheating, voltage instability, or poor fuel pressure before they escalate into costly failures.
Regulatory Compliance
For facilities like hospitals or data centers, load testing is often required by standards such as NFPA 110 to ensure emergency power systems are reliable.
Extending Lifespans
Helps maintain optimal operating conditions, reducing wear and tear and prolonging the generator’s life.
Verifying Performance
Confirms the genset can produce its rated power output and maintain stable voltage and frequency under real-world conditions. Boosting confidence knowing your genset has passed a full-load test gives peace of mind that it’ll deliver when needed most.
Maintaining Optimal Operating Temperature
Gensets need to reach full operating temperature to burn fuel properly. Load testing ensures the engine runs hot enough to avoid carbon buildup and clogged diesel particulate filters (DPFs).
Identifying Hidden Issues
Detects problems like overheating, fuel inefficiencies, or electrical faults before they cause failure during an emergency.
Supporting Preventive Maintenance
It’s a cornerstone of preventive care—helping technicians spot and fix problems early, which keeps the genset running smoothly for years.
Find out more about our service packages here.
What Happens During a Load Test?
- The genset is connected to a load bank that simulates electrical demand.
- Load is applied in stages—typically 25%, 50%, 75%, and 100% of rated capacity.
- Technicians monitor voltage, frequency, oil pressure, coolant temperature, and exhaust output.
- The genset runs at full load for 2–4 hours to validate sustained performance.
How Often Would a Generator Require Servicing?
Annually
(at 80% load for 60 mins)
Monthly
(30–50% load for 30 mins)
Annually
plus 2-hour test after repairs
Quarterly
or more, depending on conditions
What factors can Influence Testing Frequency?
NFPA Guidelines: NFPA 110 recommends monthly testing for life-safety systems and annual full-load testing for standby generators.
Environmental Conditions: Humidity, dust, salt exposure, and temperature extremes may require more frequent testing.
Usage Pattern: Generators used continuously or intermittently may have different needs.
Manufacturer Recommendations: Always check the manual for model-specific guidance.
Using commercial generators as an example, routine servicing is scheduled for every 500hrs or so depending on manufacturers.
This service usually includes:
- Oil and Oil filter change
- Fuel filter and RACOR change
- Air filter change
- Top up of coolant levels
- Oil sampling
- Adblue filter change
Sometimes additional servicing may need to be carried out every 2000hrs to ensure the generator is safe for use as wear and tear occurs. In addition to the above servicing other parts that could be changed include:
- Exhaust/inlet valve clearances
- Injector clearances (if applicable)
- Any Auxiliary belts (Fan/alternator belts)
- Brush pack in charge alternator (or a charge alternator if required)
- Radiator wash
- Remove covers on main alternator and check connections
Some service providers may include load testing within their packages, others may offer them as a separate service.
What is the Typical Lifespan of a Well-Maintained Generator?
| Generator Type | Typical Lifespan (Hours) | Estimated Years |
|---|---|---|
|
Diesal |
15,000 – 30,000 |
20 – 30 |
|
Natural Gas |
10,000 – 20,000 |
15 – 25 |
|
Gasoline |
6,000 – 10,000 |
10 – 15 |
Note: a generator running 650 hours per year could last up to 30 years before reaching 20,000 hours.
Factors That Can Influence Lifespan
Maintenance: Regular oil changes, filter replacements, and inspections are crucial.
Load Management: Operating near optimal load (not under- or over-loaded) extends life.
Environment: Extreme temperatures, humidity, and exposure to elements can shorten lifespan.
Installation Quality: Proper setup and ventilation help prevent premature wear.
For more information about how our load banks can help to maintain your generator please reach out to our sales team.
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