Case Study: Generator Load Bank Testing Ensures Reliable Backup Power for a Major Office Application
Case Study
Generator load bank testing forms a core part of preventative service and maintenance by ensuring that standby power systems perform exactly as required when real demand occurs. Reliable backup power is also essential for commercial and office environments, where even a momentary loss of electricity can disrupt operations, compromise safety, and impact business continuity.
Application: Office / Business
Service: Generator Load Bank Testing
Power Rating: 800kW
Our service team recently carried out load bank testing on an 800kW generator supporting a major office facility. Load bank testing applies a controlled, artificial electrical load to the generator, simulating real operational conditions without affecting the site’s normal supply. This allows engineers to verify the generator’s ability to deliver and sustain power at its rated output, assessing key components such as the engine, alternator, fuel system, and cooling system under realistic stress.
Generator load bank testing serves several critical purposes:
Confirms real-world performance: A generator may appear to run well off-load yet fail when placed under actual demand. Load testing can reveal these hidden issues.
Prevents wet stacking and carbon build-up: Running at low or no load can cause unburnt fuel and soot to accumulate, reducing efficiency and lifespan. Load bank testing reduces this effect.
Verifies cooling and exhaust systems: Full load conditions enable testing of temperature stability to ensure the unit can withstand prolonged operation.
Supports compliance and risk management: Many industries require annual load testing as part of regulatory or insurance obligations.
During load bank testing, some engine components reached high operating temperatures and began to glow, which is an indicator that the generator was burning fuel efficiently and operating under the correct thermal conditions. The unit performed exceptionally, sustaining 100% load without issue and responding seamlessly to a rapid load step from 0% to 50% within one second.
This generator was an older, mechanically driven model, requiring a highly skilled, technically experienced approach. Due to the generator’s size and layout of the site, the project required extensive planning and logistical preparation.
Our engineers deployed a 1:1 load bank and extensive cabling. One lead service engineer and three load bank specialists coordinated the setup, cable routing, safety measures, and execution of the test.
This case study highlights the importance of routine load bank testing in maintaining the reliability of backup power systems. By undertaking regular testing, businesses can significantly reduce the risk of generator failure during a power outage.
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