~ How to rectify common testing pitfalls ~
Load bank testing is a vital process for ensuring the reliability of power systems, but even experienced teams can make errors that compromise results or lead to equipment downtime. From underestimating testing requirements to over relying on outdated testing equipment, Andrew Keith, division director of load bank manufacturer Power Prove, explores five of the most common pitfalls seen in load bank testing and provides actionable tips to avoid them.
There are very few industries that don’t benefit from load bank testing to ensure they remain operational. Whether it’s preventing unplanned downtime in continuous processing or keeping vital infrastructure online when mains power fails, load bank testing is a non-negotiable requirement for any industry relying on electrical power.
However, testing can be rendered ineffective if it’s carried out incorrectly. So, what are some of the main errors that maintenance teams should avoid?
Skipping regular testing
Since backup power supplies are largely used in the case of emergencies, it’s easy to neglect regular testing. However, this increases the risk of unexpected failures when generators are needed most.
Routine load bank testing should be part of a comprehensive maintenance schedule to identify issues early, prevent costly repairs and ensure backup power sources are fully operational. Regularly scheduled testing also helps businesses remain compliant with industry standards, for example to ensure that emergency lighting systems are functioning and able to safely guide building occupants outside.
Low loading
While regular testing is key, simply connecting power units to a load bank and running them at a low load can lead to serious issues in itself. When generators operate under loads rated at less than 40 per cent of their rated power for prolonged periods, carbon deposits can accumulate, leading to ‘wet stacking’ and reduced efficiency.
This can also increase maintenance costs and reduce the lifespan of the generator. Regular load bank testing at the optimum load ensures that generators operate within optimal parameters, improving performance and reliability.
Underestimating load testing requirements
With low loading in mind, it’s important to properly assess the power requirements for testing. Selecting a load bank with insufficient capacity can lead to incomplete testing and an inaccurate assessment of backup power systems. On the other hand, significantly overestimating requirements can result in unnecessary costs. You should aim for a load bank setup with a slightly higher capacity than your current equipment requirements, allowing for effective testing and room for future growth.
Relying on outdated load bank technology
Ageing load bank technology is often less precise than more modern load banks, which can lead to inaccurate test results. Additionally, older load banks often lack the automation required for modern power testing. Their manual systems require on-site adjustments, making it difficult to conduct thorough and frequent tests, particularly in remote or hazardous locations.
Advancements in digital load bank control systems allow for real-time data collection, remote operation and predictive maintenance. Investing in modern load bank solutions ensures faster, more accurate testing and enhances overall power system reliability.
Disregarding test data
Load bank testing is only as valuable as the insights gained from it. Failing to record and analyse test results can render the process ineffective, as businesses miss out on key trends and early warning signs of potential failures.
Traditional manual data collection methods can be time-consuming and prone to errors, making it difficult to track performance over time. Modern load bank systems, such as Power Prove’s DIGILOAD, automatically record and store test data in easily accessible formats that are downloadable onto a USB. This streamlined approach enables quick analysis and integration into predictive maintenance strategies, ultimately reducing downtime and improving overall system reliability.
By avoiding these common pitfalls, organisations can enhance the effectiveness of their load bank testing and ensure their backup power systems are ready for any situation. Thorough planning, investing in modern technology and ensuring regular testing will help mitigate risks, improve efficiency and safeguard critical power infrastructure.
