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35 Factory Load Test

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Kareem Mamdouh
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14 views

35 Factory Load Test

Uploaded by

Kareem Mamdouh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Factory Load Test

Blue Star Power Systems, Inc’s factory testing is performed with the same extreme diligence and attention to
detail that is given to the prototype testing process. Every engine generator set receives a complete factory
load test that certifies and ensures that the set will function in accordance to every specific application.
Test metering will have an accuracy of 1.3% or better. This metering equipment is calibrated annually, and
is directly traceable to the National Institution of Standards & Technology (NIST). All test procedures are
conducted in accordance with MIL-STD-705C where applicable.

Factory Acceptance Testing Procedures


„ Insulation Resistance Test (301.1c)* „ Anticipatory Alarms and Shutdowns Test
(505.2b, 515.1b, 515.2b)
„ High Potential Test (302.1b)*
„ Optional Equipment Inspection (513.2a)
„ Alternator Over Speed Standard Reading Recorded During
„ Complete Engine Inspection
„ Load Test (640.1d Load Test Inspection
- Regulator Range Test (511.1d)
„ Generator Inspection - No Load Run Time AC Frequency
- Winding Resistance Test (401.1b) - MAX Load © 1.0 P.F. (640.2d) AC Voltage Exciter Field Voltage
- Exciter Field Stator - MAX Load @ 0.8 P.F.
- Main Field Stator - Block Loads @ 0-25%, 0-50%, 0-75%, AC Amperage Exciter Field Current
„ Mounting & Coupling Inspection 0-100% of rated load tests (640.2d) kVA Lube Oil Pressure
„ Engine Fuel System Inspection „ 1.0 Power Factor Max Load kWe Engine Coolant Temp.
„ Engine Lube Oil System Inspection „ 1.0 Power Factor Max Block Load Pickup
Power Factor Ambient Temp.
„ Engine Cooling System Inspection „ Full Name Plate Rated Load.

„ DC Charging System Inspection „ Standard Readings Taken Every 5 Minutes.

„ Main Output Circuit Breaker Inspection

* Performed By Alternator OEM

Factory Load Test Summary Witnessed Factory Load Test


All engine generator sets are visually inspected prior to testing. This includes a Standard witnessed factory load testing must be scheduled and approved at
complete visual/mechanical inspection to ensure that all fasteners and electrical least four weeks prior to the engine generator sets scheduled shipping date. Any
connections are secure, that all rotating components are free of obstruction/ requests for witnessed factory load testing after this four week period may incur
interference and are properly guarded. additional charges.
Once the unit is started, the AC voltage and frequency are set to rated values.
The unit is operated at no load while all of the safety shutdowns and warnings are
verified and tested. The unit is then restarted and run at 25%, 50% and 100% of
rated load and power factor until the engine temperature has stabilized for at least
ten minutes. During the rated and maximum load pickup portion of the test, the Witnessed Extended Run Factory Load Test
voltage regulator gain, stability and under frequency compensation adjustments are
set for optimal performance. All test procedures are performed in accordance with Witnessed extended run factory load testing must be scheduled and approved at
MIL-STD-705C where applicable. the time of order placement. Any requests for witnessed extended run factory load
Throughout these test procedures the AC parameters, engine oil pressure, engine testing after this time could be denied and would if approved incur additional cost.
temperature, exhaust temperature, timing and air/fuel ratio (gaseous units) are
monitored and recorded. The unit and all installed accessory equipment are
continually examined for oil and coolant leaks, excessive vibration and foreign
noises. All units are built and tested to cUL, CSA and NFPA 110 standards.

Once all test procedures are performed and recorded, the unit is allowed a cool
down period prior to being shut down. The unit is once again inspected for leaks,
loose fasteners and connections prior to leaving the test facility.

The unit receives another complete final inspection process prior to packaging and
shipment.

Note: All units are tested after the painting process is complete to prevent
unforeseen difficulties resulting from the painting process being performed after
testing.

Blue Star Power Systems, Inc. | 2250 Carlson Drive, North Mankato, Minnesota 56003 | Phone + 1 507 345 1776 | bluestarps.com

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