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UPS/Generator Maintenance with Load Banks UPS/Generator maintenance with load banks #DigitalEvolution #InnovationDay #EcoStruxure Presenter Spilios Rigopoulos National ASCO Business Development Manager, Australia & New Zealand ASCO Power Technologies SCHNEIDER ELECTRIC Spilios Rigopoulos Schneider Electric | Page 2 What is a Load Bank? A Load Bank provides a consistent and repeatable electrical load, that can be accurately controlled, measured and recorded. Intelligent Hand-Held Terminal SIGMA LT & SIGMA 2 Module Sigma Software Control Supply-on-Test ModBus SIGMA. The ASCO load bank control and instrumentation platform. Network multiple load banks. Numerous interfaces and options to meet market & application. Confidential Property of Schneider Electric What is a Load Bank? All industrial load banks utilize a fan and use the corresponding airflow to cool the resistive elements. The air flow can be Vertical or Horizontal discharge Must have rugged and reliable resistive elements. ASCO load bank elements can be either the helically wound “Avtron HelidyneTM or Froment style non finned sheathed elements It must accurate controls to place appropriate load on to the power system. “Accurate load bank step” Confidential Property of Schneider Electric Why Does The World Need Load Banks? “The best way to replicate, prove and verify the real life demands on critical power systems.” • Gen-Set Testing & Compliance: • Commissioning • Verify performance • Prevention of wet stacking • Engine maintenance • Meeting emission standards including Tier 4 • Testing to ISO8528 • AVR (Automatic Voltage Regulator) and governor setup • UPS / DC – Capacity testing An ASCO load bank testing two diesel gen-sets • HVAC Commissioning – data centres / server heat profiling • Power Factor Correction Testing - 0.8 lagging or leading • To Test Infrastructure – Breakers, power distribution Confidential Property of Schneider Electric Load Testing affects all major Genset Components Running the generator at 100% load, ensures all components of the generator are tested. By running the generator at full load for a period, the generator will reach the optimal running temperature to ensures; 1. The cooling system is tested 2. To remove unburnt fuel and carbon build up in the generator – a condition call ‘WET STACKING’ 3. Testing the performance of the AVR, Governor (frequency) and controls. Confidential Property of Schneider Electric Why Test Under Load? Prevent Wet Stacking • Unburned hydrocarbons produced when engine temperatures are below optimum (typically <30% of nameplate capacity. • Reduced HP and efficiency. • Increased emissions. • Carbon buildup leads to ‘frozen’ piston rings resulting in hot gasses slipping between the piston and the cylinder wall eroding away the piston and losing compression.* • Will eventually lead to engine failure Technically, the carbon builds up in the ring slot, preventing the ring from moving freely in the slot, locking the ring into one position. Confidential Property of Schneider Electric 9 Regulations & Load Testing AS/NZ 3009: 1998 B3 MAINTENANCE AND TESTING B3.1 Regular running Both automatic and manually operated plant should be run on load for at least 4 on a regular basis but not less than once a month ISO 8528 New genset operational standards Confidential Property of Schneider Electric ISO 8528 • Performance Standard for new gensets • Genset is tested to a Profile of V and HZ responses during • Load acceptance • Load rejection • Motor starting • 4 Classes: G1, G2, and G3 Profiles are pre-defined. G4 for custom • Preferred to test at nameplate PF, often 0.8 lagging: Exception reporting required if testing done at unity PF Confidential Property of Schneider Electric ISO 8528 Confidential Property of Schneider Electric Site Load Correction (SLC) Site Load Correction (SLC) is an automatic control feature for SIGMA-equipped ASCO Load Banks that automatically applies load to electrical circuits to maintain the minimum amount of load required by diesel generators. The following describes SLC features, benefits, and operation. THE NEED FOR SLC Wet stacking is the accumulation of unburned fuel residue that develop in the exhaust systems of diesel engines when they operate below minimum levels of load, which is commonly 30% of nameplate capacity. Under these conditions, engines may not reach optimal operating temperature. The resulting fuel combustion process is incomplete, resulting in increased emission of particulates as well as carbon monoxide and other green house gasses. Operating under no-load or light loaded conditions for extended periods promotes wet stacking. Maintaining minimum load levels avoids wet stacking and thus promotes reliability and longevity. Confidential Property of Schneider Electric Controls Options – Site Load Control Engine Load Bank Load Generator Desired Loading 50% to 70% Facility Load Confidential Property of Schneider Electric Load Bank Utilization in the Data Center Sector Heat Simulation • Portable Load Banks – Mobile units that allow network testing in multiple aisles Verify – Heating Ventilation Air Conditioning (HVAC) • Load banks produce heat that simulate the server’s thermal output. • Tests effectiveness of the HVAC system prior to server installation. Uninterruptible Power Supplies (UPS) Maintenance & Testing • Inverter performance Back-up Battery String • DC Load Banks for battery capacity testing Typical Data Commissioning Center Layout • Load test critical power components to identify any performance issues. • Ensure power system is working as designed. • UPS systems and testing inverter output Maintenance/Periodic Testing • Service Schedules and Diagnostics • Gen-Set Health • Wet Stacking Prevention • Ensuring Tier Emission Standards are Met • Diesel Particulate Filter (DPF) Burn Off Confidential Property of Schneider Electric Key Market: Data Centres Typical Data Centre Load Test Applications Presence & Customers • Commissioning • Current presence: • HVAC systems moderate • LV & MV gen-sets – ISO8528 • Key customers: • UPS Rental, end users and • Electrical equipment commissioning • Maintenance companies • UPS battery discharge Up to 25 Sigma LT load banks controlled by a single hand-held • ISO8528 Standards • Prevention of wet stacking • Server rack simulation Key Product Features • Data capture and reporting • Range of portable & static options • Networking and individual control • Automatic testing to ISO8528 Confidential Property of Schneider Electric Model 2705 – Suited Features Compact and Portable Compact and Portable • Manoeuvrability. Load Bank fits through doors and into elevators. • Lightweight. Easy for one operator to move with swivel casters, fork pockets, and lifting eyes. • Best-in-Class Packaging. 80 kW at 400 V, 50 Hz, weighs only 48kg. • SIGMA LT. Controls allow for flexibility, features, benefits and capabilities when compared to competitive digital control platforms. • Networking: SIGMA LT allow 25 load banks to be networked together for increased total capacity Model Capacity Frequencies Voltage Range Ambient Hot Air Control Optional Extras Name Available (Hz) (V) Temperature Discharge Options Range Direction 2705 80 kW 50 400 V -20°F to 120°F Horizontal Local Digital SIGMA LT Hand-Held Control, Toggle Cable Set, Transport Case Confidential Property of Schneider Electric Battery Capacity (Discharge) Testing Data Centers/Uninterruptible Power Supplies • Uninterruptible power supplies (UPSs) provide emergency power when main power fails. • UPS systems utilize strings of batteries for backup power during an outage. • Failure of a data center UPS can impact or interrupt operations and result in substantial business losses. • At these facilities, battery condition and performance are consistently found to be leading causes of failures. One means for avoiding these losses is accurately identifying batteries that are at risk of failure, then servicing or replacing them as needed. • The necessary data can only be derived from performance testing. • In order to obtain this data, a UPS battery string is typically tested using a DC load bank or by an AC load bank via the UPS inverter. • The type of load test will depend on the type of batteries used in the UPS. • The most meaningful tests record battery current, voltage, and temperature under load conditions. Note: Dissimilar voltages from cell-to-cell or string-to-string are a clear indication of battery degradation. Confidential Property of Schneider Electric Load Bank Utilization in the Healthcare Market Code Compliance Testing AS/NZS 3009:1998, B3.1 Regular running NFPA 99 - Healthcare Facilities Code NFPA 110 - Standard for Emergency Generator Systems NEC Article 700 - Emergency Systems NEC Article 708 - Critical Operations Power Systems The Joint Commission Standards Portable Load Banks – Mobile units that allow network testing in multiple locations Permanent Load Banks – Dedicated units installed outdoors for back up power testing Radiator Mounted Load Banks – Dedicated units mounted on radiator generator set for backup power testing Combined Resistive/Reactive Load Banks – Designed for 0.8 pf testing & verification of power source(s). Testing to ISO8528 G3 classification pass or fail. Uninterruptible Power Supplies (UPS) Testing • Inverter performance Maintenance/Periodic Testing Back-up Battery String • Service Schedules and Diagnostics • DC Load Banks for battery capacity testing • Gen-Set Health • Wet Stacking Prevention Commissioning • Ensuring Tier Emission Standards are Met • Load test critical power components to identify any performance issues.
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