Load bank

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An air-cooled load bank, being used for acceptance testing of a 3000 kW standby diesel generator set. This is one of three banks used to load the generator to verify performance on load changes and for factory run-in. Air cooled load bank.jpg
An air-cooled load bank, being used for acceptance testing of a 3000 kW standby diesel generator set. This is one of three banks used to load the generator to verify performance on load changes and for factory run-in.

A load bank is a piece of electrical test equipment used to simulate an electrical load, to test an electric power source without connecting it to its normal operating load. [1] [2] During testing, adjustment, calibration, or verification procedures, a load bank is connected to the output of a power source, such as an electric generator, battery, servoamplifier or photovoltaic system, in place of its usual load. The load bank presents the source with electrical characteristics similar to its standard operating load, while dissipating the power output that would normally be consumed by it. The power is usually converted to heat by a heavy duty resistor or bank of resistive heating elements in the device, and the heat removed by a forced air or water cooling system. The device usually also includes instruments for metering, load control, and overload protection. Load banks can either be permanently installed at a facility to be connected to a power source when needed, or portable versions can be used for testing power sources such as standby generators and batteries. They are necessary adjuncts to replicate, prove, and verify the real-life demands on critical power systems. [2] They are also used during operation of intermittent renewable power sources such as wind turbines to shed excess power that the electric power grid cannot absorb. [3]

Contents

Applications

Load banks are used in a variety of applications, including:

Load bank types

The three most common types of load banks are resistive, inductive, and capacitive. Both inductive and capacitive loads create what is known as reactance in an AC circuit. Reactance is a circuit element's opposition to an alternating current, caused by the buildup of electric or magnetic fields in the element due to the current and is the "imaginary" component of impedance, or the resistance to AC signals at a certain frequency. Capacitive reactance is equal to 1/(2⋅π⋅f⋅C), and inductive reactance is equal to 2⋅π⋅f⋅L. The unit of reactance is the ohm. Inductive reactance resists the change to current, causing the circuit current to lag voltage. Capacitive reactance resists the change to voltage, causing the circuit current to lead voltage.

Resistive load bank

A resistive load bank, the most common type, provides equivalent loading for both generators and prime movers. That is, for each kilowatt (or horsepower) of load applied to the generator by the load bank, an equal amount of load is applied to the prime mover by the generator. A resistive load bank, therefore, removes energy from the complete system: load bank from generator—generator from prime mover—prime mover from fuel. Additional energy is removed as a consequence of resistive load bank operation: waste heat from coolant, exhaust and generator losses and energy consumed by accessory devices. A resistive load bank impacts upon all aspects of a generating system.

An operator controlling a resistive 200kW load bank being used to test a diesel generator. Avtron 200kW 3020 Load Bank.jpg
An operator controlling a resistive 200kW load bank being used to test a diesel generator.

The load of a resistive load bank is created by the conversion of electrical energy to heat via high-power resistors such as grid resistors. This heat must be dissipated from the load bank, either by air or by water, by forced means or convection.

In a testing system, a resistive load simulates real-life resistive loads, such as incandescent lighting and heating loads as well as the resistive or unity power factor component of magnetic (motors, transformers) loads.

The most common type uses wire resistance, usually with fan cooling, and this type is often portable and moved from generator to generator for test purposes. Sometimes a load of this type is built into a building, but this is unusual. [4]

Rarely a salt water rheostat is used. It can be readily improvised, which makes it useful in remote locations.

For testing automotive batteries, a carbon pile load bank allows an adjustable load to be placed on the battery or charging system, allowing accurate simulation of the heavy load on the battery during cranking of the engine. Such devices are usually portable and may include metering to show voltage and current. [5]

Inductive load bank

An inductive load includes inductive (lagging power factor) loads.

An inductive load consists of an iron-core reactive element which, when used in conjunction with a resistive load bank, creates a lagging power factor load. Typically, the inductive load will be rated at a numeric value 75% that of the corresponding resistive load such that when applied together a resultant 0.8 power factor load is provided. That is to say, for each 100 kW of resistive load, 75 kVAr of inductive load is provided. Other ratios are possible to obtain other power factor ratings. An inductive load is used to simulate a real-life mixed commercial loads consisting of lighting, heating, motors, transformers, etc. With a resistive-inductive load bank, full power system testing is possible, because the provided impedance supplies currents out of phase with voltage and allows for performance evaluation of generators, voltage regulators, load tap changers, conductors, switchgear and other equipment. [4]

Capacitor bank. Prague asterix laser system-capacitor bank.jpeg
Capacitor bank.

Capacitive load bank

A capacitive load bank or capacitor bank is similar to an inductive load bank in rating and purpose, except leading power factor loads are created, so reactive power is supplied from these loads to the system instead of vice versa. Hence for a mostly inductive load this can bring the power factor closer to unity improving the quality of supply. These loads simulate certain electronic or non-linear loads typical of telecommunications, computer or UPS industries. Fluorescent light tubes are also capacitive loads.

Resistive Reactive (Combined) load bank

A combined load bank usually consists of both resistive elements and inductors that can be used to provide load testing at non-unity PF (lagging) including the capability to test the generator set fully at 100% nameplate kVA rating. Combined load banks incorporate resistors and inductors all in a single construction which can be independently switched to allow resistive only, inductive only, or varying lagging power factor testing. Combined load banks are rated in kilovolt-amperes (kVA). It’s worth noting that combined load banks can consist of resistive, inductive, and capacitive (RLC) also. [2]

Typically, facilities require motor-driven devices, transformers and capacitors. If this is the case, then the load banks used for testing require reactive power compensation. The ideal solution is a combination of both resistive and reactive elements in one load bank package.

Resistive/reactive loads are able to mimic motor loads and electromagnetic devices within a power system, as well as provide purely resistive loads.

Many backup generators and turbines need to be commissioned at nameplate capacity using a combination of resistive and reactive load to fully qualify their operating capability. Using a resistive/reactive load bank enables comprehensive testing from a single unit. A range of resistive/reactive load banks are available to simulate these types of loads on a power source and the transformers, relays and switches which will distribute the power throughout the facility.

Resistive/reactive load banks may be used for testing turbines, switchgear, rotary UPS, generators and UPS systems. They can also be used for integrated system testing of utility substation protection systems, particularly for more complex relays like distance, directional overcurrent, power directional and others. A resistive/reactive inductive and/or capacitive load is often required to test solar inverters to ensure solar panels can be stopped from producing electricity in the event of a power outage. The resistive/reactive combination load banks are used to test the engine generator set at its rated power factor. In most cases this is 0.8 power factor. [6]

Electronic load bank

An electronic load bank tends to be a fully programmable, air- or water-cooled design used to simulate a solid state load and to provide constant power and current loading on circuits for precision testing.

Railways

Where a diesel-electric locomotive is equipped for dynamic braking, the braking resistor may be used as a load bank for testing the engine-generator set.

On electric railways, old electric locomotives no longer required for regular service sometimes get converted into mobile load banks for testing the overhead line equipment and power distribution systems. [7]

See also

Related Research Articles

In electrical engineering, the power factor of an AC power system is defined as the ratio of the real power absorbed by the load to the apparent power flowing in the circuit. Real power is the average of the instantaneous product of voltage and current and represents the capacity of the electricity for performing work. Apparent power is the product of root mean square (RMS) current and voltage. Due to energy stored in the load and returned to the source, or due to a non-linear load that distorts the wave shape of the current drawn from the source, the apparent power may be greater than the real power, so more current flows in the circuit than would be required to transfer real power alone. A power factor magnitude of less than one indicates the voltage and current are not in phase, reducing the average product of the two. A negative power factor occurs when the device generates real power, which then flows back towards the source.

In electrical circuits, reactance is the opposition presented to alternating current by inductance and capacitance. Along with resistance, it is one of two elements of impedance; however, while both elements involve transfer of electrical energy, no dissipation of electrical energy as heat occurs in reactance; instead, the reactance stores energy until a quarter-cycle later when the energy is returned to the circuit. Greater reactance gives smaller current for the same applied voltage.

<span class="mw-page-title-main">Power supply</span> Electronic device that converts or regulates electric energy and supplies it to a load

A power supply is an electrical device that supplies electric power to an electrical load. The main purpose of a power supply is to convert electric current from a source to the correct voltage, current, and frequency to power the load. As a result, power supplies are sometimes referred to as electric power converters. Some power supplies are separate standalone pieces of equipment, while others are built into the load appliances that they power. Examples of the latter include power supplies found in desktop computers and consumer electronics devices. Other functions that power supplies may perform include limiting the current drawn by the load to safe levels, shutting off the current in the event of an electrical fault, power conditioning to prevent electronic noise or voltage surges on the input from reaching the load, power-factor correction, and storing energy so it can continue to power the load in the event of a temporary interruption in the source power.

A static VAR compensator (SVC) is a set of electrical devices for providing fast-acting reactive power on high-voltage electricity transmission networks. SVCs are part of the flexible AC transmission system device family, regulating voltage, power factor, harmonics and stabilizing the system. A static VAR compensator has no significant moving parts. Prior to the invention of the SVC, power factor compensation was the preserve of large rotating machines such as synchronous condensers or switched capacitor banks.

<span class="mw-page-title-main">Impedance matching</span> Adjusting input/output impedances of an electrical circuit for some purpose

In electrical engineering, impedance matching is the practice of designing or adjusting the input impedance or output impedance of an electrical device for a desired value. Often, the desired value is selected to maximize power transfer or minimize signal reflection. For example, impedance matching typically is used to improve power transfer from a radio transmitter via the interconnecting transmission line to the antenna. Signals on a transmission line will be transmitted without reflections if the transmission line is terminated with a matching impedance.

In electrical engineering, particularly power engineering, voltage regulation is a measure of change in the voltage magnitude between the sending and receiving end of a component, such as a transmission or distribution line. Voltage regulation describes the ability of a system to provide near constant voltage over a wide range of load conditions. The term may refer to a passive property that results in more or less voltage drop under various load conditions, or to the active intervention with devices for the specific purpose of adjusting voltage.

<span class="mw-page-title-main">Dummy load</span> Device used to simulate an electrical load

A dummy load is a device used to simulate an electrical load, usually for testing purposes. In radio a dummy antenna is connected to the output of a radio transmitter and electrically simulates an antenna, to allow the transmitter to be adjusted and tested without radiating radio waves. In audio systems, a dummy load is connected to the output of an amplifier to electrically simulate a loudspeaker, allowing the amplifier to be tested without producing sound. Load banks are connected to electrical power supplies to simulate the supply's intended electrical load for testing purposes.

<span class="mw-page-title-main">Inrush current</span> Maximal instantaneous input current drawn by an electrical device when first turned on

Inrush current, input surge current, or switch-on surge is the maximal instantaneous input current drawn by an electrical device when first turned on. Alternating-current electric motors and transformers may draw several times their normal full-load current when first energized, for a few cycles of the input waveform. Power converters also often have inrush currents much higher than their steady-state currents, due to the charging current of the input capacitance. The selection of over-current-protection devices such as fuses and circuit breakers is made more complicated when high inrush currents must be tolerated. The over-current protection must react quickly to overload or short-circuit faults but must not interrupt the circuit when the inrush current flows.

<span class="mw-page-title-main">AC power</span> Power in alternating current systems

In an electric circuit, instantaneous power is the time rate of flow of energy past a given point of the circuit. In alternating current circuits, energy storage elements such as inductors and capacitors may result in periodic reversals of the direction of energy flow. Its SI unit is the watt.

<span class="mw-page-title-main">Volt-ampere</span> SI unit of apparent power in an electrical circuit

The volt-ampere is the unit of measurement for apparent power in an electrical circuit. It is the product of the root mean square voltage and the root mean square current. Volt-amperes are usually used for analyzing alternating current (AC) circuits. In direct current (DC) circuits, this product is equal to the real power, measured in watts. The volt-ampere is dimensionally equivalent to the watt: in SI units, 1 V⋅A = 1 W. VA rating is most used for generators and transformers, and other power handling equipment, where loads may be reactive.

<span class="mw-page-title-main">Electrical ballast</span> Device to limit the current in lamps

An electrical ballast is a device placed in series with a load to limit the amount of current in an electrical circuit.

<span class="mw-page-title-main">Synchronous condenser</span> Machinery used to adjust conditions on the electric power transmission grid

In electrical engineering, a synchronous condenser is a DC-excited synchronous motor, whose shaft is not connected to anything but spins freely. Its purpose is not to convert electric power to mechanical power or vice versa, but to adjust conditions on the electric power transmission grid. Its field is controlled by a voltage regulator to either generate or absorb reactive power as needed to adjust the grid's voltage, or to improve power factor. The condenser’s installation and operation are identical to large electric motors and generators.

Ferroresonance or nonlinear resonance is a type of resonance in electric circuits which occurs when a circuit containing a nonlinear inductance is fed from a source that has series capacitance, and the circuit is subjected to a disturbance such as opening of a switch. It can cause overvoltages and overcurrents in an electrical power system and can pose a risk to transmission and distribution equipment and to operational personnel.

An induction generator or asynchronous generator is a type of alternating current (AC) electrical generator that uses the principles of induction motors to produce electric power. Induction generators operate by mechanically turning their rotors faster than synchronous speed. A regular AC induction motor usually can be used as a generator, without any internal modifications. Because they can recover energy with relatively simple controls, induction generators are useful in applications such as mini hydro power plants, wind turbines, or in reducing high-pressure gas streams to lower pressure.

<span class="mw-page-title-main">Static synchronous compensator</span>

A static synchronous compensator (STATCOM), is a shunt-connected, reactive compensation device used on transmission networks. It uses power electronics to form a voltage-source converter that can act as either a source or sink of reactive AC power to an electricity network. It is a member of the FACTS family of devices.

<span class="mw-page-title-main">Electric power system</span> Network of electrical component deployed to generate, transmit & distribute electricity

An electric power system is a network of electrical components deployed to supply, transfer, and use electric power. An example of a power system is the electrical grid that provides power to homes and industries within an extended area. The electrical grid can be broadly divided into the generators that supply the power, the transmission system that carries the power from the generating centers to the load centers, and the distribution system that feeds the power to nearby homes and industries.

<span class="mw-page-title-main">Applications of capacitors</span> Uses of capacitors in daily life

Capacitors have many uses in electronic and electrical systems. They are so ubiquitous that it is rare that an electrical product does not include at least one for some purpose. Capacitors allow only AC signals to pass when they are charged blocking DC signals. The main components of filters are capacitors. Capacitors have the ability to connect one circuit segment to another. Capacitors are used by Dynamic Random Access Memory (DRAM) devices to represent binary information as bits.

A permanent magnet synchronous generator is a generator where the excitation field is provided by a permanent magnet instead of a coil. The term synchronous refers here to the fact that the rotor and magnetic field rotate with the same speed, because the magnetic field is generated through a shaft mounted permanent magnet mechanism and current is induced into the stationary armature.

This glossary of electrical and electronics engineering is a list of definitions of terms and concepts related specifically to electrical engineering and electronics engineering. For terms related to engineering in general, see Glossary of engineering.

Voltage control and reactive power management are two facets of an ancillary service that enables reliability of the transmission networks and facilitates the electricity market on these networks. Both aspects of this activity are intertwined, so within this article the term voltage control will be primarily used to designate this essentially single activity, as suggested by Kirby & Hirst (1997). Voltage control does not include reactive power injections within one AC cycle; these are a part of a separate ancillary service, so-called system stability service. The transmission of reactive power is limited by its nature, so the voltage control is provided through pieces of equipment distributed throughout the power grid, unlike the frequency control that is based on maintaining the overall active power balance in the system.

References

  1. "A closer look at load banks". Resources. Wattco, Inc. website. 2020. Retrieved 13 June 2020.
  2. 1 2 3 "Load Bank Basics". Avtron Power Solutions. Retrieved 2023-03-06.
  3. "Importance of load banks in the changing energy industry". Resources. Wattco, Inc. website. 2020. Retrieved 13 June 2020.
  4. 1 2 "Simplex: What is a Load Bank". comrent.com. Retrieved 2017-11-22.
  5. Ken Pickerill, Today's Technician: Automotive Engine Performance Classroom Manual and Shop Manual , Nelson Education, 2009, ISBN   1111782385, page 51
  6. "Avtron Load Banks White Paper - Application of Resistive/Reactive Load Banks for kVA Testing" (PDF).
  7. Bayer, Gareth (2021-09-13). "Locos of the RTC (Part 2b)". Rail Express. No. 305. Horncastle. pp. 78–79. ISSN   1362-234X.