overload testing a 60 kW diesel generator

[sewerzuk]

Made up a short video of a typical load/overload test that I do on my diesel generator sets. Thought I would share the sound of the turbo when I hit the set with 120% load. Makes me grin every time!

edit:
This is a clip of testing a smaller 4 cylinder 15kW diesel generator:

 

[930dreamer]

Very nice video, what are those going for price wise?

 

[pcpro15]

Very Cool!

 

[sewerzuk]

Very nice video, what are those going for price wise?

The one in the video is $5900

Obviously varies with hours and condition...

 

[torqueman2002]

Thanks, good to see what others do.

How do you apply the loads?

 

[kc-steve]

Very nice video! I'm just guessing, but you probably learned that in the military as a generator technician. I used to be in electronics in the USAF back in the early 1970s. Those military tech manuals were great for testing and preventative maintenance. We used to joke that the Army's manuals had a lot more pictures in them.

Steve

 

[Stick]

I spent a couple years working on those generators (among others that were 2k-140KVA). We had two switchable load banks in our small back shop, one that was capable of soaking 60kW, and one that was 120kW. With the larger generators running at full load hooked up to the load banks we had to have the shop doors open to dissipate the heat, even when it was -40f outside.

Was fun for a while, but after about two years of working on pretty much only gensets and trailers I was ready to go back to working on vehicles.

 

[sewerzuk]

Very nice video! I'm just guessing, but you probably learned that in the military as a generator technician. I used to be in electronics in the USAF back in the early 1970s. Those military tech manuals were great for testing and preventative maintenance. We used to joke that the Army's manuals had a lot more pictures in them.

Steve

Almost! I was a nuclear ET in the navy for about 9 years...I dealt with milliamps and not amps. But, I enjoy working on diesel equipment and electronics, so these generators are a perfect hobby for me. I really enjoy that first startup and load run after a repair!

 

[sewerzuk]

I spent a couple years working on those generators (among others that were 2k-140KVA). We had two switchable load banks in our small back shop, one that was capable of soaking 60kW, and one that was 120kW. With the larger generators running at full load hooked up to the load banks we had to have the shop doors open to dissipate the heat, even when it was -40f outside.

Was fun for a while, but after about two years of working on pretty much only gensets and trailers I was ready to go back to working on vehicles.

Yep...its amazing how much heat is created with that much power...even outside on a cool day everything in the vicinity of my load bank gets uncomfortably warm.

 

[Danglerb]

I'm not sure I saw the 120% test, just up to 100%.

 

[diesel research]

John Deere?

 

[sewerzuk]

I'm not sure I saw the 120% test, just up to 100%.

The 120% load test is at about 3:00 in the video. At 3:21 the set is also running at 120% when I use the clamp on ammeter. Somebody quick with a calculator might point out that, at 208v, the 181 amps I am measuring works out to 65kW (208*181*sqrt3=65kw, or about 108% of rated load). Since I am using a load bank that steps up the load in approx 10kw increments, I have to adjust the voltage on the generator to "fine tune" the load. In that clip, I am running the generator at approx 230v to get 120% load, or 72kW.

John Deere?

The manufacturer is Fermont. Most parts are interchangeable with other MEP model generator sets; it uses an Allis-Chalmers 6 cylinder turbodiesel, and a standard 12 lead generator head.

 

[Grazz256]

60kW? You should hear a step load on a CAT C175

 

[sewerzuk]

60kW? You should hear a step load on a CAT C175

Cat engines have a sound that is uniquely Cat...and its a great sound!

I may end up with a Detroit 6-71 powered set here sometime soon...the sound of a 2 stroke diesel is one that I enjoy as well...

 

[theoldwizard1]

Cold start at 50F ! Ha !!

How about at -20F with a 24 hour soak !!!!!

 

[TheGrooveking]

I'm not sure I saw the 120% test, just up to 100%.

At 3:06 is the 120% test.

TheGrooveking

 

[sewerzuk]

Cold start at 50F ! Ha !!

How about at -20F with a 24 hour soak !!!!!

Wondering if somebody would comment on that!
It is a cold start in that the generator had not been started for several weeks...not that the ambient temp was particularly cold.

Since I don't have a giant generator-sized freezer, my cold start was dictated by the weather here in the great NW in the fall...no freezing temps for another month or so!

I have started the -006a in the winter before. It never gets REALLY cold here; I believe it dipped into the teens once last year. I started that generator on a day when the outside temp was about 25 F. Smokes a bit more, but still fires right up.

 

[csmitty]

I can agree a C175-16 with 3MW on it produces a nice turbo whine. Course its also got 4 of them I haven't been around when the 20cyl has been running.

 

[Provincial]

I had a 3412 genset that ran a rock crusher. It was a sweet sound when wound up. I a kind of partial to the sound of all V-12's, especially Rolls-Royce Merlins in P-51's.

 

[csmitty]

Those rock crushers can be brutal on gensets.

 

[Grazz256]

I may end up with a Detroit 6-71 powered set here sometime soon...the sound of a 2 stroke diesel is one that I enjoy as well...

Have some refrigerator straps? If you can carry it out yourself you can have our old detroit. Mind you its a 1250kW so good luck hehe

 

[sewerzuk]

Have some refrigerator straps? If you can carry it out yourself you can have our old detroit. Mind you its a 1250kW so good luck hehe

That's obviously not a 6-71! 12v-71 maybe? Would love to hear that one in person as well!

 

[diesel research]

Sorry, no pics or any real specifics, but we had several cats. 20cylinder, 1950hp, run all day and night, providing power for a "small city". 5 or 6 of them spread throughout various parts of the area.

Our shop 2 cummins VT903s. Didn't find any data plates on them, have to take a wild guess and figure maybe 300kw a piece? I know it would likely have a pretty decent rating, because diesel gensets don't particularly like low load conditions.

I have spoke of a $800,000 toolbox we had before. It to had a generator, but just a small cummins 4B (non turbo) 4 cylinder and 40kw.

In military, used a lot of those 60k's (some looked different and I think had a digital display) towed with the ol deuce. Wasn't a generator "mechanic" per se, only ever did basic PM service to the engine side and or replace shut off solenoids. Do remember they would wet stack in the cold european alp nights. Slobbering diesel out the exhaust and running like ****, sometimes to the point of stalling. Didn't like those low/no-load nights. Or the fact people were using such a large unit to power a 60w troublelight.

 

[sewerzuk]

In military, used a lot of those 60k's (some looked different and I think had a digital display) towed with the ol deuce. Wasn't a generator "mechanic" per se, only ever did basic PM service to the engine side and or replace shut off solenoids. Do remember they would wet stack in the cold european alp nights. Slobbering diesel out the exhaust and running like ****, sometimes to the point of stalling. Didn't like those low/no-load nights. Or the fact people were using such a large unit to power a 60w troublelight.

I've been pulling military surplus gensets around with my deuce for a few years now...although my deuce doesn't look too military anymore! The 60kW set was sitting on its bed during the video, although you really don't see too much of it. I have quite a few other youtube videos of the deuce though...including a few car crushes and a 6 wheel burnout pulling a jeep out of a mudhole

The turbo sets seem to wet stack pretty quickly; they like 60% or higher load for sure. I have some non-turbo sets that don't seem to mind extended runs with little or no load. Although I haven't seen one stall, I have seen them run rough, smoke, and slobber black goo when they have run too long under a light load. They purr like a kitten when you ask them to run at 120% load though!

 

[sewerzuk]

How do you apply the loads?

I use a 300kW resistive load bank; it was designed as a permanently installed artificial load for a large generator. Each bank of elements works out to about 10kW at 208v. If I need a load that isn't in a multiple of 10, then I just adjust the voltage on the generator to change how much load they apply.

 

[Grazz256]

That's obviously not a 6-71! 12v-71 maybe? Would love to hear that one in person as well!

Its like this one:
http://www.equipmatching.com/used_equipment/5/75/191944.php
except with a remote rad.

No go on hearing it run, its 50% removed now, just have to figure out how to get it out of the basement...

 

[sewerzuk]

Added another video to my original post; it is a clip of me testing a 15kW diesel set:

 

[cundifc]

What's the diesel burn rate an hour?

 

[sewerzuk]

What's the diesel burn rate an hour?

I have never tested the 60kW, but the 15 is about .7 to 1.5 gal/hr depending on load. That was just done using my watch and a 5 gallon diesel can, so it may be off a little bit but it should be fairly close.