BRINE TANK LOAD TEST TESTING ANO ADJUSTING

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SUBJECT:
BUSINESS:
PRODUCT:
Brine Tank Load Test
Building Services, Material Handling
Generator Sets
BRINE TANK LOAD TEST
The most popular and inexpensive method used to
check generator set power output is the brine tank load
test. This simple test uses a salt water solution for a
resistive load between the terminals of a generator. The
equipment required is relatively easy to acquire and
assemble.
EQUIPMENT REQUIRED
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I2n!s - Preferable circular because electrodes
should be equidistant from each other and the
walls of the tank. It should be 3 to 5 feet (0.9-
1.5m} deep with at least 2.5 gallons (9.4L} per
kW capacity. A galvanized steel stock tank
works well.
Electrodes -- 1/8" to 1/4" (3 to 6mm} thick sheet
steel with surface area of 1.5 square inches
(10cm2} per kW. The electrodes should be
fitted into slotted wooden or steel frames that will
hold them stationary in turbulent water.
Insulation is required between each of the
electrodes and between the electrodes and the
frames to prevent an electrical short. The
electrodes must be positioned equidistant from
each other and the tank walls so that each
generator phase has the same line current.
21! - About 0.1 pounds (45g} of very fine salt
per gallon.
Electrical Meters -- Portable tong ammeter and
voltmeter to check current and voltage in each
phase. (Use generator control panel if possible}.
Miscellaneous - Lumber or steel for overhead
framework and electrode frames. Sufficient cord
or cable and pulleys to control electrodes.
Rubber or plastic hose to run make-up water to
tank and to direct overflow away from tank.
OPEBATING PROCEDURES
Set up apparatus similar to example pictures.
Raise the electrodes out of the water.
Start the generator set and run it at high idle
until it is warm.
Close the circuit breaker.
Slowly lower the electrodes into the water
making sure each causes the same line current
on each phase.
Operate the unit at one-half toad for thirty
minutes. This will warm up the unit and permit
current flow to aid in dissolving the salt.
If the tine current does not approach 0.8 of rated
full load current when all electrodes are fully
submerged, add salt to lessen the resistance of
the water. The salt should be added slowly to
allow time for complete dissolving. Watch the
ammeter to ensure readings do not pass
maximum allowable. (If the water is coot when
the salt is added, the salt may dissolve suddenly
when the water begins to boil. This will cause a
rapid increase of line current}. Additional water
should be added to replace evaporation loss.
Brine tank load will remain reasonably constant
if the water level is maintained, water
does not boil. If the liquid is boiling or flashing
into steam around the electrodes, the load will
not be stable. Severe steam flashing around the
electrodes can cause governor reactions that
may appear to be governor "hunting." The best
results are always obtained with minimum liquid
conductivity (lowest
BRINE TANK LOAD TEST
amount of salt) and maximum electrode
immersion. (Greatest possible electrode area in
the liquid.)
For any current reading, the power output of a 3-
phase generator can be calculated using the
following formula:
kW= E x I x 1. 73
1.000 X P.F.
Where: kW = Kilowatt output
E =Voltage (average of 3
lines)
= Amperes (average of 3
lines)
PF= Power Factor
A brine tank is a 1.0 power factor load.
WARNING
Rated generator kW occurs at 0.8 PF.
Therefore, to obtain generator rated kW the line
current should be 80% of the nameplate ampere
rating of the generator. Operation at full rated
current would result in a 25% overload.
PORTABILITY
The brine tank can be made portable by placing
it on a small steel trailer as seen in the picture.
The trailer should be equipped with a trailer jack
on each comer to enable the tank to be leveled.
$AFETY
The brine tank test should not be used for any
generator above 480 volts. If the generator
voltage is greater, use reduction transformers.
Avoid any possible flash over between
electrodes and tank.
Be sure the tank or any of its metallic support is
connected to a good earth ground.
The tank should be equipped with overflow
outlets to prevent the boiling water from spilling
over the top of the tank.
Each opening should be four to six inches (10 to
15 CM) from the top and have a hose to direct
the water away from the tank and the operator.
TESTING AND ADJUSTING
EXPLANATION OF PICTURED BRINE TANK
This tank has three vee-shaped electrodes
connected and insulated at the center and to the
side frames. The large center hole and
numerous small holes allow complete water
circulation during the turbulence caused during
load application.
This unit is very sophisticated and is only shown
as an example for constructing a brine tank.
Many applications do not require a load bank
this elaborate. By following the basic
construction guidelines listed earlier, a less
expensive tank can be constructed.
For example, three oil barrels electrically
connected will provide about a 150 kW load
when using round electrodes about 3 inches
(Bern) in diameter and 18 inches (45cm) long.
Discarded pipe with random holes burned
through the surface makes very good
electrodes.
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