Document reference number: CRE\Biodiesel\TNBR2\04\210613\01
GENSET LOAD BANK TEST
DESIGN OF EXPERIMENT
A. OBJECTIVES
1. To conduct load bank test on a diesel generator subjected to biodiesel blended diesel, with
diesel as the baseline fuel.
2. To asses generators performance and emission characteristics when subjected to different
blends of biodiesel, as compared with diesel
3. To report and propose the way forward for biodiesel in the energy mix of power generation
sector
B. TEST PREPARATION
1. Prior to testing, the test unit shall undergo engine checking, servicing and exhaust stack
clean-up.
2. During start-up, the test unit shall undergo pre-test procedures to prepare the unit for
testing.
3. Pre-test procedures shall follow the Standard Operating Procedure (SOP) Load bank Test
established by TNB Logistic for the routine load bank test.
4. The procedures for pre-test will be performed by dedicated TNBL technicians
C. METHOD AND MATERIALS
1. Method
a. For conduct of test, the Standard Operating Procedure (SOP) Load bank Test established
by TNB Logistic shall be used
b. For analysis of data, SAE J1515 or similar test code shall be used
2. Materials/ Equipment
a. Test Unit
Genset provided by TNBL with the following specifications
ITEM
SPECIFICATION
KAPASITY (kW)
300kW
MODEL
GENSET NO.
PLATE NO.
SCANIA
B8
WBM 5852
b. Test fuel
The followings are the test fuels, according to sequence for testing
i. Test fuel #1 : Diesel (Industrial Grade) as baseline fuel
ii. Test fuel #2 : B5 (5% FGB + 95% Diesel)
iii. Test fuel #3 : B10 (10% FGB + 90% Diesel)
iv. Test fuel #4 : B15 (15% FGB + 85% Diesel)
v. Test fuel #5 : S10 (10% SGB + 90% Diesel)
Note :
FGB : First Generation Biodiesel
SGB : Second Generation Biodiesel
Document reference number: CRE\Biodiesel\TNBR2\04\210613\01
c. Instrumentations
The followings are equipments/instrumentations to be used for data acquisition
NO
MEASURED PARAMETER
EQUIPMENT/ INSTRUMENTS
1
2
3
4
1
2
Air flow rate
Fuel flow rate
Generator output
Exhaust emission
OTHER PARAMETER
Time
Fuel change
Anemometer
Flow rate meter (on-site)
Load Bank Test (on-site)
Gas Analyzer
Stopwatch
Drums/ hose (on-site)
D. TEST PROCEDURES
1. Transfer test fuel #1 from storage drum into genset fuel tank. This to be done using facilities
available at refueling station on site
2. Fill up all the Load Bank Test Datasheet (Air Intake, Fuel flow rate, Generator Output and
Emission) with the test details as follows:
a. Genset No
b. Capacity
c. Model number
d. Name of data recorder
e. Date of test
f. Time of test (start)
g. Type of fuel
3. Ensure all instruments for data collection is fitted or ready for data measurement
4. Start the genset and let it run for 5 minutes. Take the readings. This will be the initial reading
without any load
5. Set the load to 60 kW. Observe the measured parameters readings to ensure all instruments
are functioning properly
6. After 5 minutes, take the first reading. Take another reading after 10, 15, 20, 25 and 30
minutes.
7. Increase the load to 120kW and repeat step #6
8. Increase the load to 180kW and repeat step #6
9. Increase the load to 240kW and repeat step#6
10. Increase the load to maximum. Record the maximum load value and all the readings for
measured parameters.
11. End of testing. The genset technician shall proceed with routine steps for test completion.
12. Repeat all the procedures above for all the test fuel.
E. TEST PROCEDURES
The followings are Test Datasheets
Document reference number: CRE\Biodiesel\TNBR2\04\210613\01
LOAD BANK TEST DATASHEET
AIR INTAKE
GENSET NO : .. CAPACITY : MODEL :
NAME OF DATA RECORDER
DATE OF TEST
TIME OF TEST
START
END
TYPE OF FUEL
: ..
: ..
: ..
: ..
: ..
MEASUREMENT DATA SHEET
A) AIR FLOW RATE READINGS
UNIT USED
:
TIME
(min)
LOAD (kW)
0
60
120
180
240
MAX
240
MAX
5
10
15
20
25
30
B) AIR FLOW TEMPERATURE READINGS
UNIT USED
:
TIME
(min)
LOAD (kW)
0
60
120
5
10
15
20
25
30
180
Document reference number: CRE\Biodiesel\TNBR2\04\210613\01
LOAD BANK TEST DATASHEET
FUEL FLOW RATE
GENSET NO : .. CAPACITY : MODEL :
NAME OF DATA RECORDER
DATE OF TEST
TIME OF TEST
START
END
TYPE OF FUEL
: ..
: ..
: ..
: ..
: ..
MEASUREMENT DATA SHEET
A) FUEL FLOW RATE READINGS
UNIT USED
:
TIME
(min)
LOAD (kW)
0
60
120
5
10
15
20
25
30
180
240
MAX
Document reference number: CRE\Biodiesel\TNBR2\04\210613\01
LOAD BANK TEST DATASHEET
GENERATOR OUTPUT
GENSET NO : .. CAPACITY : MODEL :
NAME OF DATA RECORDER
DATE OF TEST
TIME OF TEST
START
END
TYPE OF FUEL
: ..
: ..
: ..
: ..
: ..
MEASUREMENT DATA SHEET
ENGINE SPEED (RPM)
FREQUENCY (Hz)
TIME
(min)
:
:
LOAD (kW)
60
0
VOLTAGE
RY
YB
BR
CURRENT
R
Twater
Plube
oil
VOLTAGE
RY
120
CURRENT
YB
UNITS
5
10
15
20
25
30
Twater
Plube
oil
VOLTAGE
RY
YB
BR
CURRENT
R
Twater
Plube
oil
Document reference number: CRE\Biodiesel\TNBR2\04\210613\01
LOAD BANK TEST DATASHEET
GENERATOR OUTPUT
GENSET NO : .. CAPACITY : MODEL :
NAME OF DATA RECORDER
DATE OF TEST
TIME OF TEST
START
END
TYPE OF FUEL
: ..
: ..
: ..
: ..
: ..
MEASUREMENT DATA SHEET
ENGINE SPEED (RPM)
FREQUENCY (Hz)
TIME
(min)
:
:
LOAD (kW)
240
180
VOLTAGE
RY
YB
BR
CURRENT
R
Twater
Plube
oil
VOLTAGE
RY
MAX
CURRENT
YB
UNITS
5
10
15
20
25
30
Twater
Plube
oil
VOLTAGE
RY
YB
BR
CURRENT
R
Twater
Plube
oil
Document reference number: CRE\Biodiesel\TNBR2\04\210613\01
LOAD BANK TEST DATASHEET
EMISSION
GENSET NO : .. CAPACITY : MODEL :
NAME OF DATA RECORDER
DATE OF TEST
TIME OF TEST
START
END
TYPE OF FUEL
: ..
: ..
: ..
: ..
: ..
MEASUREMENT DATA SHEET
TIME
(min)
EMISSION DATA
60 kW
0 kW
CO2
CO
O2
TEXHAUST
CO2
CO
O2
UNIT
5
10
15
20
25
30
120 kW
TEXHAUST
CO2
CO
O2
TEXHAUST
Document reference number: CRE\Biodiesel\TNBR2\04\210613\01
LOAD BANK TEST DATASHEET
EMISSION
GENSET NO : .. CAPACITY : MODEL :
NAME OF DATA RECORDER
DATE OF TEST
TIME OF TEST
START
END
TYPE OF FUEL
: ..
: ..
: ..
: ..
: ..
MEASUREMENT DATA SHEET
TIME
(min)
EMISSION DATA
240 kW
180 kW
CO2
CO
O2
TEXHAUST
CO2
CO
O2
UNIT
5
10
15
20
25
30
MAX kW
TEXHAUST
CO2
CO
O2
TEXHAUST
Document reference number: CRE\Biodiesel\TNBR2\04\210613\01
F. TEST FUELS BLENDING
1.
Test Fuel Preparation
a. There are five sets of test fuel which are Diesel, B5, B10, B15 and S10. Each test fuel
having total volume of 240 liter.
b. Waste Cooking Oil (WCO) biodiesel (FGB and SGB) are blended with diesel according to
the volumetric concentration of each fuel sample. Blending is required to produce
homogeneous fuel for testing.
c. The blended fuels are prepared by volumetric ratios for five various blends of biodiesel
as follows :BLEND
DIESEL CONTENT
BIODIESEL CONTENT
COMPOSITION
(LITERS)
(LITERS)
Diesel
240
0
B5
228
12
B10
216
24
B15
204
36
S10
216
24
2.
Apparatus for test fuel preparations
a. Weighing machine
b. 209 liter drum (one unit per sample)
c. 20 liter container (two units per sample)
d. Thermocouple
e. Washing module consisting of the followings
i. Measuring Tank
iv. Circulation pump
ii. Blending Tank
v. Centrifugal Pump
iii. Heater
Blending Process
a. Measure the volume of each diesel and biodiesel to be blended.
b. Transfer the measured diesel into the blending tank.
c. Heat up the mixture until the temperature reach 60OC.
d. After the temperature reach 60OC, transfer biodiesel into the blending tank and continue
with the stirring for 30minutes to 1 hour. Ensure the temperature to remain at 60OC
throughout this duration.
e. Transfer the blended fuel into its storage (drum and containers).
f. Ensure that all fuel storage are properly labeled and sealed.
g. Repeat step (a) (g) for all fuel blends.
3.
Document reference number: CRE\Biodiesel\TNBR2\04\210613\01
Prepared by
-----------------------------(NUR MAZLINI RAZALI)
Checked by
(Ir KUMARAN PALANISAMY)
Verified by
--------------------------(Prof Ir Dr Abd Halim bin Shamsuddin)
Approved by
-----------------------------------(Syed Roslin bin Syed Abdul Rahman)
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