Understanding the Importance of Commissioning New Systems: Load Banks, Runtime Tests, and More

service73125
Dec 1
3 min read

Updated: 20 hours ago

When a new system is installed, whether it’s a power generator, UPS, or electrical distribution setup, simply connecting it and turning it on is not enough. Commissioning plays a crucial role in ensuring the system works safely, reliably, and according to the customer’s expectations. This process involves a series of tests and inspections that verify every component performs as intended under real-world conditions.

Commissioning is the final step before handing over a system to the user. It confirms that the installation meets design specifications and regulatory requirements. This post explains what commissioning entails, why it is critical, and highlights key tools and tests used during the process, such as load banks, battery runtime tests, phase rotation meters, and torque verification.

Eye-level view of a load bank connected to a generator during testing — Load bank testing on a generator to simulate real electrical loads

What Commissioning Involves

Commissioning is a systematic process that covers multiple checks and tests to ensure the system operates safely and efficiently. It typically includes:

Visual inspections to confirm proper installation and wiring.
Mechanical checks such as verifying that all electrical terminations are torqued to the manufacturer’s specifications.
Functional tests to simulate real operating conditions.
Performance verification to ensure the system meets the required output and runtime.

Each step helps identify potential issues before the system goes live, reducing the risk of failures, downtime, or costly repairs later.

Using Load Banks to Test Real Loads

One of the most important commissioning steps for power systems is load bank testing. Load banks simulate electrical loads by drawing power from the generator or battery system, replicating the conditions the system will face during actual use.

Testing with load banks allows technicians to:

Run the system at full load for several hours to observe performance.
Detect any overheating, voltage drops, or irregularities under stress.
Verify that the system can handle the expected load continuously without failure.

For example, a generator rated for 500 kW will be connected to a load bank that draws close to that amount of power. Running this test for hours confirms the generator’s ability to sustain output and maintain stable voltage and frequency.

Battery Runtime Testing

Battery backup systems require careful runtime testing to ensure they deliver the promised duration during power outages. Commissioning includes:

Running the battery at full load to measure how long it can supply power.
Comparing the actual runtime to the customer’s specified requirements.
Testing the battery under different load conditions to verify consistent performance.

This step is critical because battery capacity can degrade over time or due to improper installation. By confirming runtime during commissioning, customers gain confidence that their backup system will perform when needed.

Close-up view of a technician using a phase rotation meter on electrical cables — Testing the uninterrupted power supply (UPS) system at full load to evaluate battery run time efficiency.

Verifying Phase Rotation and Electrical Connections

Proper phase rotation is essential for three-phase electrical systems to operate correctly. Incorrect phase rotation can cause motors to run backward, damage equipment, or create unsafe conditions. During commissioning, technicians use phase rotation meters to:

Confirm the sequence of electrical phases matches design requirements.
Identify wiring errors before energizing the system.

Additionally, verifying that all electrical terminations are torqued to the correct specifications is a vital safety and reliability step. Loose connections can cause overheating, arcing, or equipment failure. Using calibrated torque tools, technicians ensure every bolt and terminal meets the manufacturer’s torque values.

Why Commissioning Matters

Skipping or rushing commissioning can lead to serious consequences:

Unexpected failures during operation.
Reduced equipment lifespan due to improper loading or connections.
Safety hazards from incorrect wiring or loose terminations.
Customer dissatisfaction if the system does not meet performance expectations.

Commissioning provides a final quality check that protects the investment in new systems. It also documents the system’s condition at startup, which is valuable for future maintenance and troubleshooting.