RATA 7500kVA Generator Load Testing with High Power Resistive & Reactive Load Bank
Project Overview
| Project Name | The 7500kVA Load Bank for Yangjiang Nuclear Power Station Undertaken by RATA Has Successfully Passed the 10h Load Test (RATA On-site Test Project in Guangdong) |
| Client Name | Yangjiang Nuclear Power Station |
| Project Site | China Guangdong |
| Industry of Application | Generator testing |
| Project Date | 2026.08 |
| Test Object | Gas Generator |
| Test Purpose | Carry out an uninterrupted full-power actual load test of more than 10 hours |
| Supplied Equipment | RATA 7500kVA Resistive & Reactive Load Bank |
Customer Requirements
Project Background：
● High-reliability Parallel Operation: As the primary equipment, this unit can operate in parallel and serve as mutual hot standby with the existing on-site AC6.6kV-4200kW-RL mobile test load and AC6.6kV-3000kVA-RL/AC mobile test load. It ensures that faulty equipment can be electrically disconnected from the system without shutting down the emergency diesel generators.
● The system adopts intelligent fault tolerance and protection design, featuring a fan-centric load linkage mechanism. The failure of a single fan will only cut off its associated load without affecting the operation of other modules. The cooling fans are equipped with dual-power automatic fast transfer function. Temperature monitoring and overheat protection are installed for resistor/reactor units. In the event of overheating, only the faulty load will be disconnected while the fans remain running, and detailed event logs will be recorded.
● Comprehensive safety measures are implemented. Short-circuit protection is configured for each power stage of the electrical system, and overcurrent as well as instantaneous overcurrent protection are fitted at the transformer incoming terminal. The equipment has an IP54 protection rating and can operate in rainy conditions. All cables are halogen-free flame-retardant with adequate thermal insulation protection.
● Flexible control and data recording are available. Switching between remote control and local control modes is supported, and the load status remains unchanged during switching. The control system is capable of complete operation log recording and test parameter analysis, with a storage capacity of 100M and support for secondary graph plotting.
● Strict verification standards are enforced. Before delivery, the equipment will undergo an uninterrupted full-power actual load test lasting more than 10 hours to verify its stability under long-duration operation.
Load Bank Technical Specification
Equipment Model: RATA 8250kVA Resistive & Reactive Load Bank
| Main Electrical Parameters | |
| System Composition | Load enclosure, high‑voltage switchgear, dry‑type transformer, resistive load, inductive load, acquisition system, control system, cooling system and protection system |
| Active Power | 6000kW |
| Reactive Power | 4500kVAR |
| Apparent Power | 7500kVA |
| Rated Load Voltage | AC380V (stepped‑down to 380V via transformer) |
| Rated Frequency | 50Hz |
| Load Characteristics | Integrated resistive‑inductive load; resistors and reactors can be switched on and off independently |
| Power Factor | PF=0.8～1.0 adjustable |
| Load Connection | Three‑phase four‑wires |
|
Three‑phase Balance |
Unbalance degree ≤ ±2% |
| Loading Accuracy | ≤ ±2% |
| Loading Step Value | 10kW / 7.5kVAR |
| Cooling Method | Forced air cooling with fan‑centric modular design |
| Fan Power Supply | Dual‑power supply (internal / external) with automatic fast transfer |
| Air Inlet & Outlet Mode | Side air intake, top air outlet |
| Load Temperature Rise | Temperature rise ≤120℃ at 1‑meter position from air outlet |
| Operation Mode | Continuous‑duty operation |
| Load Control Power Supply | AC380V/50Hz |
| Measurement & Display Accuracy | ±0.5%FS |
| Insulation Class | Class F |
| Resistor Material | Special‑alloy resistors |
| Load Control‑Control Mode | Local / Remote |
| System Parameters‑Control Mode | Manual / Automatic |
| Loading Function | Independent loading & combined loading (supports parallel‑operation with on‑site AC6.6kV‑4200kW‑RL and AC6.6kV‑3000kVA‑RL/AC mobile test loads) |
| Measurement & Control Function | A, V, Hz, kW, cosΦ acquisition and display |
| Control Response Time | ≤200ms |
| Load Protection | Short‑circuit, over‑temperature, abnormal airflow, emergency stop and other protections |
| Operating Ambient Temperature | ‑20℃ ~ +50℃ |
| Operating Ambient Humidity | 50% ~ 95% |
| Operating Altitude | 2000 m and below |
| Relative Humidity | ≤95%, non‑condensing |
| Atmospheric Pressure | 86‑106 kPa |
| Container Dimensions | 13000 mm × 2438 mm × 2896 mm (L × W × H) |
| Weight | Approx. 20 tons per unit |
| Protection Rating | IP54 |
| Application Location | Outdoor (salt‑spray, dust, rain‑snow resistant) |
| Installation & Transportation | Load‑bearing lifting lugs fitted at four corners of enclosure to satisfy hoisting requirements |
| Load Expansion | Parallel expansion of 1+N load containers |
| Enclosure Colour | Subject to customer requirements |
| Application Scope | Suitable for gas‑turbine generator sets, marine diesel generator sets, land‑based diesel generator sets and UPS systems |
Application Scenario
After the completion of manufacturing of the load equipment, the following tests shall be carried out: rated power and load‑capacity test, load‑regulation accuracy test, electrical‑parameter fluctuation test under various working conditions, temperature‑rise test, overload and protection‑function test, insulation test, power‑frequency withstand‑voltage test, enclosure protection‑rating test, earthing test, and continuous full‑load capability test (full‑load operation for no less than 24 hours).
Project Progress
Aug 18, 2026: IRATA technical engineers and production personnel were present at the site.
Project Highlights
(1) High-Capacity 7500 kVA Resistive-Inductive Load;
(2) Independent Active and Reactive Load Adjustment;
(3) Designed for 6.6 kV Emergency Generator Testing;
(4) Fan-Centred Modular Fault Isolation;
(5) Dual-Power Automatic Fast Transfer for Cooling Fans;
(6) Forced-Air Cooling and Temperature-Based Protection;
(7) Intelligent Measurement, Control and Test Data Recording;
(8) Parallel Operation with Multiple Load Systems;
(9) Protection for Coastal Salt-Spray Environments.
