Core application scenarios and value summary of load banks in shipyards

1. Full-process detection of ship generator sets

Factory performance verification

Before installing the generator set, the load bank is used to simulate the ship's navigation, mooring, emergency and other multi-condition loads (such as propulsion system, deck machinery, household electricity and other composite loads), and the voltage stability (fluctuation ≤ ±1%), frequency response (recovery time ≤ 5 seconds), fuel efficiency and parallel operation capability of the unit are tested to ensure that the requirements of the IMO International Convention for the Safe Operation of Ships and the Prevention of Pollution are met.

Fault simulation and troubleshooting

Artificially create fault scenarios such as overload, short circuit, phase imbalance, etc., test the response sensitivity of the generator set protection device (such as reverse power protection, overcurrent protection), expose equipment hidden dangers in advance, and avoid the risk of sudden shutdown during offshore operation.

2. Ship power system integration commissioning

Multi-device compatibility test

Simulate the extreme load conditions of all ship electrical equipment (such as inverters, radars, and communication base stations) running at the same time, detect the temperature rise (≤60K), voltage drop (≤5%) and harmonic distortion rate (THD≤8%) of the distribution bank and cable lines, and ensure the stable operation of the power system under complex loads.

Special scene adaptation of new energy ships

For hybrid ships and fuel cell ships, the load bank can simulate the charging and discharging characteristics of the energy storage system, test the seamless switching logic of the diesel generator set and the battery pack, and ensure the continuity of power supply (switching time <200ms).

3. Reliability verification of ship electrical equipment

Motor and drive system test

Load test high-power equipment such as propulsion motors and anchor windlass motors, detect starting current (≤6 times rated current), stall torque (≥1.8 times rated torque) and bearing temperature rise (≤90℃), to avoid ship maneuvering failure due to motor failure.

Mandatory testing of emergency power supply system

In accordance with the requirements of the SOLAS Convention, use load banks to conduct 100% load tests on emergency generators and battery packs to verify their ability to start and load within 30 seconds after the main power fails, ensuring that key equipment such as emergency lighting and fire pumps can be powered continuously for ≥18 hours.

4. Green Shipbuilding and Compliance Certification

Energy Efficiency Optimization Testing

Use load banks to simulate power demand at different speeds, analyze the operating efficiency curve of generator sets, and assist shipyards in optimizing equipment selection (such as using variable frequency units to reduce light load losses) to meet the requirements of the International Maritime Organization (IMO) Ship Energy Efficiency Management Plan (SEEMP).

Environmental Protection Regulations Compliance Testing

Carry out load verification of the ship's shore power system to test its compatibility with the port power grid (voltage deviation ≤±5%, frequency deviation ≤±0.5Hz), help ships obtain green ship certification (such as DNV GL green ship symbol), and reduce carbon emissions when docked.

5. Application in ship maintenance and modification

Evaluation of upgrading power systems of old ships

Carry out load bank tests on power systems of ships that have been in service for more than 10 years to evaluate the degree of cable insulation aging and the breaking capacity of switchgear, and provide data basis for system transformation (such as replacing inefficient generator sets and upgrading intelligent power distribution systems).

Verification of load matching of modified ships

When large equipment (such as oil and gas recovery devices and carbon capture systems) is added to ships, the load bank is used to simulate the additional load and verify the capacity margin of the original power system to avoid safety accidents caused by overload.

The core value of load banks in shipyards

Safety assurance: expose power system defects in advance, reduce the probability of offshore failures, and comply with maritime safety regulations;

Efficiency improvement: standardized testing processes shorten the commissioning cycle (30% faster than traditional methods) and speed up ship delivery;

Cost optimization: reduce later operation and maintenance costs (fault repair costs reduced by 50%) and enhance the competitiveness of shipyards;

Green transformation: help ships meet international energy efficiency and environmental protection standards and seize the opportunity in the low-carbon shipbuilding market.