Project Spotlight

Project Overview:

One of Australia’s most technologically advanced robotic customer fulfillment centres, required a full-scale test of its emergency backup power systems. With operations heavily reliant on automation and zero room for downtime, the reliability of their 2500kVA generators was mission-critical. LoadTec Solutions was brought in to carry out comprehensive load testing, cable installation, and Black Start procedures to validate the system’s performance under real-world conditions.

Scope of Work:

•  Load testing of two 2500kVA generators over 8 continuous hours each
• Custom trifold cable installation from switchboard to load bank to manage high current loads
• Execution of full System Acceptance Testing (SAT), including:
  • Load simulations under real-world demand
  • Black Start procedure to simulate full power loss and system recovery
• On-site coordination, testing management, and safety oversight
• Site cleanup and post-project pack-down to return the facility to original condition

Challenges:

•  Managing the logistics and safety of high-current cable installation across an active industrial site
• Ensuring uninterrupted testing across 48 hours in a facility with strict operational uptime requirements
• Coordinating multiple phases of testing, including full system simulations and emergency recovery drills
• Maintaining precision under time constraints, with no room for error during testing or SAT procedures

Outcome:

✅ Both 2500kVA generators passed testing under continuous load conditions

✅ Successful execution of Black Start procedure confirming full system recovery capability

✅ No disruption to ongoing operations at the facility during the entire testing process

✅ No disruption to ongoing operations at the facility during the entire testing process