Proven quality under full load
Gensets and systems are tested in our in-house test facility under real and extreme conditions before delivery. Authorized personnel test according to the highest standards — for safe and reliable operation in an emergency.
19 test fields for comprehensive factory tests
In our in-house test facility, we test units and systems with inductive load devices under full loads. Diesel and gas gensets are tested with voltages in accordance with ISO 8528. The test equipment allows tests of several gensets and emergency power systems (EPS) in island or parallel to the grid. State-of-the-art test facilities ensure the highest quality standards and guarantee comprehensive quality assurance before delivery.
Every system can be tested under practical and extreme conditions — from a genset for manageable kVA outputs to large EPS with additional components with several MW to secure critical infrastructures: Customer-specific inspections with extensive measurement data and documentation live on site or via video transmission, also with support from independent testing institutions such as TÜV, GL or DNV.
Enormous test capacities for every system size
Together with the most modern test stations with a depth of 28 m in the new hall 6, we have a total of 19 indoors and outdoors.
This enormous capacity enables us to test a wide variety of units in parallel — from gensets for commercial applications to complex large systems for critical infrastructures. Individual systems can be tested in island mode up to 6 MW at a maximum of 15 kV. When tested in parallel operation, up to 1 MW can be synchronized with the grid. By combining several loads, tests of up to 12 MW load can be carried out as standard.
Highest standards in testing and documentation
Our test benches simulate real and extreme operating conditions. We test on a customer-specific basis and also deliberately beyond the nominal power — for maximum reliability in an emergency. All relevant electrical and non-electrical performance indicators are recorded and documented.
At indoor and outdoor test benches, we test diesel and gas gensets with voltages in accordance with ISO 8528. The test equipment allows the testing of several generator sets and emergency power systems in island or parallel to the grid. We can carry out inductive or capacitive loads on request. Expanding requirements can also be met.
Individual systems of up to 6 MW and up to 3 kV can be tested in stand-alone mode. When tested in parallel operation, up to 1 MW can be synchronized with the grid. Our test benches enable: 4 load banks with up to 13 MW, 5 adjustable water resistors of 2 MW each, 2 inductive load banks up to 3 MVA with a power factor of 0.8 and 1 capacitive load bank with 1500 kVAR.Tests of up to 12 MW load can be carried out by combining several loads. If even higher performance is required, more options are available so that there are almost no limits.
We adapt the requirements with regard to electrical power, voltage and test regulations individually for each customer. By simulating under extreme loads, we ensure reliable availability in an emergency. On customer request, we carry out long-term and type tests. During test runs, we provide special rooms for customers and acceptance personnel. In addition to in-house tests, we carry out additional tests according to customer requirements.
8 adjustable test field coolers are available for testing systems without a built-in cooling system. We can simulate the customer heating circuit to test CHP plant heat modules. Transformers and MS switches for testing in the medium voltage range are provided. We test at ambient temperatures of 45 °C over the duration of the test. The complete accessories of an emergency power system as well as central controls, power components, NSHV and MSHV can be integrated.
In addition to practical testing, a wide range of equipment is available for measuring electrical and non-electrical data: measurement of mechanical oscillations and vibrations, sound measurement of the system, verification of heat developments using a thermal imaging camera, air velocity and volume flow measurements, wave orientation using laser, lighting intensity & EMC testing of the complete container-installed emergency power system.
We record electrical data electronically during dynamic processes such as load switching, load shedding and ramp-up tests. Our data logging system records various measurement dataat the same time with variable recording intervals. We support remote factory inspections with cameras. Tests can be supervised and certified by independent testing institutions such as TÜV, GL or DNV. Evidence of overall system performance is documented and reported.
19 test benches
State-of-the-art indoor and outdoor test stations for enormous test capacities — from small gensets to large systems.
Test range up to 12 MW & more
By coupling the load devices, we test systems up to 12 MW. If required, additional power ratings are available.
Simulation: individual & extreme
We deliberately test beyond the nominal power to ensure stable function, voltage and frequency stability.
Full system audit
On request, we can test the entire backup power supply solution with accessories, central controls, power components and switchgear.
Comprehensive measurement data
Diverse measuring devices ensure the recording of relevant and specific electrical and non-electrical indicators.
Certified according to ISO 8528
Diesel and gas gensets are tested in accordance with ISO 8528 — support by TÜV, GL or DNV is possible.
Frequently asked questions
Why is testing performed beyond the actual nominal power?
It is about simulating extreme scenarios for maximum and reliable availability in an emergency. Our test benches are tested under real and overload-like conditions. It is deliberately investigated beyond the motor's nominal power to ensure that the system remains stable. It is important to ensure that there are no unacceptable drops in power, voltage or frequency deviations.
Which documents are required to operate the systems?
Verifying overall system performance including efficiency losses as well as reliability, stability and thermal resilience and their safety reserves in the event of a power failure are particularly important to us for critical infrastructures. This is documented and reported. Customer-specific documents can be edited on request.
Are only the genset or also additional components tested?
On request, we will carefully test the entire backup power supply solution with all components and, if applicable, higher-level central control systems, power components, NSHV, MSHV, etc.
Up to what maximum load can Frerk test?
Our load devices can be connected so that the systems can be tested with a load of up to 12 MW. With the help of external extensions, higher loads would also be possible. Network and island parallel operations of several units can also be implemented in the Frerk test field.
Which load banks are available at Frerk?
The load banks simulate the testing of manufactured generator sets under defined realistic conditions. Our inductive load banks can be used up to 3 MVA with a power factor of 0.8, for example, and test our systems. Generators and UPS are capacitively tested up to 1500 kVAR. With external extensions, even higher demands can be met.
Are Frerk tests certified?
Diesel and gas gensets are tested with low and medium voltage in accordance with ISO 8528. Support from an independent testing institution such as TÜV, GL, DNV is also possible.
Is it possible to take part in the final acceptance test?
All approvals can be accompanied live on site by the customer himself or his representative. Online participation (video transmission) is also possible on request.
Is your question not included?
Vendor-independent and partnership-based
Frerk works with well-known, proven manufacturers of motors, generators, batteries and components. Long-standing partnerships based on trust guarantee the highest quality and reliability. At the customer's request, we integrate preferred manufacturers into your system.
We are looking forward to hearing from you!
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