The mechanism
Below roughly 30% of rated load a diesel runs with low cylinder temperatures and incomplete combustion. Unburnt fuel and lubricating oil pass into the turbocharger, exhaust piping and silencer and build up there. The symptoms are oil weeping at the exhaust, black smoke on start, low exhaust temperature and reduced output.
The periodic full-load run
Most engine makers, and codes such as NFPA 110, call for at least one annual continuous run near rated power so that cylinder temperatures rise and the deposits burn off. Running it with a load bank means the load level and duration are controlled precisely, instead of depending on whatever the facility happens to be consuming.
How to run it
Step up through 25, 50 and 75% while watching the parameters, then hold near 100% until exhaust temperature stabilises — usually one to two hours. Log coolant and exhaust temperatures, oil pressure, fuel consumption and the electrical output throughout, and keep it as the baseline for next year's comparison.
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