Custom Features Added
Generator Source’s team worked together on a complex and custom project to upgrade a 2.5 MW Cummins diesel generator, initially intended for replacement at a data center. The project involved several critical modifications, including:
- Large Base Fuel Tank: A custom tank was mounted to the generator for adequate fuel storage, ensuring prolonged runtime without needing to refuel frequently.
- Sound-Attenuated Enclosure: A full enclosure was added to reduce noise levels from the powerful generator, making it more suitable for various operational environments.
- Wiring for Components: Extensive wiring was completed for lighting, control panels, battery chargers, and other essential components, ensuring the generator was fully operational.
Customization Process Duration
The entire customization process took several months, with different teams working on various aspects of the generator. Specific tasks included:
- Mounting the Generator: The genset was mounted onto the base tank, a delicate process involving precise measurements and the use of a large crane for placement.
- Enclosure Installation: The enclosure was carefully positioned and welded into place, requiring detailed planning and coordination between the team and the crane operator.
- Wiring: The generator technician spent about three days wiring the unit, including connecting lighting and control systems to ensure the genset was fully functional and operational.
Load Bank Testing and Certification
Once the generator was assembled and fully wired, it underwent rigorous load testing to ensure it could handle the required loads without fail:
- Test Procedure: The generator was tested by gradually increasing the load in 20% increments up to 80%, ensuring that it could perform under varying conditions.
- Run Time: The testing took about two to four hours, with the generator running at 80% load for over an hour, capturing important performance data.
- Shutdown Process: After the load was gradually removed, the unit took about 52 seconds to wind down, showcasing its stability and smooth operation.
Generator Specifications
The final unit, weighing approximately 85,000 pounds with the base tank and enclosure, is a formidable 2.5 MW Cummins genset. Although it is not the largest generator handled by Generator Source (they also work with units over 4 MW), it is still a substantial piece of equipment. The sound-attenuated enclosure ensures it operates quietly, meeting the needs of clients in various industries.
Container Builds and Other Projects
In addition to large custom generator projects like the 2.5 MW Cummins, Generator Source also specializes in container builds. They take open skid generators ranging from 1 MW to 2 MW and place them into shipping containers, creating fully functional, portable power solutions with integrated fuel systems and electrical components. These containerized units are ideal for off-grid power needs, with the added capability of being trailer-mounted for mobility.
Generator Size Range
Generator Source works with generators ranging from 1 MW to 4+ MW, providing customized solutions for different power requirements. Whether you need standby power for a business, remote site, or emergency backup, Generator Source can deliver a tailored generator package that meets your needs.
Conclusion
This 2.5 MW Cummins generator project highlights the expertise and dedication of Generator Source’s team. From customization and wiring to load testing and certification, they ensure that each unit is ready to perform reliably in any environment. Whether you’re looking for stationary or portable power solutions, Generator Source has the capabilities to provide high-quality, turnkey generator sets tailored to your specific requirements.