Project Title: High-Altitude Infrastructure Hardening & Generator Replacement
Location: Woodland Park & Cripple Creek, Colorado (Elevation: ~9,500 ft)
Sector: Telecommunications Infrastructure
Service Category: Logistics, Site Services, and Fuel System Upgrades
1. The Challenge
A major telecommunications provider faced a critical reliability issue at two remote cell tower sites located in the high-altitude terrain of the Colorado Rockies. The existing backup power assets were aging and required replacement, but the project presented significant logistical and technical hurdles:
- Extreme Terrain: The sites were located in Cripple Creek and Woodland Park, requiring navigation of steep grades and limited access roads.
- Physical Constraints: The new 350kW-class generators had to fit precisely inside existing, non-standard enclosures.
- Environmental Compliance: The sites required immediate upgrades to fuel containment and venting systems to meet new environmental standards.
- Zero-Downtime Requirement: The swap had to be executed rapidly to minimize the risk of coverage loss in these remote mountain corridors.
2. The Generator Source Solution
Generator Source mobilized a “Turnkey Site Services” team to handle the entire chain of custody, from asset acquisition to final commissioning.
Phase 1: Precision Logistics & Rigging
- We coordinated heavy-haul transport to move the replacement units from the supplier directly to the mountain sites.
- At the Cripple Creek location, where ground access was restricted, we deployed a specialized crane service to lift the old unit out and place the new unit with inch-perfect precision into the existing shelter.
Phase 2: Technical Hardening & Fabrication
To ensure the new units met strict environmental compliance, our field technicians performed on-site fabrication:
- Fuel System Upgrade: Installed a site-provided 5-gallon Fuel Fill Spill Box and integrated a custom Fuel Level Alarm Panel, wiring it directly to the generator’s control strip for remote monitoring.
- Venting Retrofit: Fabricated and installed new Black Iron NPT fuel tank vents (Two 3″ emergency vents and one 2″ normal vent), piping them externally to ensure safe fume dissipation outside the enclosure.
Phase 3: Fluid Recovery & Commissioning
- We performed a compliant evacuation of 210 gallons of diesel fuel from the legacy units, ensuring zero environmental impact.
- The team executed all mechanical and electrical disconnections and reconnections, matching the turbocharger exhaust ports and radiator ducting to the existing facility infrastructure.
3. The Results
- Speed: Both sites were completely hardened and commissioned within a strict 2-day operational window per site.
- Compliance: The sites now meet all local and federal fuel containment regulations.
- Reliability: The upgraded units provide consistent, reliable backup power for the critical communications infrastructure serving the mountain communities west of Colorado Springs.
“This project highlights our ability to operate not just in a warehouse, but on the side of a mountain. When logistics, fabrication, and electrical scope merge, Generator Source delivers a single-source solution.”