PacB Group // The Role of a Generator Manufacturer in the Provision of Back-Up Power

Articles

The Role of a Generator Manufacturer in the Provision of Back-Up Power

In the realm of power generation, generator manufacturers play a key role in providing innovative and superior quality gensets. Generator manufacturers help drive advancements that enhance efficiency, reliability, and sustainability. They take alternators and diesel engines and integrate them into complete generator sets, also known as gensets. These gensets constitute standalone power generation units capable of producing electricity.

Generator Manufacturers Create Gensets

Generator manufacturers carefully select and match alternators and diesel engines based on factors such as power output requirements, application specifications, reliability standards, and whether the unit will provide primary or standby power. Alternators are chosen based on their voltage and current ratings, while diesel engines are selected based on their maximum output power, fuel efficiency, emissions compliance, and reliability.

The generator manufacturer will then build a chassis to which the engine and alternator will be mounted. The chassis usually has a fuel tank integrated into it. Several options are possible, such as whether the genset is skid- or trailer-mounted, open or enclosed, and whether the enclosure is sound attenuated or not. Gensets may even be enclosed in prefabricated concrete “bunkers” where they are intended for remote sites that may expose them to tampering, vandalism, or theft.

Once the components are selected, the alternator and diesel engine are integrated into a single unit, including the necessary balance of system components required to produce a fully functional genset. System components include items such as the fuel tank, cooling system, exhaust system, electrical control panel, starter battery, and protective enclosures, among others.

The alternator is connected to the diesel engine via a coupling mechanism, allowing the rotational energy of the engine, which converts the chemical energy stored in the diesel, to drive the alternator, which then produces electrical energy.

Building the Genset is Not the End of the Process

After integration, the complete genset undergoes rigorous testing and quality assurance to ensure that the unit meets performance standards, regulatory requirements, and safety guidelines. Testing typically includes checks for voltage output, frequency stability, load-handling capacity, fuel efficiency, emissions compliance, and overall reliability.

Generator manufacturers often offer customisation options to produce a genset for specific customer needs, application requirements, and site-specific conditions. This could involve changes to power output levels, voltage output configurations, control systems, enclosure designs, and fuel options. Generator manufacturers work closely with their customers to understand their unique needs and provide solutions that meet their exact specifications.

Once testing and any customisations are completed, the genset is packaged and prepared for delivery to the customer’s site. The size and configuration of the genset will determine what transportation logistics are required, ranging from standard shipping methods to specialised handling for larger, utility-scale units.

After delivery, the genset will be installed and commissioned at the customer’s site by either in-house trained and qualified technicians or authorised contracted service providers. Installation involves connecting the genset to the electrical system, fuel supply, and control infrastructure, as well as conducting final checks and adjustments to ensure proper operation. Generator manufacturers also usually offer comprehensive service and support packages to ensure the ongoing performance, reliability, and efficiency of their gensets. Preventive maintenance programmes, spare parts availability, technical support, and troubleshooting assistance throughout the genset’s operational life cycle usually form part of the package.

By combining alternators and diesel engines into complete generator sets, generator manufacturers provide customers with reliable and efficient power-generation solutions for a wide range of applications, including standby backup power, prime power generation, and mobile power supply.

Innovations and Excellence Among Leading Generator Manufacturer Engine Suppliers

Generator manufacturers rely heavily on engine manufacturers to provide engines suitable for gensets. There are several market-leading companies that they can turn to for generator engines. Diesel engine manufacturers may focus on producing engines and not directly manufacture complete gensets or make complete gensets while also providing engines to Original Equipment Manufacturers (OEMs).

Cummins are renowned for their global presence and comprehensive range of diesel power units. Cummins excels in producing high-performance diesel engines for generators that can be tailored to diverse applications. Caterpillar is another prominent manufacturer of diesel engines for power generation. Caterpillar supplies engines to generator manufacturers worldwide. Perkins is also a respected manufacturer of diesel engines for power-generation applications.

There are several other diesel engine manufacturers that deserve mention, including Deutz, Volvo, Kohler, Atlas Copco, Generac, MTU, Yanmar, and FAW, among others. These diesel engine manufacturers focus on producing high-quality engines with exceptional durability, efficiency, and performance, while leaving the assembly and integration of complete gensets to specialised OEMs. This approach allows them to concentrate on their core expertise in engine design and manufacturing while providing engines to support the broader power-generation industry.

Leading generator manufacturers are committed to innovation, excellence, and sustainability, driving advancements that elevate the standards of power generation. By harnessing cutting-edge technologies, prioritising reliability, and embracing sustainability and protection of the environment, these manufacturers redefine the capabilities and possibilities of power-generation solutions.

The Alternator – The Other Half of the Equation

Alternators are the “electrical” half of a genset, without which no power would be generated. Several manufacturers specialise in producing alternators for diesel gensets. Some of the leading manufacturers in this field include:

• Stamford is a respected brand that falls under the Cummins umbrella. Stamford alternators are synonymous with quality, reliability, and performance. They have a global presence and a wide range of products catering to different power generation needs.
• Leroy-Somer is recognised for its innovative alternators designed for diesel gensets. Their alternators feature high-quality components, advanced voltage regulation systems, and excellent efficiency, ensuring stable and reliable power output in various environments.
• Mecc Alte specialises in producing alternators for diesel- and gas-powered generators, offering a diverse range of products tailored to meet specific customer requirements.
• Marathon Electric manufactures alternators with a reputation for rugged construction, high efficiency, and long-term reliability.

Alternator manufacturers that are also respected global brands include ABB, WEG, and Marelli Motori. These manufacturers are recognised for their commitment to quality, innovation, and customer satisfaction, making them trusted partners for businesses and generator manufacturers seeking reliable alternators for diesel gensets.

Trust a Generator Manufacturer that Uses Global Leading Products

We at PacB are a leading Southern African generator manufacturer, well known in the Southern African power-provision industry. We are respected for our superior quality commercial and industrial gensets. We build, install, and support units using Perkins and other top-quality diesel engines. Our sales representatives and technicians attend regular international training on the premium products we use. We make great efforts to keep up with changes in technology and are up to date with the latest product offerings.

When it comes to specifying industrial diesel gensets, a fundamental understanding of the requirements and technical know-how are prerequisites for building and installing a solution matched to the customer’s site-specific electrical architecture and load requirements.

While we are a generator manufacturer, we also have expertise in renewable energy systems and UPSes. Contact us today and guarantee always having power.