Louis Kotze, Executive for WEG Africa's Generator Sets Division, highlights the value of partnering with a generator customisation specialist to get the right generator solution for a specific need and its operating environment.
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To support emergency dewatering operations for a remote mining operation, the customised WEG generators were built to be hardy yet mobile, to hold enough fuel for long-term operations, to provide remote monitoring features, and to be easy to refuel.
A manufacturing plant needs a steady-state generator set to power sensitive CNC machines with stable, clean power. A mine requires generators that operate underground in confined spaces while meeting safety, emission, and noise requirements. Construction site generators need to be rugged, hold enough fuel for ongoing activities, and be transportable to support a range of different equipment as the site progresses.
The challenge for each is to get the right generator solution. It is rare for a standard generator set to meet such specific requirements, which is where generator customisation steps in. This process requires coordinating specifications from several stakeholders, says Louis Kotze, Executive of WEG Africa's Generator Sets Division.
"Selecting a generator set depends on factors that come from different people. The site's electrical engineer focuses on areas such as load requirements, total output and reliability. At the same time, procurement managers are interested in cost-related issues and emissions regulations, and project managers want to know that the generators will support their project goals rather than hinder them. Each party knows what they expect from a generator. What they don't have time for is to work out all the details."
Customisation needs the right partner
The generator marketplace has a wide array of ratings and standards. A generator set can range from a straightforward off-the-shelf model to more elaborate equipment and configurations, including synchronised units for large-scale power generation and careful integration with site equipment and infrastructure. An experienced generator provider collects these details and collates a site's multiple requirements.
Typical customisation options include the generator's power output capacity, fuel type, noise reduction, control system, and size. Balancing these against budget, performance, and environmental expectations is complex, which is why the value of an experienced customiser shouldn't be underestimated.
For instance, a remote mining site requires generators to support emergency dewatering operations. These generators need to be hardy yet mobile, hold enough fuel for long-term operations, provide remote monitoring features and be easy to refuel. They need to be cost-effective, and the customised units must be delivered quickly.
Such a project has several competing requirements that can undermine the generator set's value and performance. The generators might be too cumbersome to move as the dewatering operations shift focus. They might use the wrong fuel or require frequent maintenance due to dust and moisture damage.
It is the generator customiser's job to understand such issues, says Kotze. "We conduct assessments to understand factors like environmental and operating conditions, which we might get from the client or by visiting the site. We gather detailed information on power demands, peak loads, and the equipment that the generators will power. We try to speak to all the stakeholders. Customising generators is our second priority. Understanding the project's requirements from different angles is our first,” he says.
How to select a customisation provider
Customising a generator requires more than technical skills. To evaluate a generator provider's customisation service, start by looking at their track record. What is their experience with similar projects, and what references and case studies do they provide? Are they asking the right questions, showing they understand the specific characteristics of a project and its sector?
Their approach to assessments is as important. Are they thorough? Do they gather and incorporate technical and timeline requirements? Do they have the capacity to adapt responsively and provide additional services, such as maintenance?
Certifications and standards are crucial, as they define quality, safety and performance. The most fundamental is ISO 8528 for generator sets. Also look for standards such as ISO 9001 (quality management), ISO 14001 (environmental management), and ISO 3046 (combustion engine management). Others include adherence to health & safety, testing and sector-specific standards, such as food safety considerations at a food and beverage manufacturer.
Focus on the team behind the customisation to ensure a site gets the right generator sets, says Kotze.
"Engineers and managers on sites know what they want. What they need is someone who can quickly and professionally connect the dots for them. Selecting and customising a generator solution requires skill. But what is often neglected is understanding the customer's goals and how customisation will achieve them. When deciding on a generator provider, that's where the real value comes from."
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