250kVA Cummins-Powered Generator for a Steel Fabrication Facility

250kVA Cummins-Powered Generator for a Steel Fabrication Facility

Another Cummins-powered generator has left the Genelite Brisbane office, this time headed to a local steel fabrication facility.

The Cummins-Powered GC250S will provide three-phase power for high-demand fabrication equipment, including stud welding machinery. With a 250kVA prime rating and a 275kVA standby rating, the generator has been selected to support the operating demands of a busy industrial workshop.

Powering Welding and Fabrication Equipment

Steel fabrication facilities can place demanding loads on an electrical supply.

Welders, cutting equipment, extraction systems, compressors, overhead cranes and other workshop machinery may operate at the same time. Some equipment also draws considerably more power during starting or particular stages of operation.

This generator will be powering stud welding equipment, which can introduce short, sharp increases in electrical demand. Based on the welding system being used, this demand may be intermittent rather than constant.

For this reason, selecting a generator for a fabrication facility involves more than adding together the rated power consumption of each machine. The expected load profile, starting currents, operating sequence and likelihood of multiple machines running simultaneously must all be considered.

The generator must have sufficient capacity to support the connected equipment while maintaining stable voltage and frequency as the load changes.

The Solution – 250kVA Cummins-Powered GC250S

The generator supplied for this application is a Cummins-powered GC250S, rated at:

• 250kVA / 200kW prime power
• 275kVA / 220kW standby power
• 415V three-phase output
• 50Hz frequency
• 1500rpm operating speed

At the centre of the set is a Cummins 6CTAA8.9-G2 diesel engine. This is an 8.3-litre, six-cylinder engine featuring turbocharging, aftercooling and electronic governing.

The generator is paired with a Stamford alternator. Its brushless design and automatic voltage regulation help maintain consistent electrical output as workshop loads are connected, removed or changed during operation.

The alternator is also rated with less than five per cent harmonic distortion and Class H insulation, making it well suited to demanding industrial power applications.

Built for Industrial Operation

A generator installed at an industrial facility must be capable of more than simply producing the required power. It also needs to be configured for its operating environment and provide practical access for refuelling, servicing and routine inspections.

The GC250S includes:

• Cummins 6CTAA8.9-G2 diesel engine
• Stamford UCDI274K brushless AVR alternator
• Deep Sea 7420 MKII controller
• Four-pole main circuit breaker
• Heavy-duty skid base with fork pockets
• Galvanised and powder-coated silenced canopy
• Battery charger and isolator
• 1,300-litre bunded fuel tank

At 75 per cent load, the integrated fuel tank provides approximately 35 hours of operation. This extended runtime reduces the frequency of refuelling and makes the generator suitable for facilities requiring dependable power across long production shifts.

The silenced enclosure is rated at 74.6dB(A) at seven metres, helping manage operating noise around the facility. The heavy-duty skid base and fork pockets also assist with transport and final positioning.

Tested Before Delivery

Before leaving Genelite, the generator was filled with the required operating fluids and put through a complete load and function test at our Brisbane office.

Load testing allows the generator’s engine, alternator, control system and electrical protection to be checked under operating conditions. It confirms that the set can produce its rated output and respond correctly as load is applied.

Testing before dispatch also provides an opportunity to identify and address any issues before the generator arrives at the customer’s facility.

Selecting the Right Generator for a Fabrication Facility

No two fabrication facilities have exactly the same power requirements.

The correct generator capacity will depend on the welding processes being used, the number of machines operating simultaneously and the other workshop equipment connected to the system.

The objective is to select a generator that suits the facility’s real operating profile, while allowing appropriate capacity for starting loads and future requirements.

With 250kVA of prime power, a Cummins diesel engine and a Stamford alternator, this GC250S provides a reliable industrial power solution for this application.

For more information, view the 275kVA GC250S or contact Genelite on 1300 305 912.