Custom-Built Generator for an Emergency Flood Pump at a Northern NSW Coastal Site

In Australia, unpredictable weather patterns and extreme conditions can place tremendous pressure on businesses and infrastructure, especially in flood-prone regions. A coastal site located just 500 meters from the ocean faced a significant challenge: ensuring reliable power for their emergency flood pump system while battling the harsh, corrosive coastal environment.

At Genelite, we understand the critical importance of providing custom power solutions tailored to the specific needs of each site. This case study explores how our team worked closely with the client to deliver a durable and reliable generator system to ensure continuous operation during emergency situations.

The Challenge: Emergency Power for a Flood Pump in a Coastal Region

Northern NSW is no stranger to extreme weather events, including storms, flooding, and heavy rains, all of which can significantly disrupt operations. The client’s facility, located less than 500 meters from the ocean, needed a backup power solution to ensure their flood pump system could operate during a power outage.

The site itself presented a unique set of challenges:

• Highly Corrosive Environment: Being so close to the ocean, the site was constantly exposed to salt air and humidity, both of which contribute to the accelerated corrosion of metal components.
• Essential Flood Pump: The flood pump is a critical asset designed to prevent site flooding during heavy rain events, which can have devastating consequences for infrastructure and operations.
• Emergency Backup: During storms and flooding, power outages are common, and without backup power, the flood pump would be inoperable—leaving the site at risk.

The client needed a power solution that would not only provide reliable energy in emergencies but also withstand the harsh coastal environment for years to come.

The Solution: A Custom-Built 165kVA Generator and ATS

Recognising the challenges presented by the coastal environment and the critical nature of the flood pump’s operation, Genelite proposed a custom-built power solution designed to address the client’s specific needs.

Our solution included:

• 165kVA Diesel Generator: This generator was sized to provide sufficient power to operate the flood pump and any additional emergency equipment. The 165kVA unit was chosen for its reliability and ability to handle the load required in the event of a power outage.
• 250 Amp Automatic Transfer Switch (ATS): The ATS allows for seamless automatic switching between mains power and the generator during an outage. The client needed this to ensure that the flood pump would engage immediately if the main power source failed—without the need for manual intervention.

However, the coastal environment posed an additional threat to the longevity of the generator and ATS system. Without adequate protection, the salty air and humidity could corrode and damage essential components, leading to premature failures and costly repairs.

To address this, Genelite incorporated the following protective measures:

316 Stainless Steel Canopy

To protect the generator from the harsh coastal conditions, Genelite designed the unit with a 316 stainless steel canopy. This material was specifically chosen for its superior resistance to corrosion in marine and coastal environments. 316 stainless steel is designed to withstand the challenges of saltwater exposure, offering long-term durability and peace of mind. This custom canopy not only protects the generator from the elements but also ensures reliability and longevity.

Hot-Dipped Galvanized Skid Base

For additional protection, the generator was mounted on a hot-dipped galvanised skid base. This base adds an extra layer of protection, ensuring that the entire unit is structurally sound and resistant to corrosion. The galvanization process involves coating the steel with a layer of zinc, which provides sacrificial protection, making it ideal for use in corrosive environments like coastal regions.

The skid base also offers flexibility in positioning the generator on-site, allowing the client to move or reposition the unit as needed without compromising its structural integrity.

At Genelite, we don’t believe in one-size-fits-all solutions. By working closely with the client, we were able to design and build a generator system tailored to their specific needs. From power capacity to environmental protection, this installation was customized to ensure the best possible performance.

For more information on how we can help protect your business, contact us today on 1300 305 912.