case study - Keeping a Local Council Head Office Backed Up Through a Full Generator Replacement
When a 22 year old 700kVA backup generator failed during routine servicing at a local council head office, the site needed more than a replacement quote. It needed to be made safe, kept backed up and properly assessed before a long term solution was put forward.
Reactive Generators supplied temporary hire power, completed fault assessment and power analysis, then delivered a full replacement system built around the site’s actual load requirements. The final project included a new GDW550V PRAMAC generator, a custom 1000A IP56 stainless steel generator switchboard, roof structure modifications, exhaust works, remote monitoring, commissioning and ongoing support.
The Challenge
During routine service maintenance, the site’s existing 22 year old 700kVA backup generator was found to have suffered a severe alternator failure, with damage to both the rotor and stator.
For a head office environment supporting critical council operations, the issue needed to be stabilised immediately. Reactive Generators made the area safe, supplied a temporary hire generator and established temporary fencing to maintain site safety and backup power continuity while the long term solution was assessed.
Keeping the Site Backed Up While Reducing Unnecessary Works
The first priority was to stabilise the site and keep backup power available. Reactive Generators made the area safe, supplied and connected a temporary hire generator, and established temporary fencing while the failed unit was assessed.
Once the emergency situation was under control, the team moved into a more detailed review of the site. Rather than assuming the failed 700kVA generator needed to be replaced like for like, Reactive Generators completed onsite power analysis over several weeks to understand the building’s actual load requirements.
That process confirmed that recent building upgrades had reduced demand, allowing the site to move to a 550kVA generator without compromising backup power requirements.
Reactive Generators also inspected the existing slab and confirmed it was structurally suitable for reuse. Because the new generator was internally bunded, the existing block work around the failed unit could be removed, allowing the original slab to be retained.
This approach kept the site protected while also helping reduce unnecessary project costs, civil works, running costs and ongoing service requirements.
Smarter Sizing Through Power Analysis
Rather than simply replacing the failed 700kVA generator with another unit of the same size, Reactive Generators completed detailed onsite power analysis over several weeks.
Using power monitoring equipment, the team reviewed real load movements across the building. The data showed that recent building upgrades had reduced demand, meaning the site no longer required a 700kVA generator.
Reactive Generators’ engineering assessment confirmed that a 550kVA generator would meet the site’s backup power requirements. This helped reduce the upfront project cost, while also supporting lower ongoing running and service maintenance costs.
The Engineered Solution
Following the assessment and tender process, Reactive Generators was awarded the project.
The final scope included:
- Supply of a new PRAMAC GDW550V generator with 2000L diesel capacity
- Custom 1000A IP56 stainless steel generator switchboard
- Mechanically interlocked generator switchboard designed to AS61439
- Temporary generator connection point
- N+1 capability
- Roofing structure removal and reinstatement
- Exhaust extension and penetration modifications
- Hot air discharge modifications
- Noise reduction works
- Cloud based 24/7 remote monitoring
- Traffic management, lift planning and safety documentation
- Formal testing, commissioning and onsite handover
Installation and Commissioning
Once the equipment was ready, Reactive Generators coordinated technicians, traffic control, cranage, cartage and roofing contractors to complete the installation.
The existing roofing structure was removed, the failed generator was disconnected and lifted out, the new switchboard was landed and terminated, and the 550kVA generator was installed and connected.
The roofing structure was then reinstated with new exhaust penetrations, and the new system was formally tested and commissioned. Onsite training was completed, handover documentation was supplied, and an ongoing service maintenance proposal was prepared.
Only once the permanent system had been completed and handed over was the temporary hire generator disconnected.
The Outcome
The local council head office received a modern, right sized backup power system designed around the site’s actual load requirements.
By combining emergency response, onsite power analysis, custom switchboard design, generator supply, complex lifting works, compliance management and ongoing support, Reactive Generators delivered a complete solution while maintaining backup power throughout the project.
For critical commercial, government and council sites, backup power is not just about installing a generator. It is about keeping the site protected before, during and after the works are complete.
