Case Study: Generator Control Panel Upgrades & Overhauls Across Utilities and Water Sectors
Case Study
Dale Power Solutions recently delivered a series of successful generator upgrade and overhaul projects across key infrastructure sectors. These projects involved modernising legacy control systems and extending the life of critical backup power assets through targeted mechanical works. From major utilities to essential water suppliers, each upgrade was tailored to the operational and resilience needs of the site.
Sector: Utilities & Water Supply
Services Delivered: Control Panel Upgrades, Mechanical Overhauls, Mains Failure Testing
Locations: Regional and National Sites Across the UK
Client Types: Regional Water Supplier, National Utility Provider, Critical Infrastructure Site
1. Full Panel Rewire – Regional Water Supplier
A 1991 FG Wilson generator supporting a regional water supply site required urgent panel modernisation. The outdated controller was replaced with a Deep Sea Electronics (DSE) 7310 MK2, supported by:
A full panel rewire
Removal of obsolete and redundant components
A new custom parameter file aligned to operational requirements
Installation of a new electrical schematic
The upgrade concluded with a successful mains failure test, restoring full automatic start functionality and ensuring resilience in the event of power loss.
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2. Top-End Overhaul & Control Upgrade – National Utility Provider, Wales
At a critical national utility site, Dale’s engineers replaced a legacy FG Wilson control system with a DSE7310MK2 controller for improved interface and diagnostics. Mechanical engineers carried out a top-end engine overhaul on the site’s Perkins 3008 generator, including:
Replacement of all core plugs
Installation of new hot start engine heaters
Full coolant system flush
Following these works, the generator passed load bank and mains fail testing and was returned to the client fully operational.
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3. Controller Replacement at Critical Infrastructure Site
A critical backup generator was rendered inoperative due to a faulty Mic’s Telys controller stuck in stop mode. Dale’s team quickly intervened to:
Remove the failed controller and CB12 board
Install a DSE6110 MK3, selected for its plug-and-play compatibility
Upgrade the system from legacy fuses to modern MCBs
Complete a successful mains failure test, reinstating reliable backup power
This rapid response ensured uptime at a highly sensitive site, which was dependent on consistent power availability.
These projects demonstrate Dale Power Solutions’ capabilities in extending the operational life of older generators, upgrading legacy controls to modern standards, and ensuring ongoing reliability through thorough testing and inspection. Each solution was tailored to sector-specific challenges, contributing to safer, smarter, and more resilient infrastructure across the UK.
