When Winter Struck, Weld Power Delivered: Turnkey Project Management Saves Generator

A commercial office building in downtown Boston experienced a major generator failure after a harsh winter caused internal building pipes to freeze. As a result, the building’s older Consolidated city-water cooled generator suffered internal engine block damage due to frozen water within the system. Unsure of how to proceed, the building’s management team turned to Weld Power Generator for expert guidance.

What Did We Do?

On-Site Assessment:

Weld Power promptly dispatched a technician to perform a full evaluation of the generator system and overall site conditions. After determining that the frozen water had compromised the generator’s internal components, we collaborated with the customer to identify the most practical and cost-effective solution for their unique urban setting.

Exploring Alternatives:

Given the logistical challenges of equipment replacement in a downtown Boston high-rise, the customer was reluctant to pursue a full generator replacement. Instead, we proposed a more tailored option—removal of the engine block for a full teardown and evaluation to determine if an overhaul or rebuild was viable. We provided a detailed scope, budget, and estimated timeframe that aligned with the customer’s expectations.

Turnkey Project Management & Engine Removal:

Weld Power provided full Turnkey Project Management, coordinating with a rigging crew to safely remove the engine block from the building without disrupting operations. Once transported to our shop, our team conducted a comprehensive inspection. Despite the freeze, the evaluation revealed no structural damage to the engine block’s integrity.

Custom Generator Repair Plan:

With the block cleared for rebuild, Weld Power created a customized Generator Repair plan that met the customer’s operational needs and budget. We rebuilt the engine in our facility, sourced several hard-to-find components, and prepared the system for reinstallation.

Seamless Reinstallation & Testing:

The reinstallation process went smoothly, and our technicians completed a full reassembly and operational test to confirm the rebuilt generator was running reliably. The entire project—from initial site evaluation to final testing—was completed in approximately 12 weeks.

Despite the complexities of working in a downtown location and sourcing rare parts, the project was completed within the expected timeframe and came in slightly under budget. The result was a successful rebuild that allowed the customer to restore emergency power capabilities without the cost and disruption of full generator replacement.