How We Customized a Multi-Genset Synchronization System for a Southeast Asian Client: A Case Study
Estimated reading time: 6 minutes
In many parts of Southeast Asia, power outages and unstable grid supply remain common—especially in industrial zones and remote commercial areas. For businesses with high power demands, a single diesel generator often cannot offer the flexibility, redundancy, or operational efficiency required for continuous and scalable operations.
To solve this, we engineered and deployed a multi-genset synchronization system tailored for a large-scale packaging facility in Southeast Asia. This blog details how we approached the project—from needs assessment to final commissioning.
1. The Client’s Requirements
The customer, a packaging manufacturer located near an industrial port zone, had the following operational challenges:
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Intermittent grid supply, especially during peak hours
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Total power demand of >1200 kVA, with load fluctuations during production cycles
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Preference for redundancy to ensure zero downtime
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Need for future scalability as the factory planned to expand
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Desire to optimize fuel efficiency and reduce overall maintenance cost
2. Why a Multi-Genset Solution?
Rather than deploying one massive generator, we proposed a parallel system of 3 × 500 kVA diesel generators, synchronized using a digital automatic control system.
Key Advantages:
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Load Sharing: Generators work together to handle fluctuating loads
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Redundancy: One genset can shut down for maintenance without affecting operations
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Scalability: Additional units can be added later without redesigning the system
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Fuel Efficiency: When the load is low, only one or two gensets operate, reducing fuel consumption
3. System Components & Configuration
A. Gensets
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3 x 500 kVA diesel generators (prime-rated)
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Cummins engines with Stamford alternators
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Tropical-rated radiators with 50°C ambient cooling capacity
B. Synchronization System
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DEIF AGC-4 parallel genset controllers
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Automatic start/stop logic with load demand management
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Busbar synchronization panel with circuit breakers and protective relays
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CANbus & Modbus communication protocols for SCADA integration
C. Additional Features
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Remote monitoring via GSM-based telemetry
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Weatherproof soundproof enclosures (for low-noise compliance)
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Smart fuel tanks with level sensors and leak detection
4. Engineering & Installation Challenges
Challenge 1: Heat & Humidity
Southeast Asia’s tropical climate demanded enhanced cooling and anti-condensation design.
✅ Solution: We upgraded radiator capacity and installed dehumidifier kits inside control panels.
Challenge 2: Grid Instability
Frequent voltage sags and brownouts required sensitive synchronization logic.
✅ Solution: Implemented fast-response controls to switch between grid and gensets without surges.
Challenge 3: Operator Training
The client had limited experience with digital parallel control systems.
✅ Solution: We delivered a bilingual (English/Local) training manual, onsite commissioning sessions, and 24/7 remote support.
5. Results After Commissioning
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System Uptime: >99.5% over the first 6 months
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Fuel Savings: Estimated 15% lower consumption vs single-genset setup
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Zero Unscheduled Downtime: Prevented factory shutdowns during 3 major grid failures
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User Feedback: Operators praised the simplicity of the touchscreen HMI and auto load demand control
6. Lessons Learned & Best Practices
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Always assess load profile thoroughly before designing parallel systems
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Choose modular designs to allow easy expansion
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Invest in training & documentation for long-term operator success
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Use reputable controller brands for stable synchronization and support
Conclusion
This case demonstrates how a well-designed multi-generator parallel system can provide more than just backup power—it offers resilience, efficiency, and peace of mind. For industrial clients across Southeast Asia and other developing regions, synchronized diesel generator solutions are becoming the new standard for energy continuity.
Author: Projects Division – [Ningde City Lion Motor Co., Ltd.]
Last updated: June 17, 2025