FW Power proud to complete a successful decommission of 48 FG Wilson P550-1 Generators from UK STOR Facility.
At FW Power, we specialise in the supply, testing, and export of high-quality diesel generators across the UK and worldwide. With decades of combined experience in the generator industry, our reputation is built on trust, engineering excellence, and the ability to deliver complex projects that many others in the industry simply cannot manage.
This case study details one of our challenging yet rewarding projects: the decommissioning of 48 FG Wilson P550-1 diesel generators from a UK STOR (Short Term Operating Reserve) facility located in Dowlais, Wales. These units, rated at 500 kVA prime and 550 kVA standby, powered by Perkins 2506A-E15TAG2 engines and coupled with Leroy Somer alternators are highly respected within the power generation industry as being a robust and reliable generator. They represent durability, efficiency and reliability, making them some of the most sought-after generators in both the UK and overseas markets.
The project required precision planning, coordination, and execution. Our team has to liaise with transport and crane companies to ensure a smooth and co-ordinated removal. They also had to assess site layouts and overcoming any logistical difficulties. once such logistical difficulty was the rural location of the STOR site. While the scale of handling the removal of 48 generators demanded strict project management, our Head of Operations, Gavin Dean, played a pivotal role in leading the project, ensuring each stage was carried out safely and to the highest possible standard.
This is our several site removal of this size and it is safe to say although we are very experienced in the removal of mass generators there is a huge amount of work that goes on behind the scenes.
By the end of the project, every generator had been safely removed, transported to our depot in Crewe, Cheshire. The generators were thoroughly tested, serviced and successfully shipped to international clients in Iraq, Libya, Nigeria, Ghana, and the United Arab Emirates.
This case study explores the project from start to finish, highlighting the challenges, the solutions, and the results that have further cemented FW Power’s reputation as a leader in large-scale generator projects and global distribution.
Background
About STOR Facilities in the UK.
STOR (Short Term Operating Reserve) facilities were established to provide additional electricity capacity to the National Grid at short notice. During times of peak demand or unexpected shortages, these facilities could quickly deliver additional power to maintain grid stability.
Generators installed at STOR sites are typically low-hour units, often used intermittently. As such, they remain in excellent condition, with relatively little wear compared to generators used in prime continuous applications. This makes them highly attractive to international buyers who seek reliable, cost-effective power solutions without the waiting times and costs associated with new equipment.
The Dowlais STOR Facility:
The Dowlais site in Wales was equipped with 48 FG Wilson P550-P1 Diesel Generators, each capable of producing 500 kVA prime and 550 kVA standby. These were housed in canopies and installed with the infrastructure required to provide rapid standby power to the UK grid.
When the site was decommissioned, FW Power was selected to undertake the complex process of removing all generators, transporting them safely, servicing and testing them at our depot, and preparing them for global resale.
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The FG Wilson P550-1 Generator.
The FG Wilson P550-1 is powered by the Perkins 2506A-E15TAG2, a 6-cylinder turbocharged diesel engine renowned for its durability and efficiency. The generator is typically fitted with a Leroy Somer alternator, ensuring high performance, reliable voltage output, and excellent build quality. FW Power have a number of these for sale now, view here: 500 kVA Diesel Generators for sale.
These units are highly versatile, suitable for both standby and prime power applications. The combination of Perkins engines and Leroy Somer alternators has long been regarded as a benchmark for quality in the generator industry, and they continue to be in strong demand worldwide.
The Challenge.
Decommissioning 48 industrial generators from a STOR site is a task that demands careful preparation and execution. However, the Dowlais project presented additional challenges that made the work even more complex.
Rural and Elevated Location.
The site was located in a rural part of Wales, at an elevated location that made access difficult. Narrow, winding roads had to be navigated by heavy transport vehicles, while the uneven terrain required specialist lifting equipment to ensure safe loading.
Weight and Size of the Generators.
Each FG Wilson P550-1 weighs over 5 tonnes and measures nearly five metres in length. Moving almost 50 of these units out of the facility and onto flatbed trucks required precise coordination, careful crane operation, and experienced operators to prevent delays and ensure safety.
Weather and Site Conditions.
As is often the case in Wales, unpredictable weather added to the challenge. Wind and rain complicated lifting operations, while the ground conditions made positioning of cranes and trucks more difficult. Schedules had to be adjusted to work safely in changing conditions.
Coordination of Transport.
To move 48 generators, multiple flatbed trucks had to be arranged, with tight scheduling to avoid bottlenecks at the site. Each truck had to arrive on time, be loaded quickly and safely, and then make the journey to our Crewe depot. The timing of crane hire, truck arrivals, and on-site operations required detailed planning.
Health and Safety.
Removing generators from a live STOR site meant strict adherence to health and safety regulations. Electrical disconnection, lifting operations, and transport logistics all carried risks that had to be mitigated. FW Power has an excellent safety record, and maintaining this standard was a top priority.
Execution.
Despite the challenges, the project was executed to the highest professional standards, thanks to the leadership of Head of Operations, Gavin Dean, and the commitment of his team.
Decommissioning and Disconnection.
The first stage involved safely disconnecting each generator from the STOR infrastructure. This included electrical isolation, fuel line disconnection, and preparation for removal. Each step was carried out methodically to ensure safety and protect the integrity of the equipment.
Crane and Flatbed Operations.
A mobile crane was brought in to lift each generator onto waiting flatbed trucks. Precision was essential, as each unit had to be lifted from its position within the site and loaded securely for transport. Gavin Dean’s team coordinated the lifting and loading process with precision, ensuring efficiency while maintaining the highest safety standards.
Transportation to Crewe.
Once loaded, the flatbed trucks made the journey from Wales to our depot in Crewe. Careful scheduling ensured a steady flow of units, preventing congestion at either end of the journey. Over the course of the project, all 48 generators were successfully transported without incident.
75-Point Inspection.
On arrival at the depot, each generator underwent a comprehensive 75-point inspection. This included detailed mechanical, electrical, and structural checks to identify any issues and ensure the units were in top condition.
Servicing and Load Banking.
Following inspection, the generators were fully serviced by our engineering team. Filters, fluids, and other consumables were replaced, and any necessary repairs were carried out. Each unit was then load bank tested, simulating operational conditions to verify performance at both prime and standby ratings. This process guaranteed that the generators met FW Power’s strict standards before being prepared for resale.
Export and Global Distribution.
Once serviced and tested, some of the generators were prepared for export. FW Power handled every aspect of the logistics, including containerisation, flat-racking, documentation and compliance with international shipping regulations.
Destinations.
Some of the generators were shipped to long-standing clients in:
Iraq
Libya
Nigeria
Ghana
United Arab Emirates
Each client required reliable, ready-to-run power solutions for projects ranging from industrial applications to critical infrastructure. The FG Wilson P550-1 sets were an ideal fit, offering immediate availability and proven reliability.
Shipping Methods.
Depending on client requirements and port facilities, the generators were shipped either containerised, flat-racked, or as open units. FW Power coordinated the logistics to ensure cost-effective and safe transport, providing clients with updates throughout the process.
The Dowlais STOR decommissioning project was a complete success. Despite the challenges of location, logistics, and weather, all 48 generators were safely removed, tested, and delivered to international clients.
The project demonstrated FW Power’s expertise in large-scale generator projects, from decommissioning and transport to servicing and export. Our clients benefitted from immediate access to high-quality, fully tested FG Wilson generators without the long lead times associated with new builds.
A project of this scale could not have been completed without the professionalism and dedication of our team. Head of Operations, Gavin Dean, played a central role, overseeing every stage of the project and ensuring safety, efficiency, and quality throughout. His leadership, combined with the skill and commitment of our engineering and logistics teams, ensured the project was delivered on time and to the highest standards.
About FW Power.
FW Power is one of the UK’s leading suppliers of new and used diesel generators. Based in Cheshire, we specialise in Perkins, FG Wilson, Cummins, CAT, Baudouin, and other premium brands. Our services include decommissioning, servicing, testing, and export, with clients across the UK, Europe, the Middle East, Africa, and beyond.
With a large stockholding and decades of industry experience, we provide immediate access to high-quality power solutions, backed by expert support and engineering excellence.
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