A mining contractor in northern Canada faced a power problem. Their site sat 200 kilometers from the nearest town. No grid power reached the location. The contractor relied on diesel generators to run everything. Lights. Heat. Communication equipment. Battery chargers for electric machinery. The camp kitchen. The water pumps.
Their old generators caused constant headaches. One unit broke down twice a month. Another unit produced so much noise that workers complained about sleep loss. The fuel consumption kept rising. The contractor spent more time fixing generators than running them.
The contractor required a dependable power solution—one capable of continuous operation with minimal breakdowns, low acoustic output for camp comfort, and reliable cold-weather starting performance.
This article tells his real story. You will see the challenges he faced, how he chose YG’s silent diesel generator set, and what results he achieved.
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Customer Background: A Mining Contractor in Northern Canada
The customer operates a mining exploration camp in a remote region of northern Canada. The camp houses 30 workers. The camp runs 24 hours a day during the exploration season, which lasts from May to October. Temperatures range from +25°C in summer to -35°C in early spring and late fall.
Before buying from YG, the contractor owned two aging diesel generators. One unit produced 100kW. The other produced 50kW. Both units had over 15,000 operating hours. Both units broke down frequently. The contractor spent an average of $2,500 per month on repairs and replacement parts.
The contractor had three main power requirements. First, the camp needed at least 120kW of continuous power to run all equipment simultaneously. Second, the generator had to operate quietly because workers slept in tents near the generator shed. Third, the generator had to start reliably in cold weather.
The contractor started searching for a new engine generator set. He wanted a unit that offered reliability, low noise, and cold-weather capability.
Customer’s Specific Problems Before Buying the Silent DG Set
The contractor had four major problems with his old power system.
Problem 1: Frequent breakdowns. The old generators broke down every 2-3 weeks. Each breakdown meant a 6-12 hour outage. The camp lost heating during breakdowns. Workers had to huddle in sleeping bags. Food storage became a problem. Communication with the main office stopped.
Problem 2: High noise levels. The old generators produced over 85 decibels at the operator’s position. Workers in nearby tents complained about sleep disruption. The contractor received complaints from workers who said they could not rest properly. Fatigue became a safety concern.
Problem 3: Poor cold-weather starting. When temperatures dropped below -20°C, the old generators struggled to start. The contractor had to use propane heaters to warm the engines for 30 minutes before cranking. This wasted time and fuel.
Problem 4: High fuel consumption. The old generators consumed 45 liters of diesel per hour at full load. Fuel had to be trucked in from the nearest town, a 6-hour round trip. Fuel costs ate into the project budget.
The contractor calculated his total monthly operating cost for the two old generators. Fuel plus maintenance plus repair parts came to approximately $8,500 per month. He wanted a generator set that could reduce these costs.
The Search for a Reliable Engine Generator Set
The contractor started searching online for an engine generator set. He needed a machine with specific features.
First, the machine had to produce at least 150kW of continuous power. This would give him a safety margin above the 120kW requirement. It would also allow for future expansion.
Second, the machine had to operate at noise levels below 70 decibels. The contractor wanted workers to sleep without earplugs. The camp’s location in a quiet wilderness area made noise a sensitive issue.
Third, the machine had to include a cold-weather starting package. This meant battery heaters, oil pan heaters, and coolant heaters. The contractor needed reliable starting down to -40°C.
Fourth, the machine had to be fuel-efficient. The contractor wanted to reduce his monthly fuel bill.
The contractor contacted several DG set suppliers. He requested quotes for a 150kW silent DG set. Some suppliers offered machines that met his requirements but at very high prices. Other suppliers offered lower prices but could not guarantee cold-weather performance.
Then he found YG Machinery.
YG’s Solution: The 150kW Silent Diesel Generator Set
To tailor the right solution, YG’s sales engineer posed a series of targeted questions: which equipment would run concurrently, what the maximum load would be, the expected temperature extremes, the available fuel type, and whether an automatic transfer switch was needed.
Based on the answers, YG recommended the 150kW silent diesel generator set. The contractor reviewed the specifications and agreed.
Key Specifications of the 150kW Model:
| Item | 150kW |
|---|---|
| Power | 150kW |
| Cylinders | 6 Cylinder |
| Voltage | 400/230V |
| Frequency Range | 50HZ |
| Rotating Speed | 1500rpm |
| Cylinder Diameter × Stroke | 105×130mm |
| Rated Current | 270A |
| Phase | Three-Phase Four-Wire |
The machine uses a 6-cylinder diesel engine. It produces 150kW of continuous power at 1500rpm. The 400/230V output matches the camp’s electrical distribution system. The 270A rated current provides enough capacity for all camp equipment.
The contractor noted several specific advantages of the YG 150kW silent diesel generator set.
First, the machine includes a factory-installed soundproof enclosure. The enclosure reduces noise to approximately 65 decibels at 7 meters. This meets the contractor’s requirement for quiet operation.
Second, the machine includes a complete cold-weather starting package. This includes a coolant heater, oil pan heater, and battery heater. The machine can start reliably at temperatures down to -40°C.
Third, the machine uses a fuel-efficient engine. The contractor calculated that the YG unit would consume approximately 28 liters per hour at full load. This represents a 38% reduction compared to his old generators.
Fourth, the machine includes a digital control panel. The panel displays voltage, current, frequency, oil pressure, coolant temperature, and battery voltage. The panel also includes remote monitoring capability.
The contractor placed the order for one 150kW silent DG set as a replacement for his two old units. He planned to keep one old unit as a backup.
Implementation Process: Delivery and Setup
Step 1: Factory Production and Testing
YG Machinery delivered the 150kW engine generator set within 25 working days. Throughout assembly, the team adhered to the company’s quality checklist at every station—conducting engine leak checks, full-load generator tests, noise measurements, and cold-weather starting system validations.
The machine passed all tests. YG sent the contractor a video of the machine running at full load. The contractor approved the shipment.
Step 2: Shipping to Canada
The machine traveled from YG’s factory to the port by truck. The sea freight took 28 days to reach Vancouver. Customs clearance took 5 days. YG provided all necessary documents: commercial invoice, packing list, bill of lading, and certificate of origin.
The contractor’s freight forwarder handled the customs process. The unit cleared customs without issues. A flatbed truck carried the machine from Vancouver to the contractor’s camp. The total shipping time from factory to site was 45 days.
Step 3: On-Site Installation
YG Machinery sent a service technician to Canada. The technician arrived at the camp three days before the machine. He inspected the installation site. He checked the foundation, fuel supply, exhaust routing, and electrical connections.
Delivered via flatbed truck, the unit was crane-lifted to the ground, then maneuvered into place by the technician and the contractor’s crew. They leveled it on the concrete foundation, hooked up the fuel lines and exhaust system, and wired the electrical cables to the camp’s distribution panel.
The installation took two days. The technician ran a series of tests. The machine started on the first attempt. The technician measured noise levels. The machine produced 65 decibels at 7 meters.
Step 4: Operator Training
The YG technician trained two of the contractor’s operators. The training covered:
- Daily startup and shutdown procedures
- Control panel operation
- Cold-weather starting procedures
- Battery charging and maintenance
- Oil and filter change schedules
- Troubleshooting common issues
- Safety procedures
Each operator completed a two-hour hands-on session, covering cold-weather startup procedures, control panel interpretation, and daily inspection routines.
The technician stayed for three days. He answered questions and watched the team operate the machine. He left a training manual and a spare parts list.
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Challenges During Implementation
The contractor faced three challenges during the first month of operation.
Challenge 1: Fuel quality. The first batch of diesel fuel delivered to the camp had high water content. The water caused the fuel filter to clog within 12 hours. The contractor switched to a different fuel supplier. He also installed a water separator on the fuel line. The problem was resolved.
Challenge 2: Exhaust routing. The initial exhaust pipe routing caused the exhaust to blow toward the camp tents. Workers complained about the smell. The contractor rerouted the exhaust pipe to discharge away from the camp. The problem was resolved.
Challenge 3: Remote monitoring setup. The contractor wanted to monitor the generator from the main office in the nearest town. The remote monitoring system required a cellular connection. The camp had limited cellular coverage. The contractor installed a signal booster. The remote monitoring started working.
Final Results: Measurable Improvements
The contractor tracked performance for 60 days after receiving the 150kW silent DG set. Here are the results.
Fuel Cost Savings: 38% Reduction
The old generators consumed 45 liters per hour at full load. The YG generator set consumes 28 liters per hour at full load. That is a 38% reduction. The contractor saves $2,800 per month on fuel.
Maintenance Cost Savings: 65% Reduction
The old generators cost $2,500 per month in maintenance and repairs. The YG generator set costs $875 per month in maintenance. Scheduled oil changes and filter replacements only. No unexpected breakdowns. The savings come to $1,625 per month.
Total Monthly Operating Cost Comparison
| Cost Type | Old Generators (per month) | YG 150kW Silent DG Set (per month) | Savings |
|---|---|---|---|
| Fuel | $5,500 | $3,700 | $1,800 |
| Maintenance | $2,500 | $875 | $1,625 |
| Repairs | $500 | $0 | $500 |
| Total | $8,500 | $4,575 | $3,925 |
The silent DG set saves the contractor $3,925 per month compared to his old generators. The machine will pay for itself in approximately 18 months.
Noise Reduction: 23% Lower
The old generators produced 75 decibels at the operator’s position. The YG generator set produces 65 decibels. That is a 23% reduction in noise. Workers report sleeping better. The contractor has received zero noise complaints.
Reliability: 100% Uptime
The YG engine generator set has run continuously for 60 days with zero unplanned downtime. The machine has started reliably every morning, even on days when temperatures dropped to -28°C. The cold-weather starting package works as advertised.
Remote Monitoring
The remote monitoring system sends data to the contractor’s main office. The office staff can view the generator’s status, fuel level, and performance data in real time. They receive alerts if any parameter goes outside the normal range. This allows proactive maintenance.
Customer’s Direct Feedback
The contractor shared his experience after two months of using the 150kW silent DG set.
*”I should have bought this silent DG set years ago. The fuel savings alone justify the purchase. The machine starts every morning, even in -30°C weather. The noise level is much lower than our old units. My workers sleep better. The remote monitoring gives me peace of mind. I can check the generator status from my office. I plan to order a second unit for our next camp.”*
The camp manager added his comments.
“The generator set runs all day without issues. We have not had a single power outage since installation. The control panel is easy to read. The operator training was thorough. The YG technician answered all our questions. We have recommended YG to other contractors in the area.”
Future Outlook
The contractor plans to order a second engine generator set from YG for a new exploration camp next season. He has already received a quote for a 200kW unit. He is also considering a backup unit for the current camp.
YG Machinery continues to support the contractor with remote technical assistance. The YG service team answers questions via WhatsApp within a few hours. They have shipped a set of spare filters and belts to the contractor as a preventative measure.
The contractor has recommended YG to two other mining companies in northern Canada. One of them has already requested a quote for a silent DG set.
Contact YG Machinery today for your silent DG set needs. Tell us your power requirements, operating environment, and noise constraints. We will recommend the right model and send you a full price, including shipping to your port. Every machine comes with a 12-month warranty and lifetime technical support.
Click the contact button now to request a quote. Ask for our free operating cost calculator to estimate your potential fuel and maintenance savings.
