From Design to Installation: How Power Distribution Systems Come Together

When it comes to keeping your facility powered safely and reliably, your distribution system is one of the most important investments you’ll make. Whether it’s supporting a backup generator or an on-site power unit, a carefully planned and correctly installed system helps prevent costly downtime and keeps people and equipment protected.

This guide walks through the essential phases of a power distribution project, from planning and system layout to final testing and long-term care.

Design Phase

A power distribution system should always be built to fit the specific needs of its site. The design phase focuses on tailoring the setup to match your daily power demands, local environment, grid conditions, and safety requirements.

Key steps include:

Load Calculation

One of the first and most important tasks is determining how much power your system needs to handle. Technicians total the connected load in kilovolts-amperes (kVA) by adding up all the equipment and devices requiring power. A 25% safety margin is added to support future growth and accommodate occasional spikes in demand.

Component Selection

Every part of the system, from breakers to wiring, must be selected based on the expected electrical load and surrounding conditions. For example, systems near the ocean should include corrosion-resistant components, while high-temperature facilities may require heat-tolerant hardware.

System Layout

This stage determines how your components are positioned and connected. An effective layout balances reliability, ease of access, and long-term serviceability. Systems designed with clear pathways and service points reduce repair times and make routine inspections safer and simpler.

Grounding and Bonding

Grounding is essential for protecting people and equipment from electrical hazards. A solid grounding plan safely redirects fault currents and stabilizes voltage during normal use and emergencies. Their guide highlights the importance of creating a low-resistance path to earth while integrating bonding connections to maintain equal potential across all system components. This approach helps limit electrical noise, prevent equipment damage, and reduce safety risks.

By following established safety practices like these, power systems become safer, more reliable, and easier to maintain over time.

Installation Phase

After finalizing the design, certified technicians move forward with the installation process, following strict safety rules and code requirements throughout.

Safety Precautions

During installation, crews wear protective gear and follow clear procedures to keep themselves, the site, and the system safe.

Component Installation

Each piece, from control panels to busways, is installed following manufacturer instructions and industry standards. Wiring, terminations, and torque settings are double-checked to ensure proper connections and long-term reliability.

System Testing

Once installed, the system is thoroughly tested under load. These tests confirm that every component works as intended and that the system can safely handle its designed electrical demand. Test results also serve as a performance baseline for future inspections and maintenance.

Documentation

Accurate records are essential for supporting your system long-term. Technicians compile detailed documentation, including installation diagrams, component details, test results, and safety checks. This ensures future service teams can troubleshoot issues or make repairs confidently, even if original components are discontinued.

Ongoing Support

A power distribution system isn’t a one-time project, it’s an important part of your infrastructure that requires regular care and occasional updates. At GenTech, our team stays involved from the earliest planning stages through installation, testing, and ongoing support.

We’ve spent decades building, installing, and maintaining power systems for industries of every kind. Whether you’re starting from scratch, upgrading an older system, or scheduling preventative maintenance, we’re ready to help.

Reach out to GenTech today to see how we can support your power distribution needs.