Background

Containerised generator systems are readily transportable, and can be deployed at sites at which supply of electric power to the site from a power distribution network is prohibitive or insufficient for the needs at site. Such generator systems may also be used where there is an absence of power networks, or indeed where a typically-used power network has been disrupted in some manner (e.g. due to acts of nature). In some cases, the site may be used to feed power to an existing network.

Such transportable generator systems may be stand alone, or may be modular in so far as the power output at site can be provided cumulatively from multiple transportable generator systems, e.g. where a single power output is provided.

Typically, such generator systems can be deployed and operated from containers that meet standardised shipping container requirements (e.g. dimensions, etc.). Those containers may be modified from a standard container in so far as access panels, air inlet panels, or the like may be provided. In some cases, the generator systems may be deployed for a period of time, and then removed from site and used elsewhere. These standardised shipping containers are sometimes referred to as ISO containers, which have predefined sizes, shipping weight constraints, etc. At site, it is typical to require some form of ground works in order to accommodate the containerised generator systems.

However, there is a continuing need to deploy, including retrieve, such containerised generator systems quickly and effectively so as to reduce deployment time and costs. Further, and to prevent unwanted downtime at site, there is a continuing desire to improve the deployment and instalment methods used so as not to impact unduly - and where possible improve - the reliability, serviceability and lifespan of such systems, either during or after deployment.

This background serves only to set a scene to allow a skilled reader to better appreciate the following description. Therefore, none of the above discussion should necessarily be taken as an acknowledgement that that discussion is part of the state of the art or is common general knowledge. One or more aspects/embodiments of the invention may or may not address one or more of the background issues.

Summary

In some examples there are described containerised generator systems, and methods for deployment (including retrieval), and power generation. Aspects of the described systems and methods may help reduce deployment time and costs, and/or maintaining or improving the reliability, serviceability and lifespan of such systems, either during or after deployment. In one example, there is described a method for deploying a containerised generator system (e.g. at site). Such containerised generator systems may, for example, comprise an engine unit and a generator unit. Such engine units and generator units may be configured to couple together so as to provide electric power.

The method may comprise providing the engine unit and the generator unit in separate shipping containers (e.g. standardised transportation containers).

The method may comprise removing one of the engine unit or generator unit from its respective container. The method may further comprise aligning the engine unit together with the generator unit. The method may comprise coupling the engine unit together with the generator unit.

In some examples, the method may comprise positioning the engine and generator units in the other container. Such positioning may be assisted by using deployment guides of that other container. The deployment guides may be configured to permit the movement of the units within the containers.

The method may comprise partially (or indeed fully) removing the other of the engine unit or generator unit from its respective container, and aligning and coupling the engine unit together with the generator unit. The method may comprise aligning (e.g. initially aligning) the separate containers of the engine unit and the generator unit, and providing a bridging skid between the containers in order to assist with movement of one unit from one container to the other container. Each container may comprise respective deployment guides. In such cases, removal of the engine unit or generator unit from its respective container may be assisted by deployment guides of that container. Such deployment guides may fixed within the containers (e.g. within both container).

Such deployment guides may form part of the structure of the containers. For example, the deployment guides may be formed at least on a base portion of the respective containers. The guides may be configured to assist movement of the engine and generator units within the containers.

The bridging skid may comprise complementary deployment guides. Such complementary deployment guides may be configured to align with deployment guides of the respective engine and generator unit containers.

The engine and generator units may both (e.g. at least initially) be partially removed from respective containers onto the bridging skid. In some examples, the units may be aligned and coupled together at the bridging skid, before positioning the coupled engine and generator unit in one container.

The engine or generator unit may be removed from its respective container, and/or the engine and generator unit may be positioned in the other container, using a drive arrangement.

Removing one of the engine unit or generator unit from its respective container may provide an unoccupied container. In such cases, the method may comprise subsequently removing from site that unoccupied container.

In some examples, it may be that the engine unit as such is removed from its respective container. In those cases, the method may comprise aligning and coupling the engine unit together with the generator unit; and positioning the engine and generator units in the container used to deploy the generator unit. The method may comprise removing, from site, the container having been used to ship the engine unit. Likewise, the method may comprise re-using the removed container for shipping a further engine unit.

The engine unit and/or generator unit may be provided in 40-foot ISO shipping containers. The engine unit may be configured for use with Heavy Fuel Oil (HFO). In some examples, there is described a method for removing a containerised generator system from site. Such a system may comprise an engine unit and a generator unit aligned and coupled together in a shipping container, for example. The method may comprise uncoupling the engine unit from the generator unit. The method may comprise positioning one of the engine unit or generator unit in a separate container using deployment guides of that container, for example, and/or the separate container. Such deployment guides or the like may be configured to permit the movement of the units within the container(s). The method may also comprise removing from site both the containerised engine unit and the separately-containerised generator unit. In further examples, there is described a method for replacing one of an engine unit or generator unit of a containerised generator system. Such engine unit and generator units may be aligning and coupling together in a shipping container. The method may comprise uncoupling the engine unit from the generator unit. One of the engine unit or generator unit may be positioned in a separate container (e.g. using deployment guides of that container and/or the separate container). The deployment guides may be configured to permit the movement of the units within the container(s). The method may comprise retaining an existing unit, but removing or repositioning the containerised unit to be replaced. Further, the method may comprise providing a replacement unit in a further separate shipping container, and removing one of the existing unit or replacement units from its respective container. The method may comprise aligning and coupling the existing unit together with the replacement unit; and positioning the engine and generator units in the other container using the deployment guides of that other container, the deployment guides being configured to permit the movement of the units within the containers.

In further examples there is described a containerised generator system comprising an engine unit provided in a first shipping container and a generator unit provided in a second shipping container. Each of the shipping containers may be configured to be transported to a site for deployment. The engine unit and generator unit may be configured to couple together so as to provide electric power. One or both of the containers may comprise deployment guides configured to permit the movement of the units within the containers.

The system may comprises a bridging skid configured to be positioned between the first and second containers in order to assist with movement of at least one unit from one container to the other container, in use. Each container may comprise respective deployment guides. In such examples, the bridging skid may be configured for complementary alignment with the deployment guides of each container.

The deployment guides may be fixed within the containers and, in some cases, may additionally provide structural support for the containers. The deployment guides may be formed at least on a base portion of the respective containers. The guides may be configured to assist movement of the engine and generator unit within the containers. The deployment guides, or the like, may be formed at the base portion of the container. The guides may be configured to distribute load across from the generator/engine units across the base portion (e.g. in addition to providing guides). In some examples, the deployment guides may be configured to provide rigidity to the container, in use. In other similar words, the container may have a different flexural characteristic with and without the guides, whereby the guides additional serve to stiffen the container. In some case, the deployment guides comprise I-beams or the like.

In some examples, each container may comprise a plurality of foundation support beams. Each support beam may be configured to mate with complementary foundation pads at site. The support beams may be configured to space the base portion of the container from foundations pads.

In some examples, the bridging skid may comprise complementary deployment guides. The complementary deployment guides may be configured to align with deployment guides of the respective containers (e.g. engine and generator unit containers).

One or both shipping containers may comprise a drive arrangement. Such a drive arrangement may be configured to move the particular units (e.g. engine/generator units) within their respective containers (e.g. along the deployment guides).

One or both of the he engine unit and generator unit may be provided in 40-foot ISO shipping containers. The engine unit may be configured for use with Heavy Fuel Oil (HFO).

In some examples, there is described a container comprising a plurality of foundation support beams. Each support beam may be being configured to mate with complementary foundation pads at site. In such examples, the support beams may be configured to space the base portion of the container from foundations pads.

Those containers may comprise one or more stiffening beams, provided with the containers (e.g. within the containers). Those stiffening beams may be configured to increase the distribute loads within the container, and/or increase the rigidity of those containers.

The invention includes one or more corresponding aspects, embodiments or features in isolation or in various combinations whether or not specifically stated (including claimed) in that combination or in isolation. As will be appreciated, features associated with particular recited embodiments relating to systems may be equally appropriate as features of embodiments relating specifically to methods of operation or use, and vice versa.

It will be appreciated that one or more embodiments/aspects may be useful in reducing deployment time and costs of containerised generator systems, and/or maintaining or improving the reliability, serviceability and lifespan of such systems, either during or after deployment.

The above summary is intended to be merely exemplary and non-limiting. Brief Description of the Figures A description is now given, by way of example only, with reference to the accompanying drawings, in which :-

Figure 1 shows an example of containerised generator system;

Figure 2 shows a further example of a containerised generator system having first and second containers;

Figures 3a-3e shows the containerised generator system of Figure 2 being deployed;

Figures 4a-4d show features of the containerised generator system of Figures 2 and 3 in which an engine unit and generator unit are positioned within one of the two containers; and Figures 5a-c shows an example of the container systems in Figures 2, 3 and 4 having a plurality of foundation support beams.

Description of Specific Embodiments As explained above, there is a need for improved ways to reduce deployment time and costs of containerised generator systems, i.e. generator systems that are deployed in standardised shipping containers. Similarly, there is a continuing desire to maintain - or indeed improve - the reliability, serviceability and lifespan of such systems, either during or after deployment.

Containerised generator systems that produce electric power typically comprise a number of system components, such as engine units coupled together with generator units. These containerised systems are configured to convert mechanical energy provided by the engine into electrical energy at the generator, and so provide an electric power output from the system. Such power output may be supplied to a local power network for further distribution, and/or may be used locally at site. The generator systems may be standalone, or may be modular in so far as the power output from each deployed generator system can be provided cumulatively, e.g. effectively as a power plant, which may supply a local power network or the like.

The following described examples relate to new systems and methods that provide exemplary ways to deploy (including retrieve), maintain, etc. such containerised generator systems. In the following examples, engine units have been described that use internal combustion to produce mechanical power, and in particular are configured to operate using Heavy Fuel Oil (HFO). Heavy Fuel Oil is typically considered to be a lower-cost fuel, and therefore has the potential to provide lower-cost power output at site. However, using such fuels in an engine unit can be more complex than other fuels. Therefore, to realise the benefits of using such a low-cost fuel, the cumulative cost of deploying and maintaining such systems must not erode any gains made when using HFO. While engine units running HFO have been considered in the examples below, it will be appreciated that aspects of the following description may equally be used with alternative fuels, and indeed alternative engine units. A skilled reader will readily be able to implement those various embodiments accordingly.

Similarly, the following examples describe systems and methods for use with standardised 40-foot (12 m) ISO shipping containers. Such containers permit greater volume of engine and generator units than, for example, 20-foot (6 m) containers, and so may be preferably used with HFO engine units providing greater power output - albeit the transportation requirements of such containers may change when the weight exceeds 30 tons. However, it will be appreciated by a skilled reader than aspects of the following description may be equally be used with alternatively-sized shipping containers. It will also be appreciated that herein the term "shipping container" may generally relate to a container that complies with shipping container standards (e.g. dimensions). In some cases, however, those "shipping containers" may be specifically configured for deployment of a generator system, and may comprise additional components, access panels, etc., as will be appreciated.

Consider now Figure 1 , which shows a schematic example of such a containerised generator system 100 that is provided in a 40-foot (12 m) shipping container 50. Here, the system 100 comprises a number of system components including an engine unit 1 10 and a generator unit 120, which are coupled together. As mentioned, the engine unit 1 10 is configured to operate using Heavy Fuel Oil (HFO). Ancillary system components 130 are also shown and provided within the shipping container 50. Such ancillary components 130 may include a cooling system, fuel processing unit, lubrication oil separator, or air compressor devices, switchgear, or the like. In some examples, some of the ancillary components 130 may be provided in additional shipping containers, which may be arranged together with the container when deployed (e.g. in a stacked arrangement).

Prior to deployment, each system component 1 10, 120, 130 can be operatively arranged and coupled together within the container 50, and essentially ready for use when deployed. In order to optimise power output for a given footprint of container, there is often a desire to optimise the overall system 100 packaging and maximise the use of space within the container 50. However, of course, this can restrict access space after deployment that may assist with maintenance or repairs. Further, such optimised packaging may increase deployment costs due to increased costs associated with transporting heavier containers (e.g. increased shipping costs, as well as additional road transport and site deployment costs for containers over 30 tons). The optimisation of the packaging of the system 100 may also need to take into account the centre of gravity of the container 50, and consequentially the power efficiency of the overall generator system 100 may be affected.

Consider now Figure 2, which shows a further schematic example of a generator system 200, as will be further described. In this example, the system 200 for deployment comprises two shipping containers: a first container 60 and a second container 70. Each of the containers 60, 70 are again 40-foot (12 m) ISO shipping containers. Here, an engine unit 210 is provided in the first shipping container 60 and a generator unit 220 is provided in the second shipping container 70. For ease of explanation, any ancillary components 130 are not shown. In the following example - and as will be described - the first container 60 may be considered to be, or indeed ultimately be considered to be when fully deployed, a genset container, e.g. a container that comprises not only the generator unit 220, but also additional components that would otherwise be used to provide the overall generator system 200 and power output (were an engine unit 210 to be installed). The second container 70 may comprise essentially the engine unit 210 (e.g. and no additional components for use with the final assembled system 200). It will readily be appreciated that in other examples, that need not be the case, however, and the second container may comprise additional components with the engine unit 210. In Figure 2, any additional components that may be provided with first container 60 so as to ultimately may be used to form a complete genset, have not been shown for ease.

In any event, in this example, each container 60, 70 comprises deployment guides 230. Here, the deployment guides 230 can be considered to be formed on a base region 65, 75 of each respective container 60, 70 and affixed thereto (e.g. bolted, welded, or the like) Here, the deployment guides 230 are configured to permit movement of units 210, 220 within the containers 60, 70. As such, both the engine unit 210 and generator unit 220 are configured to co-operate with the guides to permit such movement (e.g. translation along the container 60, 70). Securable guide rollers (see later description of Figures 4b and 4c) or the like may be used to co-operate with the deployment guides 230. Skid shoes, or the like, may also be used.

In this particular example, each deployment guide 230 comprises an I-beam, or the like, and is fixed to the base regions 65, 75. In addition to providing a means for accurate movement, by fixing the deployment guide 230 to the base regions 65, 75 the overall rigidity of the containers 60, 70 can be improved. In other words, the guides 230 serve also as structural members within the container 60, 70, which may help mitigate flexural movement of the containers 60, 70 in use. Further, in such a way, the guides 230 may additionally serve to distribute the load within the container 60, 70 more appropriately.

In use, and as will be explained, the containers 60, 70 each housing the engine unit 210 and generator unit 220 respectively are configured to be shipped separately to a site for deployment. Consider now Figures 3a to 3e, which show a plan-section view of the system 200, and serve to exemplify one method for deploying the containerised generator system 200 of Figure 2, at site. In Figure 3a, the first container 60 housing the engine unit 210 is shipped or otherwise transported and positioned at site. Similarly, the second container 70 housing the generator unit 220 is shipped or otherwise transported and positioned at site. It will be appreciated that the term "shipping" may include transportation by road, rail or the like, and need not necessarily include shipping by sea, and certainly not shipping by sea only. It will also be appreciated that when at site, cranes or other hoist means may be used to position the containers 60, 70 in an appropriate location. By way of an example, ancillary component 240 contained with the second container 70 are also shown in Figure 3a-3e (as mentioned above).

Here, and as is shown in Figure 3a, the first and second containers 60, 70 are positioned and aligned relative to one other. Access hatches or doors 250 at a minor side of the containers 60, 70 are opened, which permits access to the inside of the containers. A bridging skid 260 is positioned between the containers 60, 70. Here, the bridging skid 260 comprises complementary deployment guides 270 configured to align with deployment guides 230 of the respective engine and generator unit containers 60, 70 in order to assist with movement of one unit from one container to the other container. It will be appreciated that the bridging skid 260 may be shipped in one of the respective containers.

In Figure 3b, a drive arrangement 280 is provided in order to assist with movement of the engine unit and generator unit using the deployment guides 230. Here, the drive arrangement 280 is positioned and fixed at the first container 60, and is also coupled to the generator unit of the second container 70. In the example shown, the drive arrangement 280 may comprise a winch arrangement secured at the first container 60, and separately providing a winching member 285 secured to a towing attachment 287 at the generator unit 220, as will be appreciated. As shown in Figure 3c, the generator unit 220 can then be removed (and in this example partially removed) from the second container 70 using the drive arrangement 280 together with the deployment guides 230, 270 and bridging skid 260.

Similarly, as shown in Figure 3c, the drive arrangement 280 can then mounted with the second container 70 and - as above - the winching member 285 can be secured to a towing attachment 289 at the engine unit 210. Similarly again, the engine unit 210 can be removed (and in this example partially removed) from the first container 60 using the drive arrangement 280 together with the deployment guides 230, 270 and bridging skid 260.

As will be appreciated, in some examples, a bridging skid 260 need not be provided, and so the respective containers (and deployment guides 230) may be positioned and aligned with one of the engine unit or generator unit being removed and positioned in the other respective container, prior to coupling. However, as is shown in Figure 3d, when both the engine unit 210 and generator unit can be partially removed (e.g. using the bridging skid 260), they can also be aligned and coupled together with ease of access between the containers 60, 70. In either situation, both the engine unit 210 and the generator unit 220 may comprise mating connections to permit ease of coupling together, and/or to ancillary components 240 (e.g. control looms may comprise pluggable attachments).

As is shown in Figure 3e, in this example - after being coupled together - the engine unit 210 and the generator unit 220 can then be positioned within one of the containers (in this case, the second container 70, which comprises the additional components for use to provide the overall genset). Figure 4a shows a perspective representation of the engine unit 210 coupled together with generator unit 220, sitting on, or otherwise mounted with, the deployment guides 230. Figure 4b shows an example of securable guide rollers 290 fitted in this example with the generator unit 220. Figure 4c shows similar guide rollers 290, but in addition the towing attachment 287, 289.

Figure 4d shows a perspective representation of the second container 70 for housing the units 210, 220 shown in Figure 4a. As can be seen a number of internal strengthening beams 300 may also be provided within the container 70. Such stiffening beams may help improve the rigidity of the container, and reduce localised loading at site. In such a way, less ground works may be required for an equivalently weighty container. After being housed within the one container 70, the other container (in this case the first container 60 that otherwise was used to ship the engine unit 210) is essentially unoccupied, and can be removed from site (if desired). In some examples, that first container 60 may be re-used for the purposes of transporting a further engine unit 210. It will be appreciated that the second container 70 as shown in Figure 4d may be specifically configured for the purposes of housing both the generator unit 220 and engine unit 220, when deployed. As such, the container 70 may comprise access panels 310, ventilation panels 320, and the like. By contrast, the first container - if not being used in the same manner - may be provided by a more standard shipping container, without the additional panels or the like. Although not shown, it will also be appreciated that the same containerised generator system 200 can be removed from site by reverse order of Figure 3a-3e, i.e. uncoupling the engine unit 210 from the generator unit 229; and positioning one of the engine unit 210 or generator unit 220 in a separate container 60, 70 using deployment guides 230 of that container and/or the separate container, and removing from site both the containerised engine unit 210 and the separately-containerised generator unit 220.

Similarly, due to the manner in which the system 200 is configured, then one or both of the engine unit 210 and generator unit 220 can be removed and replaced entirely, without the need to remove the remainder of the containerised system 200 from site. Further, if access is required to a portion of the engine unit 210 and/or generator unit 220, then this may be provided by replacing either the bridging portion or other skid, or indeed an empty container, and removing the relative component from the container. Further, by shipping each of the engine unit 210 and generator unit 220 separately, then the costs for transportation can be minimised for the desired footprint and power output from a site. This is due to the fact that excessively heavy containerised systems, which you may expect from an HFO system, may otherwise exceed the standard weight constraints for an ISO 40-foot (12 m) shipping container. In such circumstances, an additional shipping cost may be applied, road transportation may require escorts, and hoisting equipment at site may have to be higher rated, increasing equipment and operational costs. While these costs may be acceptable for a single deployment, the cumulative effect of these increase costs during multiple deployments and retrievals may offset any gains in fuel cost saving (e.g. when deploying the generator system 200 short term). Further, even if costs are not increased, the additional time and effort required when transmitting heavy loads may increase significantly the deployment time (e.g. when road escorts are required). By minimising container weight and avoiding the need for complex safety requirements, the time of deployment can be reduced. This may be particularly key at sites requiring temporary power, e.g. due to acts of nature.

Further still, each of the engine unit 210 and generator units 220 can be appropriately positioned within the containers for transportation so as to optimise the weight distribution within that container (e.g. optimise the centre of gravity of the container). In such a way, forces and accelerations imparted to the containers and contents may be minimised (e.g. to avoid component failures or warranty issues during transit). It will further be appreciated that, as mentioned above, the reinforcement or otherwise stiffening of the container 60, 70 - in this example at least using the deployment guides and/or stiffening beams - may additionally help during deployment when considering the ground works that may be required. Typically, ground at site on which a containerised system is to be located may be excavated and traditional foundations may be installed (e.g. using concrete). Such foundations may be to minimise isolated loading and unwanted movement from vibrations.

However, by appropriately reinforcing the container (e.g. distributing the load from the container across the base portion of the container), the need for time consuming establishment of foundations may be obviated. Consider now Figure 5a which show a container 400 intended for housing the engine and generator unit 210, 220, after deployment (as well as optional additional components). Figure 5b shows an end view, and Figure 5c shows an enlarged view of a support beam 410. Here, the system comprises a plurality of foundation support beams 410, which are configured in use to extend from the supported container 400 and to mate with complementary foundation pads 420 at site. Here, four support beams 410a-410d have been provided. Each are arranged as an I-beam, which in this case extend in the minor direction across the base portion of the container 400 (i.e. transverse the inner deployment guides 230). The support beams 410 are configured to space the container 400 from foundations pads 420 at site. Due to the stiffening of the container 400, only the support beam 410 and foundation pads 420 may be required at site in order to suitable support the generator system 200. As such, complex or time consuming foundations need not be provided (e.g. even with a 40-foot (12 m) ISO container).

Further, it will be appreciated that by stiffening the container 400 itself rather than - or in addition to - providing robust ground works, that the alignment of components within the container 400 can be maintained. In other words, unwanted flexural movement of the container can be minimised by integrally stiffening the container 400 in the manner described, without necessarily spending significant time and effort on grounds works. Hence, time and cost for deployment can be reduced.

It will be appreciated that in some examples, the stiffened container and support beams may be used without the arrangement described in Figure 3. In other words, the integrally stiffened container 400 may be used with other generator systems. It will also be appreciated that in the above examples, and in addition to the generator system 200, other system components may be deployed in order to provide a power plant, for example containerised fuel storage, containerised control systems, or the like. For ease of explanation, these further containerised systems have not been described in detail. However, a skilled reader will readily be able to implement such systems accordingly. The applicant discloses in isolation each individual feature described herein and any combination of two or more such features, to the extent that such features or combinations are capable of being carried out based on the specification as a whole in the light of the common general knowledge of a person skilled in the art, irrespective of whether such features or combinations of features solve any problems disclosed herein, and without limitation to the scope of the claims. The applicant indicates that aspects of the invention may consist of any such individual feature or combination of features. In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention.