ELECTRICAL GENERATOR

Technical field

The invention relates to radiator assemblies for use with containerised electrical generators. In particular embodiments, the invention relates to radiator assemblies comprising a vertical core radiator arrangement. Background

Typically, containerised generator systems are 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. The standardised shipping container requirements relate to containers that are sometimes referred to as International Organization for Standards (ISO) containers, which have predefined sizes, shipping weight constraints, etc. Containerised generator systems are readily transportable and can be deployed at sites at which supply of electrical 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 containerised 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. in a power plant arrangement where a single power output is provided. Further, a containerised generator may be formed of apparatus contained in multiple containers that may be coupled or connected together.

There is a continuing need to deploy, including retrieve, such containerised generator systems quickly and effectively so as to reduce deployment time and costs. In order to minimise costs, and/or maximise power output for a given footprint, there is a further desire to package such systems as effectively as possible within ISO containers for shipping and transportation, while minimising any compromises in relation to package layout and generator efficiencies. In particular, there is a need to optimize cooling of combustion engines used in a containerised generator without exceeding the size and weight requirements of the ISO container.

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 The inventors have appreciated that vertical core radiator assemblies (described in detail below) may be implemented in containerised electrical generators including a combustion engine running on heavy fuel oil (HFO), but that the radiator assemblies must be adapted to ensure adequate cooling. Further, the inventors have appreciated that vertical core radiator assemblies may be adapted to provide improved access to components within a containerised generator and increased cooling performance.

According vertical core radiator assembly for use in an electrical generator, the vertical core radiator assembly being configured to be fitted within an International Organization for Standards, ISO, shipping container and the electrical generator comprising a combustion engine for producing mechanical power and an electrical generator for converting the mechanical power into electrical power, the radiator assembly comprising: a radiator unit configured to receive coolant from the combustion engine and to be positioned adjacent an internal wall of the ISO shipping container; a cowl coupled to the radiator unit and configured to define a fluid path from the radiator unit to an opening of the cowl; and one or more fluid drivers positioned at the opening and configured to drive a fluid over the radiator unit and out of the opening for transferring heat from the coolant to the fluid, wherein a thickness of the radiator unit over which the fluid is driven is less than approximately 300 mm. Optionally, the cowl comprises a base wall extending transverse to a plane defined by the radiator unit for a distance in a range from approximately 100 mm to 200 mm.

Optionally, an inboard corner of the cowl is chamfered by a first part of a rear wall of the cowl extending from the base wall at an angle in a range from approximately 50 degrees to 70 degrees to a plane defined by the base wall.

Optionally, the inboard corner of the cowl is further chamfered by a second part of the rear wall of the cowl extending from the first part of the rear wall at an angle in a range from approximately 65 degrees to 80 degrees to the plane defined by the base wall.

Optionally, the opening has a width approximately of 724 mm or more.

Optionally, the one or more fluid drivers are positioned at the opening such that it does not overlap the radiator unit.

Optionally, the one or more fluid drivers comprise one or more fans and optionally wherein the fans have a blade diameter of substantially 630 mm. Optionally, an overall width of the vertical core radiator assembly is less than approximately 1 100 mm.

Optionally, the radiator unit comprises a low temperature radiator and a high temperature radiator.

Optionally, the high temperature radiator is inboard of the low temperature radiator.

Optionally, the vertical core radiator assembly further comprises a frame on which the radiator unit, the cowl and the fluid driver are positioned, wherein the frame further comprises skids configured to support the vertical core radiator assembly.

Optionally, the skids comprise apertures configured to receive tines of a forklift or other lifting apparatus. According to the invention in an aspect, there is provided an electrical generator for fitting within an International Organization for Standards, ISO, shipping container, and comprising: a combustion engine for producing mechanical power; an electrical generator for converting the mechanical power into electrical power; and two vertical core radiator assemblies according to any preceding claim, wherein the vertical core radiator assemblies are positioned such that the radiator units are adjacent to opposed walls of the ISO shipping container.

Optionally, a gap is defined between the rear walls of the cowls of the two vertical core radiator assemblies, and wherein a minimum dimension of the gap is in a range from approximately 170 mm to approximately 190 mm.

Optionally, the gap between the first parts of the rear walls of the two vertical core radiator assemblies is sufficient to accommodate a power cylinder of the combustion engine.

Optionally, the gap between the first parts of the rear walls of the two vertical core radiator assemblies defines a trapezium, and wherein the first and second parallel sides of the trapezium have lengths in a range from approximately 550 mm to approximately 650 mm and in a range from approximately 1350 mm to approximately 1450 mm respectively.

According to the invention in an aspect, there is provided a containerised electrical generator comprising an electrical generator as disclosed herein.

According to the invention in an aspect, there is provided a vertical core radiator assembly for use in an electrical generator, the vertical core radiator assembly being configured to be fitted within an International Organization for Standards, ISO, shipping container and the electrical generator comprising a combustion engine for producing mechanical power and an electrical generator for converting the mechanical power into electrical power, the radiator assembly comprising: a radiator unit configured to receive coolant from the combustion engine and to be positioned adjacent an internal wall of the ISO shipping container; a cowl coupled to the radiator unit and configured to define a fluid path from the radiator unit to an opening of the cowl; and a fluid driver positioned at the opening and configured to drive a fluid over the radiator unit and out of the opening in a direction substantially aligned with a plane defined by the radiator unit for transferring heat from the coolant to the fluid, wherein the fluid driver is positioned adjacent to the radiator unit and an overall width of the radiator assembly is less than approximately 1 100 mm.

According to the invention in an aspect, there is provided a vertical core radiator assembly for use in an electrical generator, the vertical core radiator assembly being configured to be fitted within an International Organization for Standards, ISO, shipping container and the electrical generator comprising a combustion engine for producing mechanical power and an electrical generator for converting the mechanical power into electrical power, the radiator assembly comprising: a radiator unit configured to receive coolant from the combustion engine and to be positioned adjacent an internal wall of the ISO shipping container; a cowl coupled to the radiator unit and configured to define a fluid path from the radiator unit to an opening of the cowl; and a fluid driver positioned at the opening and configured to drive a fluid over the radiator unit and out of the opening for transferring heat from the coolant to the fluid, wherein the cowl comprises a base wall extending transverse to a plane defined by the radiator unit for a distance in a range from approximately 100 mm to approximately 200 mm. Brief description of the drawings

Figure 1 is a perspective view of an exemplary containerised electrical generator; Figure 2 is a perspective view of exemplary cooling apparatus housed within a containerised electrical generator;

Figure 3 is a side elevation of a vertical core radiator assembly;

Figure 4 is a perspective view of a cowl and fluid driver arrangement of a vertical core radiator assembly; and

Figure 5 is a side elevation of an arrangement of two vertical core radiator assemblies within an ISO shipping container.

Detailed description

Generally, disclosed herein are methods and apparatus for improved noise reduction in relation to engines used within containerised electrical generators. As discussed above, containerised generators are required to fit within the internal dimension constraints of a container, typically a container meeting ISO shipping container requirements. This places significant constraints on the design of apparatus for use in such generators. In addition, the engines used in the containerised generators may include a forced induction system, such as a turbo charger, to increase engine efficiency and output power.

It will 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.

Vertical core radiator assemblies comprise a radiator unit (also termed a core or a coil) that is configured to be aligned with a vertical plane within the containerised generator and typically placed against an internal wall of the containerised generator. A grille forms part of the wall of the containerised generator and is aligned with the radiator unit to allow air from the external environment to pass over the radiator unit. A cowl is typically connected to an inboard (i.e. closer to a longitudinal axis of the containerised generator) side of the radiator unit to restrict airflow. Typically, the cowl has an opening that allows air to escape the cowl in an upward or vertical direction. One or more fluid drivers (typically fans or impellers) may be disposed at the opening to drive air (or another fluid) over the radiator units, through the cowl and out of the opening. This is explained in greater detail below. In exemplary arrangements, two vertical core radiator assemblies are positioned at opposed sidewalls of a containerised generator in a mirrored arrangement.

When used with HFO combustion engines, vertical core radiator assemblies are required to provide high levels of cooling of a coolant used in the HFO combustion engine. This would typically require larger radiator units so that a greater surface area is provided. The inventors have appreciated that the thickness of a radiator unit used in a vertical core radiator assembly may be reduced to allow improved fluid driver positioning and improved cowl arrangements to maintain cooling performance seen with thicker radiator units. Further, the cowl may be configured to permit greater access to other components of the containerised generator. This is particularly relevant within the restricted internal dimensions offered by the container. Containerised generator systems that produce electrical power typically comprise a number of system components, such as an engine unit coupled together with a generator unit. 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 HFO. HFO 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 for shipping than, for example, 20-foot (-6 m) containers, and so may be preferably used with HFO engine units providing greater power output for a given foot print. However, it will be appreciated by a skilled reader that aspects of the following description may be equally be used with alternatively-sized shipping containers.

Figure 1 shows a containerised generator 100 comprising apparatus for generating electrical power contained within two ISO containers 102, 104. In the exemplary arrangement of Figure 1 , an upper ISO container 104 is located on top of a lower ISO container 102. The lower container 102 includes an engine unit that is configured to generate mechanical energy and a generator unit configured to convert the mechanical energy into electrical power. The upper container 104 includes a number of cooling apparatus for cooling various parts of the containerised generator and, in particular, the engine unit. The upper container 104 also comprises grilles 106a-c (and corresponding grilles on the opposite side of the container 104 - not shown in Figure 1 ) configured to allow air to pass through and be used for cooling in the cooling apparatus. Figure 2 shows a perspective view of apparatus contained within the upper container 104. In particular, Figure 2 shows a vertical core radiator assembly 200, which is aligned with the grille 106a, and two V-core radiator assemblies 202, 204, which are aligned with the grilles 106b and 106c respectively. The vertical core radiator assembly 200 is discussed in greater detail herein.

Figure 3 shows a side elevation of an exemplary vertical core radiator assembly 200 comprising a radiator unit 206, a cowl 208 and at least one fluid driver (in this case a fan) 210. Although not shown in detail, the radiator unit 206 may be configured to receive a coolant, e.g. a fluid, which has come from the engine unit and is to be cooled before recirculation into the engine unit. Accordingly, the radiator unit 206 may comprise a network of thermally conductive heat dissipation elements, such as metallic pipes and/or fins configured to transfer heat from the coolant and to provide a large surface area over which cooling air may pass in order to transfer heat from the coolant to the passing air. In exemplary radiator units, the heat dissipation elements may comprise a plurality of heat conducting (e.g. metallic) pipes through which coolant may flow and arranged in a coiled or serpentine path from an inlet to an outlet. In the exemplary arrangement of Figure 3, the radiator unit 206 comprises a low temperature radiator 212 and a high temperature radiator 214. The low temperature radiator 212 is located outermost (or outboard) with respect to the high temperature radiator 214. In such arrangements, air passing through the radiator unit 206 and out of the fluid driver 210 (as shown by the dashed arrows in Figure 3) passes the low temperature radiator 212 first and so is not heated too significantly before being used to cool the coolant in the high temperature radiator 214. Accordingly, the high temperature radiator 214 is downstream of the low temperature radiator 212 with respect to airflow. The low temperature radiator 212 receives coolant from a low temperature cooling circuit of the engine unit and the high temperature radiator 214 receives coolant from a high temperature cooling circuit of the engine unit.

The exemplary radiator unit 206 shown in Figures 2 and 3 is generally rectangular in shape, having an inner surface 216 and an outer surface 218. In exemplary radiator assemblies, the thickness 220 of the radiator unit 206 may be less than approximately 300 mm, less than approximately 280 mm, less than approximately 260 mm, less than approximately 255 mm, in a range from approximately 240 mm to 260 mm and, in specific examples, the thickness 220 may be approximately 250 mm. The thickness 220 of the radiator unit 206 defines a distance over which air passing through the radiator unit 206 must travel. As discussed above, the thickness 220 of the radiator unit 206 may comprise a thickness of the low temperature radiator 212 and a thickness of the high temperature radiator 214. In exemplary arrangements, the thickness of the low temperature radiator 212 and the thickness of the high temperature radiator 214 may be substantially the same. It is noted that, whilst inner and outer surfaces 216, 218 are defined this may be merely illustrative and to aid description of the radiator assembly 200. In particular, the heat dissipation elements discussed above may mean that a surface, as such, is not actually formed.

Exemplary radiator units 206 may have a height 222 in a range from approximately 1500 mm to 1700 mm, or in a range from approximately 1550 mm to 1650 mm, and in a specific arrangement may have a height of approximately 1605 mm. Exemplary radiator units 206 may have a length in a range from approximately 2500 mm to 2700 mm, or in a range from approximately 2550 mm to 2650 mm, and in a specific arrangement may have a length of approximately 2600 mm. Exemplary radiator units 206 may have an outer and/or inner surface area in a range from approximately 4 m ² to approximately 4.4 m ² and in a specific arrangement may have an outer and/or inner surface area of approximately 4.17 m ² .

The low temperature radiator 212 includes a coolant inlet 224 and a coolant outlet 226. Similarly, the high temperature radiator 214 includes a coolant inlet 228 and a coolant outlet 230. The inlets 224, 228 are configured to receive coolant after which it is circulated around the heat dissipation elements of the radiator unit 206 before being output from the outlet 226, 230 and returned to the corresponding area of the engine unit. As will be understood, there are many configurations of radiator unit that may be used and methods and apparatus disclosed herein may be applied to those different configurations.

The radiator unit 206 may be mounted on a frame 230 configured to be fitted within the container 104. The width of the frame 232 is therefore restricted based on the internal dimensions of the container 104. These internal dimensions are standardized in the case of ISO shipping containers. In exemplary arrangements, the width of the frame 232 and the radiator assembly 200 may be configured to permit a minimum distance between radiator units of opposed vertical core radiator assemblies within the container 104. Further, the height the radiator assembly 200 including the frame 232 may be configured to fit through a doorway of the container 104, which may have an aperture of height of 2620 mm with a nominal, for example 70 mm, clearance. As shown in Figure 3, the frame 232 may comprise skids 234, 236 having holes configured to receive tines of a forklift truck, or other lifting apparatus. This may aid fitting and removal of the radiator assembly 200 in the container 104.

The fan(s) 210 is positioned at an opening 238 of the cowl 208 and is configured to drive air from within the cowl 208 through the fan(s) 210 and out of the opening 238. The fan(s) 210 is configured to drive the air out of the opening in a direction substantially aligned with a plane defined by the inner 216 and/or outer 218 surfaces of the radiator unit 206. This in turn draws air through the radiator unit 206 such that it passes over the heat dissipation elements to transfer heat from the coolant into the air. In exemplary arrangements, the fans comprise a plurality of fans, for example three fans (see figure 4), having a blade diameter (i.e. a diameter of a circle drawn by a revolution of the blade tips) of 630 mm, such as the 63JM/20/4/6/26 - short cased, manufactured by Flakt Woods Limited, Colchester, UK. The 630 mm fans may be arranged in a 3x1 array in the opening 238. The opening may have a width (i.e. a dimension extending inboard from the radiator unit 206) of approximately 724 mm or more to accommodate the fan(s) 210 and in exemplary arrangements may have a width of approximately 760 mm. An overall height of the vertical core radiator assembly 200 may be approximately 1930 mm including the height of the fans 210 (225 mm) and the frame 232 including the skids.

Referring to Figure 4, the cowl 208 comprises opposed sidewalls 240 (only one shown in Figure 3) extending inboard from opposed edges of the radiator unit 206, a base wall 244 connected between the sidewalls and extending inboard from a bottom edge of the radiator unit 206. The cowl 208 also comprises a rear wall 246 connected between the sidewalls 240, 242 and the base wall 244. As can be seen in Figure 4, a capping plate 248 may be configured to cover the opening in the area surrounding the fans 210a-c. Further, in exemplary arrangements the volume defined by the cowl 208 and the radiator unit 206 may comprise internal walls 250a-b partitioning the volume into discrete sections. Each section may comprise a single fan 210a-c at the opening 238a-c thereof .

The base wall 244 of the cowl 208 extends substantially horizontally from the radiator unit 206 and transverse to a plane defined by the inner surface 216 and/or the outer surface 218 of the radiator unit 206. This allows a greater volume of air to be drawn over the lower region of the radiator unit per unit of time. That is, an increased rate of airflow over the lower region of the radiator unit 206 is possible. This in turn increases the uniformity of airflow rate over the entire radiator unit 206 and increases the cooling efficiency of the vertical core radiator assembly 200. In exemplary radiator assemblies, the base wall 244 may extend from the radiator unit 206 by a distance in a range from approximately 100 mm to approximately 200 mm and in a particular example may extend by approximately 150 mm. Further, it is noted that, whilst in the exemplary cowl 208 of Figures 3 and 4 the base wall 244 extends horizontally, in other exemplary arrangements the base wall 244 may be transverse to the radiator unit 206 and may extend at an angle from a horizontal plane. The transverse base wall 244 is made possible because the radiator unit 206 has a thickness as set out above. Cooling efficiency lost by having a thinner radiator unit 206 are mitigated by increased uniformity of airflow across the radiator unit 206.

An inboard corner of the cowl 208 is chamfered. The inboard corner is shown for illustrative purposes by dashed lines 252, 254. It should be understood that the dashed lines 252, 254 do not show a feature of the cowl 208, but illustrate where the inboard corner would be were it not chamfered. In exemplary arrangements, the chamfered corner may comprise part 246a of the rear wall 246 and may extend from the base wall 244 at an angle to the horizontal plane in a range from approximately 50 degrees to approximately 70 degrees and in a specific example may extend at an angle to the horizontal of approximately 60 degrees. As discussed below, the chamfered corner creates a space between cowls of opposed vertical core radiator assemblies to allow greater access to other features of the containerised generator. In a specific case, the space between the cowls may be configured to receive a power cylinder of an engine unit in the lower container 102.

The specific cowl shown in Figures 3 and 4 has an inboard corner chamfered in two stages. A first part 246a of the rear wall 246 chamfers the corner at a first angle and a second part 246b of the rear wall chamfers the corner at a second angle steeper than the first. In exemplary radiator assemblies, the first chamfer angle may be in a range from approximately 50 degrees to approximately 70 degrees and in a specific example may be approximately 60 degrees to the horizontal and the second chamfer angle may be in a range from approximately 65 degrees to approximately 80 degrees and in a specific example may be approximately 75 degrees to the horizontal.

The thickness 220 of the radiator unit 206 is configured to allow the fan 210 to sit entirely inboard from the radiator unit 206. That is, the fan 210 is adjacent to the radiator unit 206 and does not overlap the radiator unit 206. In exemplary arrangements, a distance between the outer surface of the radiator unit 206 and the centre of the fan(s) 210 may be approximately 630 mm.

In order to fit the constraints of the container 104 when the radiator assembly 200 is fitted within the container opposed to a second vertical core radiator assembly, an overall width 256 of the radiator assembly 200 must be less than half the internal width of the container 104. In practical implementations, the overall width 256 must be sufficiently less than half the width of the container 104 to leave a gap between the inboard extents of the two vertical core radiator assemblies. This is discussed in more detail below. Because the overall width 256 is restricted in this way, the fan 210 may only be positioned such that it does not overlap the radiator unit 206 if the thickness 220 of the radiator unit is sufficiently small. By placing the fan 210 such that it does not overlap the radiator unit 206, more air may be driven over the radiator unit and any reduction in cooling efficiency due to reduction in the thickness 220 of the radiator unit 206 is mitigated. In exemplary vertical core radiator assemblies, the overall width 256 may be less than approximately 1 100 mm and in specific examples may be approximately 1009 mm.

It is noted that the fan comprises a housing surrounding the blades with flanges at the top and bottom that extend laterally. In some exemplary arrangements, the flanges may overlap the radiator unit 206, while in other exemplary arrangements, the flanges do not overlap the radiator unit 206.

Figure 5 shows an exemplary arrangement of two vertical core radiator assemblies 200a, 200b positioned adjacent to opposed sidewalls of an ISO shipping container (not shown). The rear walls 246 of the vertical core radiator assemblies 200a, 200b define a gap therebetween. At an upper part of the rear walls 246, a minimum distance 258 between the vertical core radiator assemblies 200a, 200b is defined. In exemplary arrangements, the minimum distance 258 is in a range from approximately 170 mm to approximately 190 mm and in a specific arrangement may be approximately 180 mm. Further, the first parts 256a of the rear walls 246 may define an area 259 of a trapezium shape (shaded in Figure 5) that is sufficiently wide to accommodate a power cylinder from the combustion engine unit, which is typically located in the lower container 102 below the vertical core radiator assemblies 200a, 200b. The trapezium has two parallel sides. A first of the parallel sides has a length 260 in a range from approximately 550 mm to approximately 650 mm and in a specific example may have a length of approximately 601 mm. A second of the parallel sides has a length 262 in a range from approximately 1350 mm to approximately 1450 mm and in a specific example may have a length of approximately 1388 mm. The lengths of the parallel sides of the trapezium are distances between the rear walls 246 caused by the chamfered inboard corner of the cowls 208.

During maintenance of a containerised generator, a power cylinder of the combustion engine unit may be lifted into the area 259 such that an engineer or technician is able to access previously unreachable parts of the combustion engine. In use, the radiator units 206 receive coolant from the combustion engine and the fluid drivers 210 drive air vertically out of the cowls 208, which in turn draws more air into the cowls 208 through the radiator units 206, thereby transferring heat from the coolant to the air.

The skilled person will be able to envisage further embodiments of the invention without departing from the scope of the appended claims.