FIELD

The present disclosure describes containerized electric power supply units. Such units may comprise an electrical storage system, such as a battery or other electrochemical or electrostatic storage system.

BACKGROUND

Containerised power supply 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 not available, 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 system 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.

Traditionally, such containerized power supplies have contained an electrical generator operated by a diesel or other fossil fuel engine and these units work well for a wide range of applications. However, some applications may benefit from a containerized power supply based on electrical storage rather than generation or users may simply prefer an electrical storage based containerized power supply, for example, if they require a containerized power supply unit with less on site emissions or that is more environmentally friendly, amongst other possible reasons. In this case, containerized power supplies that use a generator driven by an engine that uses fossil fuels may be replaced by electrical storage solutions that use batteries or other electrical storage devices. However, a containerized power supply unit based on electrical storage systems may present different challenges to generator based systems. In addition, providing an electrical storage system in a container, such as a standard ISO shipping container, having limited volume, presents challenges over providing such systems in unconstrained footprints.

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

Aspects of the present disclosure are defined by the independent claims appended herewith. Optional features are defined by the dependent claims appended herewith.

In some examples there are described containerised generator systems, and methods for power supply.

According to a first example is a containerized electrical supply unit, comprising: a container; and an electrical storage system provided, e.g. wholly provided, within the container.

The containerized electrical supply unit may comprise one or more or each of: a temperature control system; an electrical conditioning system; a controller; a protection unit and/or a suppression system, which may be provided, e.g. wholly provided, within the container.

The electrical storage system may comprise and/or be configured to receive one or more, e.g. a plurality of, electrical storage units. The electrical storage units may be configured to hold or store electrical charge. The electrical storage units may be or comprise electrochemical and/or electrostatic electrical storage units. One or more or each of the electrical storage units may be or comprise a battery or electrochemical cell, such as by way of example a lithium, lithium ion, lithium-air, lithium-sulphur, NiCd, NiMH, or lead-acid battery or cell, and/or the like. Optionally at least one of the electrochemical storage units may comprise a fuel cell, capacitor, super-capacitor, and/or the like.

The electrical storage system may comprise at least one rack for holding or receiving the electrical storage units. The at least one rack may be configured with contacts for electrically connecting the one or more electrical storage units. The at least one rack may comprise wiring to electrically connect the one or more electrical storage units, e.g. to electrical connections (such as inputs and/or outputs) of the containerized electrical supply unit, which may comprise indirect connection via one or more other electrical components of the containerized electrical supply unit, such as the electrical conditioning system, one or more bus bars, the protection system (e.g. circuit breakers) and/or the like.

The container may be compartmentalized. The container may comprise a primary compartment for housing at least one or each of: the electrical storage system or electrical generation system, the controller and/or at least part of the electrical conditioning system, e.g. the transformer and/or inverter. The container may comprise a secondary compartment for housing at least part of the temperature control system, e.g. for housing the fan and/or the heat exchanger of the temperature control system. At least part of a suppression system, e.g. a reservoir of the suppression system, may also be provided in the secondary compartment. The primary compartment may be separated, sealed and/or isolated from the secondary compartment, e.g. by an internal wall of the container.

The containerized electrical supply unit may comprise the temperature control system, which may be provided, e.g. wholly provided, within the container. The temperature control system may comprise a heating, ventilation and/or cooling, e.g. air conditioning, system, such as a HVAC system. The temperature control system may be configured to run off electricity supplied by the electrical storage system. The temperature control system may comprise one or more fans such as centrifugal cooling fans. The temperature control system may comprise a heating and/or cooling distribution system, which may comprise ducting.

The temperature control system may be a closed system, e.g. a closed air system. The flowpath may be separated or isolated from an interior of the secondary compartment. The temperature control system may be configured to circulate air within at least part of the container, e.g. through the heating and/or cooling distribution system and/or within the primary compartment of the container that houses at least one or each of: the electrical storage system, the controller and/or at least part of the electrical conditioning system, e.g. the transformer and/or inverter. The temperature control system may be configured to circulate the air using a further fan

The temperature control system may comprise a heat exchanger. The heat exchanger may be provided at an interface between the primary and secondary compartments, e.g. on or in the internal wall separating the primary and secondary compartments. The heat exchanger may be configured to exchange heat between air in the closed air system and/or in the primary compartment of the container and air that is in the secondary compartment, such as air drawn or received from the exterior of the container, e.g. using the fan. The heat exchanger may be configured to exchange heat from the air in the distribution duct to ambient. The temperature control system may be configured such that air in the closed air system, the distribution system and/or in the primary compartment of the container is separated or isolated from the air in the secondary compartment, which may have been drawn or received from the exterior of the container, e.g. using the fan. The temperature control system may be configured to pass the air drawn in by the fan across or through the heat exchanger in manner in which it is isolated from the air used to cool the primary compartment. The heat exchanger may comprise a heat exchange liquid, which may be circulated, and may be configured to receive heat from the air in the distribution system and/or in the primary compartment of the container and may be configured to provide the heat to the air in the secondary compartment, e.g. drawn into the secondary compartment by the fan.

In this way, efficient temperature control of the primary compartment of the container may be carried out without introducing contaminants, or external material form the exterior of the container than might pose a fire or electrical hazard or erroneously trigger the suppression system.

The containerized electrical supply unit may comprise the electrical conditioning system. The electrical conditioning system may be configured to convert the electrical output of the electrical storage system into an electrical output of the containerized electrical supply unit and/or vice versa. The electrical output of the containerized electrical supply unit may be different to the electrical output of the electrical storage system, e.g. it may have a different voltage and/or current and/or the electrical output of the containerized electrical supply unit may be alternating current (AC) and the electrical output of the electrical storage system may be direct current (DC). The electrical conditioning system may comprise one or more inverters, e.g. to convert the DC output of the electrical storage system to the AC output of the containerized electrical supply unit. The electrical conditioning system may be comprised, e.g. wholly comprised, inside the container. The electrical conditioning system may be provided in an electrical circuit between the electrical storage system and the electrical connections of the containerized electrical supply unit.

The electrical conditioning system may comprise a transformer, e.g. for changing the voltage of the electrical output of the electrical storage system into a different voltage for the electrical output of the containerized electrical supply unit. The transformer may have a plurality of ratings, e.g. voltages, as outputs. The transformer may be configured such that the output ratings are selectable, e.g. using the controller and/or control panel. The transformer may provide isolation, e.g. galvanic isolation, of the controller and/or inverter from the external electrical power system, and/or load.

The electrical conditioning system may be configured to receive the electrical output from the electrical storage system and may be configured to output an electrical output to the one or more electrical connections, e.g. via the protection system and/or one or more bus bars.

The containerized electrical supply unit may comprise the controller. The controller may be provided in the primary compartment, e.g. proximate the energy storage system. The controller may be configured with a user interface or control panel. The controller may comprise at least one processing unit. The controller may be configured to control the operation of the containerized electrical supply unit, e.g. responsive to user input via the control panel or user interface. The controller may be configured to control the level of output and/or charge of the electrical storage system and/or the level of output of the containerized electrical supply unit, e.g. by controlling the electrical conditioning system and/or the electrical storage system. At least part or all of the controller may be comprised in the container. The user interface or control panel of the controller may be accessible from an exterior of the container.

The containerized electrical supply unit may comprise the at least one external electrical connection, which may comprise or be connected to at least one bus bar, e.g. two or more bus bars. The at least one external electrical connection may be configured to output an electrical supply derived from the electrical storage system. The at least one external electrical connection may be configured to receive a charging electrical supply to charge the electrical storage units of the electrical storage system.

The user interface or control panel of the controller may be accessed via an end of the container, whereas the electrical connections may be provided on a different surface (e.g. side) of the container 5. For example, at least the control panel of the controller and/or the user controls of the protection unit may be accessible from an end (e.g. a shorter dimensioned face) of the container, whereas the electrical connections of the containerized electrical supply unit may be provided on one of the sides (e.g. a longer dimensioned face) of the container. In this way, the chances of accidents involving a user operating the control panel or user controls of the protection unit are reduced, e.g. as the electrical cables extend from a different surface of the container and/or in a different direction to the control panel.

The containerized electrical supply unit may comprise at least one protection unit, e.g. an overcurrent or over voltage protection unit. The at least one protection unit may comprise one or more circuit breakers, such as air circuit breakers (ACBs). The at least one protection unit may be provided in the electrical circuit between the electrical storage system and the electrical connections of the containerized electrical supply unit. The at least one protection unit may be comprised in, e.g. wholly located within, the container. The protection unit may be comprised in its own enclosure. The protection unit and optionally the enclosure may be located or locatable, e.g. releasably located or locatable, in a recess or compartment of the container, which may be accessible from the exterior of the container. The protection unit may comprise user controls, e.g. a trip reset or the like. The user controls may be provided on or in a different exterior surface of the container to the electrical connections of the container.

The containerized electrical supply unit may comprise at least one suppression system, such as a fire suppression system. The suppression system may comprise at least one supply of suppressant material, e.g. fire suppressant liquid, gas or powder. The supply of suppressant material may comprise a tank or reservoir. The suppression system may comprise at least one sensor for detecting a fire, smoke, excess heat or other thermal event. The suppression system may comprise at least one delivery system for delivering the suppressant material into the container, e.g. responsive to detection of the fire or other thermal event using the at least one sensor. The at least one delivery system may comprise pipeline or conduit. The supply of suppressant material may be located at one end of the container. The at least one delivery system may extend upwardly from the supply of suppressant material, e.g. to an upper or upmost portion of the container and may then extend laterally within the container within the upper or upmost portion of the container. Thereafter, the delivery system may be configured to convey at least part or all of the suppressant material downwardly, e.g. to a location in the interior of the container. The delivery system may be configured to convey the suppressant material to at least one discharge location, which may be a location within a void or space where there are no components located, e.g. there a no components within a threshold distance. The discharge location may be a location in which the suppressant material can act on the electrical storage system, the electrical conditioning system and/or the controller. The discharge locations may be such that the delivery system discharges the suppressant material into voids or spaces around components, e.g. rather than directly onto components themselves. This arrangement may better utilize space within the container, may result in better delivery of suppressant material and/or may be easier to install.

The container may comprise the electrical circuit comprising electrical coupling (e.g. wiring) between the one or more electrical connections of the containerized electrical supply unit and the electrical storage system. The electrical circuit may comprise control couplings (e.g. wiring) between the controller and the electrical conditioning system and/or the electrical storage unit, e.g. for carrying control signals from the controller to, and for controlling, the electrical conditioning system and/or the electrical storage unit. At least part of the electrical coupling and/or the control couplings may extend upwards from at least one or each of: the electrical storage system, the electrical connections of the containerized electrical supply unit, the controller and/or the electrical conditioning system, e.g. to an upper or upmost portion of the interior of the container and may then extend laterally within the upper or upmost portion of the interior of the container. This arrangement may facilitate easier connection and/or better utilization of space within the container.

The electrical storage system and/or at least part of the wiring or circuit may be formed into modules or banks comprising a plurality of racks or provided or mounted on a sub frame, e.g. formed from metal beams. The racks and/or the wiring or circuit may be assembled and/or provided, in modules or banks, e.g. before insertion into the container. The modules or banks may comprise a plurality of the racks fixed together, e.g. 3, 4, 5 or more separate racks fixed together using fixings, such as bolts. The respective modules or banks comprising the electrical storage system and/or wiring and/or circuit may be removable from, and/or insertable into, the container as one unitary entity. In this way, the containerized electrical supply unit may be easier to assemble.

One or more of the other components of the containerized electrical supply unit, such as the transformer, controller, inverter and/or the electrical conditioning system, may be provided together on one or more associated sub-frame. For example, the transformer may be provided on one sub frame. The inverter and/or the controller may be provided on one sub frame. The associated sub-frame may be formed from beams, e.g. metal beams. The sub-frame may comprise one or more supports, which may be or comprise skids and/or fork-lift fork receptacles, for supporting the sub-frame and anything (e.g. the electrical storage system) mounted thereon. The associated sub- frame may define a platform, upon which the one or more other components are mounted or provided. The one or more supports may be provided on the platform, e.g. on an opposite surface of the platform to a surface upon which the one or more other components are provided or mounted. The associated sub-frame may comprise a frame or skeleton cage that extends over at least part of the one or more other components. The one or more other components may be assembled and/or provided, on the associated sub-frame, e.g. before insertion into the container, e.g. the associated sub-frame comprising the one or more other components may be removable from and/or insertable into the container as one unitary entity. In this way, the containerized electrical supply unit may be easier to assemble.

The container may be in a generally cuboid form, e.g. having two long or elongate sides and two shorter ends, i.e. the container is longer than it is wide. The container may be or comprise an ISO container.

The container may comprise a frame, e.g. a skeleton frame. A majority of the frame may be open. The frame may be formed of beams. The beams may have a two dimensional cross sectional profile, e.g. the beams may be box sectioned, C-sectioned, l-sectioned, T-sectioned or the like. The frame may be closable, e.g. to form a sealed or enclosed container. The frame may be at least partly and/or selectively closable by one or more doors and/or walls. The frame may extend on all 6 sides of the container. The frame may be generally cuboid. This frame arrangement may provide improved structural stability and/or increased stacking whilst still maintaining open access via a majority of the sides of the container.

The container may comprise doors that open along a majority, e.g. open at least 70%, at least 80% or at least 90% of at least one or both sides of the container. The doors may comprise multi hinged, e.g. double hinged, doors. Each door may comprise at least two door sections, which may be distributed along a length of one or both sides of the container. At least one door section may be pivotally attached to the frame of the container via hinges and at least one other door section may be pivotally attached to the at least one door section via hinges. Each door section may be lockable into a closed configuration to close, enclose and/or seal the container.

The open frame construction may be selectively closable with the doors, e.g. double hinged doors that extend over a majority, e.g. at least 70% or 80% of one or both sides of the container. As such, it may be easier to assemble the contents of the container, e.g. by sliding in the module, sub-frame and/or associated sub-frame with components pre-assembled thereon through the more widely opening multi-hinged doors. As the delivery system of the suppression system and/or at least part of the circuit is routed along an upper or upmost portion of the interior of the container, then this frees more space in the lower portion of the interior of the container, making it easy to slide the other components, e.g. as modules or on sub-frames, into place. This may result in an easier to assemble containerized electrical supply unit. The provision of a frame rather than solely relying on exterior panels for strength, may provide for improved strength and stackablity of the containers whilst still allowing open access via at least the sides and optionally also at least one end of the container, e.g. via the doors. This may allow at least 9-high stacking and/or assist in meeting the stacking requirements for an ISO container.

The container may be provided with a plurality of mount pads, e.g. at least six mount pads, e.g. at least three along each side. The mount pads may be configured to support the container, e.g. when placed on the ground or other supporting structure. The arrangement comprising a plurality of mount pads may prevent sagging of the container and may allow the particularly large doors to more reliably open.

The container may be sealed. That is, the container may be provided with seals around each door and/or external opening. The container may be provided with seals and/or shrouds at air intakes and/or vents. The container may be compartmentalised. At least part (e.g. a majority of) or all of the temperature control system and/or the suppression system may be provided in a separate compartment to one or more or all of: the electrical storage system and/or the controller and/or at least part of the electrical conditioning system (e.g. the inverter and/or the transformer). Internal secondary seals may be provided within the container, e.g. between compartments and sections. Internal secondary seals may assist in keeping any deployed suppressant material in desired areas of the inside of the container, e.g. around the electrical storage system, the electrical conditioning system, and/or the like. This may permit a suitably high concentration of suppressant to be more surely maintained inside the container.

In a second example described herein, there is a method of assembling, repairing or producing a containerized electrical supply unit according to the first example.

The method may comprise providing a container. The method may comprise locating an electrical storage system within the container. The method may comprise locating, within the container, one or more or each of: a temperature control system, an electrical conditioning system that may comprise at least one inverter and/or at least one transformer, at least part of a controller, one or more protection unit (e.g. circuit breaker), and/or a suppression system.

The method may comprise opening at least one or both sides of the container, e.g. opening up a majority or at least 70%, at least 80% or at least 90% of at least one or both sides of the container, e.g. by opening at least one door, e.g. at least one multi- sectioned and/or multi-hinged door, that extends over the majority, e.g. at least 70%, at least 80% or at least 90% of at least one or both sides of the container, before inserting at least one or each of: the electrical storage system, the temperature control system, the electrical conditioning system, the at least part of a controller, the one or more protection unit (e.g. circuit breaker), and/or the suppression system into an inside of the container.

The method may comprise routing at least part of a delivery system of the suppression unit and/or wiring or electrical couplings so as to extend upwardly to an upper or upmost part of the inside of the container and then laterally along the upper or upmost part of the inside of the container.

The method may comprise assembling at least part of the electrical storage system, e.g. one or more of: the racks and/or wiring and/or the electrical storage units (such as batteries), as at least one module before insertion into the container and then inserting the bank or module having the at least part of the electrical storage system on it, into the container, e.g. as a single unitary entity. The bank or module may comprise a plurality of separate racks fixed together, e.g. at least 3, 4, 5 or more separate racks fixed together. The method may comprise assembling at least part or all of the electrical conditioning system, e.g. the transformer and/or inverter, and/or at least part of the controller onto one or more sub-frames before insertion into the container and then inserting the sub-frame(s) having at least part or all of the electrical conditioning system, e.g. the transformer and/or inverter, and/or the controller, into the container, e.g. as a single unitary entity or as single unitary entities. For example, the transformer may be provided on a sub-frame. The inverter and/or the controller may be provided on a sub-frame, which may be a different sub-frame to the transformer.

In a third example described herein, there is a method of operating the containerized electrical supply unit according to the first example. The method may comprise operating the containerized electrical supply unit so as to draw power from the electrical storage system to an external load via the one or more electrical connections (e.g. the one or more bus bars) of the containerized electrical supply unit. The method may comprise converting the voltage or current output by the electrical storage system to a different voltage or current for output by the one or more electrical connections of the containerized electrical supply unit, e.g. using the transformer. The method may comprise converting a DC electrical output by the electrical storage system to an AC electrical output by the one or more electrical connections of the containerized electrical supply unit, e.g. using the inverter. According to a fourth example described herein, there is provided a containerized electrical supply unit, comprising: a container; an electrical storage system; a temperature control system for maintaining a temperature of the electrical storage system control system; an electrical conditioning system configured to convert an electrical output of the electrical storage system into an electrical output of the containerized electrical supply unit; a protection system configured to protect against faulty electrical output of the electrical storage system; and optionally a suppression system and/or the containerized electrical supply unit; wherein the electrical storage system, temperature control system, electrical conditioning system, protection system and optionally also the suppression system are provided, e.g. wholly provided, within the container, e.g. without being provided or extending outwith the external volume of the container and/or without being hung on, mounted or extending away from the outside of the container.

This arrangement may represent a simple “drop and go” power supply arrangement that is easy to store and transport and can be deployed rapidly.

The containerized electrical supply unit may comprise a controller. The controller may be configured with a user interface or control panel. The controller may comprise at least one processing unit. The controller may be configured to control the operation of the containerized electrical supply unit, e.g. responsive to user input via the control panel or user interface. At least part or all of the controller may be provided within, e.g. wholly within, the container, e.g. within a primary compartment of the container.

The containerized electrical supply unit may be, comprise or be comprised in, or comprise one or more features of, the containerized electrical supply unit of the first example.

According to a fifth example described herein, there is provided a container for a containerized electrical supply unit, such as the containerized electrical supply unit of the first and/or fourth example.

The container may be in a generally cuboid form, e.g. having two long or elongate sides and shorter ends, i.e. the container is longer than it is wide. The container may be or comprise an ISO container. The container may comprise a frame, e.g. a skeleton frame. A majority of the frame may be open. The frame may be comprised of a plurality of beams. The beams may have a two dimensional cross sectional profile, e.g. the beams may be box sectioned, C-sectioned, l-sectioned, T-sectioned or the like. The frame may be closable, e.g. to form a sealed or enclosed container. The frame may be closable using doors. The frame may extend on all 6 sides of the container. The frame may be generally cuboid. This frame arrangement may provide improved structural stability and/or increased stacking whilst still maintaining open access via a majority of the sides of the container.

The container may comprise doors that open along a majority, e.g. open at least 70%, at least 80% or at least 90% of at least one or both long sides of the container. The doors may comprise multi-hinged, e.g. double hinged doors. At least one or each door may comprise a plurality (e.g. two) door sections. At least one door section may be pivotally attached to the frame of the container via hinges and at least one other door section may be pivotally attached to the at least one door section via hinges. Each door section may be lockable into a closed configuration to close, enclose and/or seal the container. This open frame construction may make it is easier to assemble the contents of the container, e.g. by providing the open space to slide in the modules, banks, and/or sub-frames with components pre-assembled thereon. As at least part of the heating and/or cooling distribution system (e.g. duct), the delivery system of the suppression system and/or at least part of the circuit is routed along an upper or upmost portion of the interior of the container, then this may free more space in the lower portion of the interior of the container, which may make it easy to slide the other components, e.g. in modules, as banks or on sub-frames, into place. This may result in an easier to assemble containerized electrical supply unit. The provision of a frame rather than solely relying on exterior panels for strength, may provide for improved strength and stackablity of the containers whilst still allowing open access via at least the sides and optionally also at least one end of the container, e.g. via the doors. This may allow at least 9-high stacking and/or assist in meeting the stacking requirements for an ISO container.

The container may be provided with a plurality of mount pads, e.g. at least six mount pads, which may comprise at least three mount pads along each side. The mount pads may be configured to support the container, e.g. when placed on the ground or other supporting structure. This arrangement comprising a plurality of mount pads may prevent sagging of the container and may allow the particularly large doors to more reliably open. The container may be sealed. That is, the container may be provided with seals around each door and/or external opening. The container may be provided with seals and/or shrouds at air intakes and/or vents. The container may be compartmentalised. One or more or each of: the electrical storage system, the controller and/or the electrical conditioning system (e.g. the inverter and/or the transformer) may be provided in a primary compartment, which may be a different compartment to a secondary compartment that houses at least part (e.g. a majority part, such as the fan and at least part of the heat exchanger) or all of the temperature control system and/or the suppression system. Secondary internal seals may be provided within the container, e.g. between compartments and sections. Internal secondary seals may assist in keeping any deployed suppressant material in desired areas of the inside of the container, e.g. around the electrical storage system, the electrical conditioning system, and/or the like. This may permit a suitably high concentration of suppressant to be more surely maintained inside the container. This arrangement may also help with cooling and in preventing contaminants from outside affecting the electrical storage and conditioning systems.

According to a sixth example described herein, there is provided a containerized electrical supply unit comprising: a container; an electrical storage system; a controller configured to control the operation of the containerized electrical supply unit and/or the electrical storage system, e.g. responsive to user input a the control panel or user interface; and an electrical conditioning system configured to convert an electrical output of the electrical storage system into an electrical output of the containerized electrical supply unit. The electrical conditioning system may comprise an inverter configured to convert a DC output of the electrical storage system to an AC output of the containerized electrical supply unit. The electrical conditioning system may comprise a transformer for changing the voltage of the electrical output of the electrical storage system into a different voltage, e.g. for the electrical output of the containerized electrical supply unit.

At least part of the electrical storage system, e.g. a racking system for receiving one or more electrical storage units, such as batteries, and associated wiring may be provided in banks or modules. Each bank or module may comprise a plurality of separate racking systems fixed together, e.g. 3, 4, 5 or more racking systems. The respective banks or modules may be selectively insertable into, and/or removable from, the container on the sub-frame as a unitary entity.

At least part of the electrical conditioning system, e.g. the transformer and/or the inverter, may be provided on one or more sub-frames, e.g. along with the controller. For example, the inverter and/or controller may be provided on a sub-frame. The transformer may be provided on a different sub-frame. The electrical conditioning system and/or the controller may be selectively insertable into, and/or removable from, the container on the respective sub-frames as unitary entities.

The containerized electrical supply unit may be, comprise or be comprised in, or comprise one or more features of, the containerized electrical supply unit of the first, fourth and/or fifth examples.

It will be appreciated that features analogous to those described in relation to any of the above aspects may be individually and separably or in combination applicable to any of the other aspects.

Apparatus features analogous to, or configured to implement, those described above in relation to a method and method features analogous to the use and fabrication of those described above in relation to an apparatus are also intended to fall within the scope of the present invention.

Description of the Drawings

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, which are:

Figure 1 an external perspective view of a containerized electrical supply unit in a closed configuration;

Figures 2 an external perspective view of the containerized electrical supply unit of Figure 1 , with part of the exterior of the container cut away to show part of the interior of the container;

Figure 3 a side view of the containerized electrical supply unit of Figure 1 , with one side exterior removed to show the interior of the container;

Figure 4 a cross-sectional plan view of the containerized electrical supply unit of Figure 1 ;

Figure 5 a perspective view of the contents of the container of the containerized electrical supply unit of Figure 1 with a side and top walls removed; Figure 6 a side view of an alternative containerized electrical supply unit, with one side exterior removed to show the interior of the container;

Figure 7 a cross-sectional plan view of the containerized electrical supply unit of Figure 6;

Figure 8 a perspective view of the contents of the container of the containerized electrical supply unit of Figure 6 with a side and top walls removed;

Figure 9 shows exemplary improvements in efficiency possible by using the containerized electrical supply unit of Figure 1 or Figure 6 to replace spinning reserve in an electrical network;

Figure 10 shows an example of peak shaving / arbitrage effect possible by using the containerized electrical supply unit of Figure 1 or Figure 6;

Figure 11 illustrates an example of control of production ramps of photovoltaic generation apparatus achievable using the containerized electrical supply unit of Figure 1 or Figure 6; and

Figure 12 illustrates an example of the use of the containerized electrical supply unit of Figure 1 or Figure 6 to provide uninterrupted power supply.

Detailed Description of the Drawings

Figure 1 shows a perspective view of an exterior of a containerized electrical supply unit 5 in a closed or “in use” configuration. The containerized electrical supply unit 5 comprises a container 10, which in this example is an ISO container having an elongate, generally cuboid form. The container 10 is formed from metal, particularly metal walls and doors suspended from a metal skeleton frame, as will be described later. Figure 2 shows the same containerized electrical supply unit 5 but with a portion of one of the doors cut away to reveal the contents of the container 10.

The containerized electrical supply unit 5 also comprises respective pairs of double hinged doors 15a, 15b that extend over a majority of each long side 20a, 20b of the container 10, e.g. over at least 80% of the length of each long side 20a, 20b of the container 10. Each of the doors 15a, 15b is hinged 22a, 22b on opposite sides such that distal opening edges 24a, 24b of the doors 15a, 15b meet when closed. Each door 15a, 15b, is formed of two door sections 25a, 25b, 25c, 25d that are hinged together, with one door section 25a, 25c of each door 15a, 15b being hinged 22a, 22b to an upright 30a, 30b of the frame (see Fig. 3), and another door section 25b, 25d of each door 15a, 15b being hinged 32a, 32 to the other door section 25a, 25c of each door 15a, 15b. In this way, each door 15a, 15b can be opened by unlatching the door sections 25b, 25d and pivoting them open on the hinges 22a, 22b between door sections 25a and 25b and between sections 25c and 25d. Further, the door sections 25a and 25c can also be unlatched and opened by pivoting them (and consequently also door sections 25b and 25d) about the respective hinges 32a, 32b between door section 25a and the frame upright 30a and between door section 25c and frame upright 30b. As can be seen particularly in Fig. 3, this multi-hinged, multi-sectioned door 15a, 15b arrangement, in conjunction with a skeleton frame, allows for a very wide opening in each side 20a, 20b of the container 10 for ease of access into the interior of the container 10, e.g. for assembly, operation, maintenance, repair, inspection and/or the like. Flowever, due to the presence and construction of the frame, integrity is maintained.

The container 10 is provided with a plurality of mount pads 35 (e.g. at least three per side) in order to prevent sag of the container 10 and to ensure reliable operation of the wide doors 15a, 15b. At least some of the mount pads 35 may be configured to receive forks of a fork lift truck.

The walls of the container 10 are provided with vents 110, e.g. adjacent either ends of the container 10, to allow cooling air to be drawn in and hot air to be expelled, as will be described later. Separate vents 110 can be provided for drawing air in and for expelling air out.

Fig. 3 shows a side view of the inside of the container 10 of the containerized electrical supply unit 5 with the doors 15a, 15b removed. The interior of the container 10 comprises a secondary compartment 40 at one end for housing a temperature control system 95 and a suppression system 100 (not shown in Fig. 3, see Figs. 4 and 5). The container also comprises a further compartment or volume 45 at the other end of the container 10 houses a secondary cooling system 127 for cooling at least part of the conditioning system, e.g. an inverter (not shown in Fig. 3, see Figs. 4 and 5). A protection system 130 (not shown in Fig. 3, see Figs. 4 and 5) may be mounted in a dedicated enclosure proximate the further compartment 45. The secondary cooling system 127 comprises a heat exchanger and fan and has its own vent or airflow channel 129 that extends through an end wall or door of the container 10 to the exterior of the container 10. A closed cooling loop extends from the heat exchanger to the inverter 85, so as to provide cooling.

A primary compartment 47 in a central portion of the interior of the container 10 houses an electrical storage system 50. The electrical storage system 50 is configured to store electrical charge, in contrast to generator units that generate electrical charge by operation of a generator by a motor, typically fuelled by fossil fuels. The electrical storage system 50 comprises a plurality of racks 70, in which multiple racks 70 can be optionally bolted or otherwise fixed together to form banks 55 of racks 70 (in this example eight racks 70 are provided as two banks 55 of four racks 70 provided back to back). Each bank 55 also comprises associated wiring for receiving and connecting a plurality of electrical storage units 75. The banks 55 of racks 70 allow wiring to be connected outside of the container 10 and thereby more easily connected. The use of banks 55 of racks 70 allows the racks 70 to be installed quicker and more easily than by installing each rack 70 individually. In this case, each bank 55 comprising a plurality of separate racks 70 fixed together can simply be lifted into the container 10 during assembly.

In this example the energy storage units 75 comprise rechargeable batteries such as lithium ion rechargeable batteries, but could comprise any other suitable form or electrochemical or electrostatic storage, such as but not limited to: lithium-air batteries, lithium-sulphur batteries, nickel-cadmium (NiCd) batteries, nickel-metal hydride (NiMH) batteries, lead acid batteries, super capacitors, fuel cells (e.g. hydrogen fuel cells, proton electrolyte membrane (PEM) fuel cells, solid state fuel cells, direct carbon fuel cells, ethanol fuel cells, or the like), flow cells, and/or other suitable electrical storage units. The wiring from each of the electrical storage units 75 is routed upwards through the racks to an upper space 80 provided in an upmost portion of the interior of the container 10, e.g. into a cable tray provided on top of the racks 70 and electrical storage units 75, in which the wiring can extend laterally inside the container 10 to connect with the controller 125 and/or an electrical conditioning system 60.

The primary compartment 47 of the interior of the container 10 houses the controller 125 provided adjacent the racks 70 for controlling operation of the energy storage units 75 and the electrical conditioning system 60. The controller 125 controls operation of the energy storage units 75 and the electrical conditioning system 60 to provide a required output at electrical connections 92 of the containerized electrical supply unit 5 and to manage safe condition and operation of the energy storage units 75.

The primary compartment 47 of the interior of the container 10 also houses at least part of the electrical conditioning system 60 provided on one or more removable conditioning system sub-frames 65. In this case, the part of the electrical conditioning system 60 comprises a transformer 90 and the sub-frame 65 is a transformer sub- frame. In addition, the inverter 85 is optionally also provided on its own sub-frame (not shown). By providing the transformer 90 and inverter 85 on respective sub-frames 65, the transformer 90 and inverter 85 can be assembled and wiring connected with the transformer 90 and inverter 90 and respective sub-frames 65 outside of the container 10 where there is more room to work. Thereafter, the sub-frames 65 with the transformer 90 and inverter 85 respectively mounted thereon, are simply inserted into place and secured inside the container 10, leaving fewer electrical connections to be made inside the container 10.

The electrical conditioning system 60 is configured to convert the electrical output of the electrical storage system 50 into a different electrical output of the containerized electrical supply unit 5. The electrical conditioning system 60 comprises the inverter 85 and the transformer 90. The inverter 85 is configured to convert the DC output of the electrical storage system 50 to the AC output of the containerized electrical supply unit 5. The inverter 85 and controller 125 are provided together on their own sub-frame (not shown) for ease of assembly and installation.

The transformer 90 is configured to selectively change the voltage of the electrical output of the electrical storage system 50 into a different voltage for the electrical output of the containerized electrical supply unit 5. The voltage output by the transformer 90 may be variable and selectable, e.g. by physically changing a tap point. The transformer 90 also galvanically isolates the inverter 85 and controller 125 from the external electrical power system.

The electrical conditioning system 60 is electrically connected to receive the electrical output from the electrical storage system 50, responsive to control by the controller 125. The electrical conditioning system 60 is further configured to output a modified electrical supply to electrical connections 92 via one or more bus bars (not shown). In this example, the electrical connections 92 are provided on a side 20a of the container 10, whereas access (e.g. via a door or hatch) to a control panel 135 for controlling the controller 125 and/or the protection unit 130 is provided on a different face of the container 10 (in this case an end face of the container 10). In this way, a user using the control panel 135 is distanced from the electrical connections 92 and associated cabling, which may minimize the risk of accidents, e.g. due to tripping.

Figs. 4 and 5 further show the components of the containerized electrical supply unit 5 that are provided inside the container 10.

The temperature control system 95 and suppression system 100 are provided in the enclosure 40 at one end of the container 10. The enclosure 40 is provided with a door 102 forming at least part of an end face of the container 10. The walls of the container 10 that form the enclosure 40 are provided with a plurality of vents 110 for direct venting of the enclosure 40 to the exterior of the container 10.

The temperature control system 95 comprises a heating, ventilation and air conditioning or cooling (HVAC) system. In particular, the temperature control system 95 comprises at least one centrifugal cooling fan 105 arranged to face one of the vents 110 provided in the door 102 of the secondary enclosure 40. The fan 105 is configured to force air from the secondary enclosure 40 out through the vent 110 in the door 102 of the secondary enclosure 40, wherein air is received into the secondary enclosure 40 from the exterior of the container 10 directly via other vents in the exterior side wall of the secondary enclosure. A different vent 110, which may face in a different direction to the vent 110 in the door through which air is drawn in, e.g. in a side wall, may be arranged to receive air from inside the enclosure 40 for exhausting therefrom to the exterior of the container 10. In this way, cooling ambient air from the exterior of the container 10 can be circulated within the enclosure 40, but is not provided to the central portion of the interior of the container 10 that houses the electrical storage system 50 and the electrical conditioning system 60. The vent 110 is provided with a shroud or cowling (not shown) configured to direct the air directly from the exterior of the container 10 to the fan 105. The cowling or shroud is fixed around the vent 110 (e.g. to the door 102 of the enclosure 40) but is not fixed to the fan 105 or the rest of the temperature control system 95 but instead optionally engages a surface of the temperature control system 95 around the fan 105 with a gasket seal. In this way, the door 102 of the enclosure 40 may be opened for easy access to the temperature control system 95 but a reasonably airtight channel for providing air with minimal losses may be provided. Furthermore, the cowling or shroud may act to separate inflow air from outflow air, which may result in more efficient cooling and/or airflow.

The fan 105 of the temperature control system 95 is configured to suck air from the exterior of the container 10 through the vents in the side wall and through a heat exchanger 112 and out through the different vent 110 in order to exchange heat from the heat exchanger 112 to ambient. In other examples, the air could be sucked in through vents in the door and our through vents in the side of the container, and the location of the vents is not limited to any particular arrangement. However, by having the air intake for the secondary compartment 40 on a different face of the container to the air outlet for the secondary compartment 40, the amount of warmer expelled air being drawn in via the intake vent may be reduced. The heat exchanger 112 is operable to cool air (and/or optionally cooling fluid) in a closed circuit. In particular, a cooling fluid is provided within the heat exchanger 112 that acts to transfer heat from the air in the primary compartment 47 that houses the electrical storage system 50 to air in the secondary compartment 40. The temperature control system 95 comprises a conduit 115 that extends from the heat exchanger 112 into the upper space 80 at the top of the interior of the primary compartment 47 of the container 10, where it extends along the inside of the primary compartment 47 of the container 1#0 to locations above the electrical storage system 50 and the electrical conditioning system 60 to direct the air thereto. As such, the temperature control system 95 is operable to circulate air within the primary compartment (i.e. the primary compartment 47) that houses the electrical storage system 50 in a closed loop via the conduit 115 and that is cooled by the heat exchanger 112. The circulation of air within the primary compartment 47 is driven by a fan (not shown). With the above arrangement, the airflow can be routed in a relatively efficient pathway that also best utilizes space inside the container 10 and is easy to install. Furthermore, as a closed air circuit is used to cool the primary compartment 47 in the container 10 that contains the electrical storage system 50, and which is sealed from the secondary compartment 40 in which the heat exchanger 112 is mounted, the risk of introducing outside contaminants into the chamber in the container 10 that contains the electrical storage system 50 that could otherwise lead to fires or the incorrect release of the suppressant if there is a smoke filled ambient.

The suppression system 100 comprises a pressurized tank 120 of fire supressing material, e.g. a fire suppressing fluid (e.g. liquid or gas) or powder that is selectively releasable responsive to a fire sensor (e.g. a smoke or heat detector, not shown) into a delivery system 122 that also runs upwardly from the tank 120 into the upper space 80 at the top of the interior of the container and along the upper space 80 to the regions above the electrical storage system 50 and the electrical conditioning system 60 and then downwardly into voids or spaces in the primary compartment 47 that surround the electrical storage system 50 and the electrical conditioning system 60 to direct the fire suppressing material into the voids or spaces, when released. In this way, the fire suppressing material can be routed in a relatively efficient pathway that also best utilizes space inside the container 10 and is easy to install.

The further compartment 45 for housing the secondary temperature control system 127 that is used to cool at least some of the electrical conditioning system 60, e.g. the inverter 85, is provided at an opposite end of the interior of the container to the secondary compartment 40. The further compartment 45 has a direct vent to the exterior of the container 10 through the walls or door of the enclosure 45 so that the secondary temperature control system 127 can exchange heat with the exterior / ambient air. By providing the secondary temperature control system 127 in this arrangement, the load on the main temperature control system 95 can be reduced.

The controller 125 is provided in the primary compartment, e.g. proximate the electrical storage system. The controller 125 comprises a processing system, having a processor, memory, and a communications system configured to relay control commands to the electrical storage system 50 and electrical conditioning system 60 and to receive sensor and operating data therefrom. Optionally, the controller 125 comprises a network interface, e.g. a wireless network interface such as a cellular network or Wi-Fi interface for conveying operating data to a remote site for condition monitoring and diagnostics and for receiving control commands for operating the containerized electrical supply unit 5. The controller 125 is also in communication with the control panel 135 for receiving user commands for operating the containerized electrical supply unit 5 and for providing operational data, such as parameters, conditions and alarms or alerts relating to operation of the containerized electrical supply unit 5. As noted above, the control panel 135 is accessible via an end of the container 5 (e.g. via a hatch or door therein), whereas the electrical connections 92 are provided on a different surface (e.g. side) 20a of the container 5, so as to minimize unwanted interaction between an operator and the electrical connections 92 and associated cables.

The protection system 130 comprises one or more circuit breakers, such as air circuit breakers (ACBs). The electrical connections 92 that provide the electrical output of the containerized electrical supply unit 5 and to which supply/output cables can be connected are coupled to the protection system 130, in order to protect the containerized electrical supply unit 5 and/or the load from unwanted electrical events, such as a short circuit and/or over-voltage. The protection system 130 is in turn electrically connected to the conditioning system 60, which is in turn electrically connected to the electrical storage system 50. In this way, electrical charge can be discharged from the electrical storage system 50 to the load connected to the electrical connectors 92 and/or the electrical storage units 75 of the electrical storage system 50 can be recharged via electrical supply received via the electrical connectors 92. Optionally, the protection system 130 is provided in its own dedicated enclosure, which can be fixed or inserted into a corresponding recess in the container 10. Optionally, the protection system 130, can also be provided with its own temperature control system.

The further compartment 45 and/or the secondary compartment 40 may be thermally insulated. For example, a thermally insulated wall of the further and secondary compartments 40, 45 may extend between the interiors of the further and secondary compartments 40, 45 and the primary compartment 47 that houses the electrical storage system 50 and the electrical conditioning system 60. In this way, the amount of heat produced by the systems housed in the further and secondary compartments 40, 45 that reaches the electrical storage system 50 may be reduced.

Furthermore, a thermally insulating wall 140 may be provided between the electrical storage system 50 and the electrical conditioning system 60. In this way, the amount of heat produced by the electrical conditioning system 60 that reaches the electrical storage system 50 may be reduced. Furthermore, the wall 140 may define part of a chamber around the electrical storage system 50 and that receives cool air from temperature control system 95 via the conduit 115 running in the upper space 80. This may effectively form a pool of cool air around the electrical storage system 50, which may help keep the electrical storage units 75 at optimum temperature.

As can be seen particularly from Figs. 2 to 5, the container 10 is an ISO container that is formed from a metal skeleton frame 145 that supports metal doors 15a, 15b, 102 and walls that close the container 10. The frame 145 is formed of metal beams having a 2D cross sectional profile. Beams having a generally C-shaped sectional profile have been found to be particularly beneficial, but other beam sections such as box section, l-section, T-section or L-section could potentially be used. The use of such sections can provide the additional strength required to compensate for the very large doors 15a, 15b that allow wide access to the interior of the container 5. The use of such a frame 145 provides the required structural strength and stacking ability, e.g. nine high stacking, but still allows a large degree of easy access into the interior of the container 10 for ease of assembly, manufacture, repair, and/or the like.

Beneficially, all of the components of the containerized electrical power supply 5 are provided inside or at least within the footprint of the container 10 and no components are ‘hung’ on or bolted onto the outside wall of the container 10 (with the possible exception of the enclosed module comprising the protection system, albeit, this can be recessed) or extend out from the basic cuboid ISO container form. In this way, the containerized electrical power supply 5 is easier to ship and store.

Furthermore, the containerized electrical power supply 5 has all or most of the components to be run without extensive set-up and connections being made. As such, the system operates almost as a “plug and play” or “drop and use” system.

It will be appreciated that variations to the above example of Figs. 1 to 5 are possible. One possible alternative example of containerized electrical power supply 5’ is shown in Figs. 6 to 8. Most features of containerized electrical power supply 5’ are substantially the same or similar to those of containerized electrical power supply 5 and like features are provided with like numerals and equivalent but different features are provided with the same numeral appended with an apostrophe

In particular, the containerized electrical power supply 5’ differs from the containerized electrical power supply 5 in that the electrical conditioning system doesn’t comprise a transformer 90 but instead comprises extra racks 70’ (thirteen battery racks 70’ rather than eight battery racks 70 in the containerized electrical power supply 5). This may allow for extra energy density at the expense of flexibility in output voltage.

Containerized electrical power supplies such as the containerized electrical power supplies 5, 5’ that comprise electrical charge storage can be beneficially used in a range of applications, as illustrated in Figs. 9 to 12.

For example, using the containerized electrical power supplies 5, 5’ to replace spinning reserve can significantly increase generator efficiency, as can be seen from Fig. 9.

Furthermore, as can be seen from Fig. 10, the containerized electrical power supplies 5, 5’ can be used to perform peak shaving or arbitrage. For example, the containerized electrical power supplies 5, 5’ can be used to provide additional power at times of peak load. This flattening of the electricity demand profile may allow a network to be operated without expensive and under-used peak power generation assets and/or allow generation assets to be run more efficiently or consistently. In addition, the containerized electrical power supplies 5, 5’ can be used to perform arbitrage by charging the electrical storage units 75 during times of low demand and low cost and releasing energy back at times of high demand and high cost. This may be particularly beneficial in electricity intensive industries such as smelting and ore refining.

Similarly, as illustrated in Fig. 11 , the containerized electrical power supplies 5, 5’ can be used to smooth or control supply of electricity to a network from renewable sources. For example, the smoothing of the production curve from a photovoltaic (PV) generation system is shown in Fig. 13, where the containerized electrical power supplies 5, 5’ are used to accept excess electricity production and/or to release charge when required in order to provide a steady feed-in profile.

Another potential application is in uninterrupted power supply (UPS), as illustrated in Fig. 12. In this case, charge can be selectively released from the containerized electrical power supplies 5, 5’ to compensate for grid outages and the containerized electrical power supplies 5, 5’ can be recharged from the grid when the grid is operating correctly.

The specific examples are given in order to provide understanding and variations thereon would be apparent from the teaching provided herein. As such, the scope of protection is defined by the claims and not limited to the specific examples provided herein.