Technical field The invention relates to cooling assemblies for use with containerised electrical generators. In particular embodiments, the invention relates to cooling assemblies comprising a V-core radiator arrangement, although it need not be limited to such.

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

Such 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 with such containers for shipping and transportation, while minimising any compromises in relation to package layout and efficiencies.

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 the 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

According to an aspect of the invention, there is provided a V-core radiator assembly for cooling an engine of an electrical generator, the radiator assembly being configured to be fitted within an International Organization for Standards, ISO, shipping container, and comprising: two opposed radiator units having an angle therebetween such that they diverge towards an opening and define a volume between inner surfaces of the radiator units; and one or more fluid drivers disposed at the opening and configured to drive a fluid over the radiator units for cooling thereof, wherein a maximum distance between outer surfaces of the radiator units is not more than an internal width of the ISO shipping container, and wherein a maximum distance between the inner surfaces of the radiator units is more than 1260 mm.

The internal dimensions of the ISO shipping container provide a challenging environment into which the V-core radiator assembly must be fitted. The expansion of the opening in which the fluid drivers are fitted requires thinner radiator units because of the width restrictions imposed by the ISO shipping container. However, increased cooling is desired and it is therefore counter-intuitive to use thinner radiator units. The inventors have realised that a larger opening allows configurations of fluid drivers that increase cooling performance and offset or mitigate any loss of cooling performance as a result of the thinner radiator units.

Optionally, a thickness of one or more of the radiator units is less than 260 mm. Optionally, the angle between the radiator units is in a range from 10 to 14 degrees. Optionally, the one or more fluid drivers comprise one or more fans.

Optionally, the V-core radiator assembly comprises six fans arranged in a rectangular 3x2 array at the opening.

Optionally, the fans have a blade diameter of 630 mm.

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

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

Optionally, the V-core further comprises a frame on which the radiator units and/or the fluid drivers are mounted.

Optionally, the frame further comprises a base plate covering an area between the radiator units at an opposite end to the opening, and two end plates extending from opposite ends of the base plate along an edge of each radiator unit to the opening, wherein the base plate and the end plates form a cowl to resist fluid flow, such that a majority of the fluid driven by the fluid drivers is directed through the radiator units.

Optionally, the frame further comprises skids comprising holes configured to receive tines of a lifting apparatus.

Optionally, a maximum width of the radiator assembly is less than 21 10 mm. Optionally, a maximum height of the radiator assembly is less than 2620 mm. According to a further aspect of the invention, there is provided a V-core radiator assembly for cooling an engine of an electrical generator, the radiator assembly being configured to be fitted within an International Organization for Standards, ISO, shipping container, and comprising: two opposed radiator units having an angle therebetween such that they diverge towards an opening and define a volume between inner surfaces of the radiator units; and one or more fluid drivers disposed at the opening and configured to drive a fluid over the radiator units for cooling thereof, wherein a maximum thickness of the radiator units substantially 260 mm or less.

According to a further aspect of the invention, there is provided a containerised generator comprising one or more V-core radiator described herein.

According to a further aspect of the invention, there is provided a containerised electrical generator comprising: an International Organization for Standards, ISO, shipping container having disposed therein an engine configured to generate mechanical power by combustion of heavy fuel oil, HFO, and an electrical generator configured to convert the generated mechanical power into electrical power; and a V- core radiator assembly for cooling the engine, the radiator assembly being configured to be fitted within an International Organization for Standards, ISO, shipping container, and comprising: two opposed radiator units having an angle therebetween such that they diverge towards an opening and define a volume between inner surfaces of the radiator units; and one or more fluid drivers disposed at the opening and configured to drive a fluid over the radiator units for cooling thereof.

The containerised electrical generator may optionally include any of the features mentioned above.

According to a further aspect of the invention, there is provided a V-core radiator assembly for cooling an engine of an electrical generator, the radiator assembly being configured to be fitted within an International Organization for Standards, ISO, shipping container, and comprising: two opposed radiator units having an angle therebetween such that they diverge towards an opening and define a volume between inner surfaces of the radiator units; and one or more fluid drivers disposed at the opening and configured to drive a fluid over the radiator units for cooling thereof, wherein the V- core radiator assembly is configured to be removed from the container in a modular fashion.

Removal in a modular fashion encompasses removal of the V-core radiator assembly as a discrete unit. That is, once any connections to other features of the electrical generator have been disconnected, the V-core radiator assembly may be removed from the ISO shipping container as a single unit. Optionally, the width and height of the V-core radiator assembly is less than the width and height respectively of a door of the ISO shipping container, such that the V-core radiator assembly may be pass through the door. Optionally, the width of the V-core radiator assembly is less than 21 10 mm and/or wherein the height of the V-core radiator assembly is less than 2620 mm.

Optionally, the V-core radiator assembly further comprises skids comprising apertures configured to receive tines of a lifting apparatus, such as a forklift.

Optionally, the radiator units comprise inlets and outlets for circulating coolant from an engine of the containerised generator, wherein the inlets and outlets comprise quick release connectors. The invention includes one or more corresponding aspects, embodiments or features in isolation or in various combinations whether or not specifically stated (including claimed) in that combination or in isolation. As will be appreciated, features associated with particular recited embodiments relating to systems may be equally appropriate as features of embodiments relating specifically to methods of operation or use, and vice versa.

It will be appreciated that one or more embodiments/aspects may be useful in reducing deployment time and costs of containerised generator systems, and/or maintaining or improving packaging of such systems.

The above summary is intended to be merely exemplary and non-limiting.

Brief description of the drawings Figure 1 is a perspective view of a containerised generator comprising apparatus contained within two ISO shipping containers;

Figure 2 is a perspective view showing cooling apparatus within a containerised generator;

Figure 3 shows a section through a V-core radiator assembly;

Figure 4 shows a perspective view of a V-core radiator assembly; Figures 5a-b show a number of fluid driver arrangements and an associated area coverage; and

Figure 6 shows airflow rates in an exemplary V-core radiator assembly. 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.

V-core radiator assemblies comprise two opposed radiator units that have an angle between them such that they diverge towards an opening, at which one or more fluid drivers (typically fans/impellers) are fitted and configured to drive cooling fluid (typically air) over the radiator cores. This is explained in greater detail below. The inventors have appreciated that increasing a distance between the inner surfaces of the opposed radiator cores at a cooling opening permits greater flexibility in the arrangement of the fluid drivers, which may be used to improve or optimise airflow. However, such an increase in distance is restricted by the internal dimensions of the container.

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

The following described examples relate to new systems and methods that provide exemplary ways to deploy (including retrieve), maintain, etc. such containerised generator systems. In the following examples, engine units have been described that use internal combustion to produce mechanical power, and in particular are configured to operate using Heavy Fuel Oil (HFO). 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 than 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. The lower container 102 includes an engine that is configured to generate mechanical energy and a generator 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. 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 V-core radiator assembly 202 is discussed in greater detail herein, although it will be appreciated that the features of that V-core radiator assembly may equally be applied to the V-core radiator assembly 204. Figure 3 shows a schematic representation of a section through the V-core radiator assembly 202. The V-core radiator assembly 202 comprises a pair of opposed radiator units 206, 208.

Although not shown in detail, the radiator units 206, 208 may be configured to receive a coolant, e.g. a fluid, which has come from the engine and is to be cooled before recirculation into the engine. Accordingly, the radiator units 206, 208 may comprise a network of thermally conductive heat dissipation elements, such as metallic pipes or fins configured to transfer heat from the fluid 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 the exemplary arrangement of Figure 3, each radiator unit 206, 208 comprises a low temperature radiator 203, 207 and a high temperature radiator 205, 209. The low temperature radiator 203, 207 is located outermost with respect to the high temperature radiator 205, 209. In such arrangements, air passing through the radiator units 206, 208 and out of the fluid drivers (as shown by the dashed arrows in Figure 3) passes the low temperature radiators 203, 207 first and so is not heated too significantly before being used to cool the high temperature radiators 205, 209. Accordingly, the high temperature radiators205, 209 is downstream of the low temperature radiator 203, 207 with respect to airflow. The low temperature radiators 203, 207 receive coolant from a low temperature cooling circuit of the engine unit and the high temperature radiators 205, 209 receive coolant from a high temperature cooling circuit of the engine unit.

The exemplary radiator units 206, 208 shown in Figures 2 and 3 are generally rectangular in shape, having an inner surface 210 and an outer surface 212. In exemplary radiator assemblies, the thickness 214 of the radiator units may be less than approximately 260 mm, less than approximately 250 mm, less than approximately 225 mm, less than approximately 200 mm and, in specific examples, the thickness 214 may be approximately 252 mm or 198 mm. As discussed above, the thickness 214 of the radiator units 206, 208 may comprise a thickness of the low temperature radiator 203, 207 and a thickness of the high temperature radiator 205, 209. In exemplary arrangements, the thickness of the low temperature radiator 203, 207 and the thickness of the high temperature radiator 205, 209 may be substantially the same. It is noted that, whilst inner and outer surfaces 210, 212 are defined this may be merely illustrative and to aid description of the assembly 202. In particular, the heat dissipation elements discussed above may mean that a surface, as such, is not actually formed.

Exemplary radiator units 206, 208 may have a height 215 in a range from 2000 mm to 2300 mm, or in a range from 2100 mm to 2200 mm, and in a specific arrangement may have a height of 2135 mm. Exemplary radiator units 206, 208 may have a length in a range from 2300 mm to 2700 mm, or in a range from 2450 mm to 2550 mm, and in a specific arrangement may have a length of 2500 mm. Exemplary radiator units 206, 208 may have an outer and/or inner surface area in a range from 5.2 m ² to 5.5 m ² and in a specific arrangement may have an outer and/or inner surface area of 5.34 m ² .

Each of the low temperature radiators 203, 207 and the high temperature radiators 205, 209 includes a coolant inlet and outlet pairs 21 1 , 213, 215, 217. The inlets are configured to receive coolant after which it is circulated around the heat dissipation elements of the radiator before being output from the outlet 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 units 206, 208 are opposed within the radiator assembly 202. That is, they are on opposite sides of the radiator assembly 202, such that the inner surfaces 210 are broadly facing each other. The radiator units 206, 208 therefore define a volume 216 between their inner surfaces 210, which is configured to allow air (or another fluid) to pass through the radiator units 206, 208 and upwards out of an opening 218. Fluid drivers (e.g. fans) 220 are located at the opening 218 and are configured to drive the air out of the opening. This is explained in greater detail below.

The radiator units 206, 208 are arranged such that there is an angle 222 between them. The radiator units 206, 208 are therefore not parallel and diverge towards the opening 218. In exemplary arrangements, a minimum distance 224 between the inner surfaces 210 of the radiator units 206, 208 (i.e. the distance between the inner surfaces at a lower (narrower) end of the radiator assembly) is in a range from 1000 mm to 1040 mm and in a specific example may be 1019 mm. In exemplary arrangements, a maximum distance 226 between the inner surfaces 210 of the radiator units 206, 208 (i.e. the distance between the inner surfaces at an upper (broader) end of the radiator assembly, at the opening 218) may be more than 1260 mm and may be in a range from 1450 mm to 1600 mm and in specific examples may be 1470 mm or 1580 mm. Therefore, in exemplary arrangements, the angle 222 may be any angle supporting the distances 224 and 226 and in exemplary arrangements may be in a range from 1 1 degrees to 13 degrees and in a specific example may be 12 degrees.

The thickness 214 of the radiator units 206, 208 along with the distances 224 and/or 226 and/or the angle 222 may define a maximum distance 228 between outer surfaces 212 of the radiator units 206, 208 (i.e. the distance between the outer surfaces at the upper (broader) end of the radiator assembly). However, in exemplary arrangements, the distance 228 may be in a range from 1950 mm to 2000 mm and in specific examples may be 1970 mm or 1962 mm. The radiator units 206, 208 may be mounted on a frame 230 configured to be fitted within the container 104. The width of the frame 230 is therefore restricted to a maximum internal dimension (in this case, the width) of the container 104. This internal dimension is standardized in the case of ISO shipping containers. In exemplary arrangements, the width of the frame, and therefore the radiator assembly 202, may be configured to fit through a doorway of the container 104, which may have an aperture of width 21 10 with a nominal, for example 70 mm, clearance. As shown in Figure 3, the frame 230 may comprise skids having holes 232, 234 configured to receive tines of a forklift truck, or other lifting apparatus. This may aid fitting and removal of the radiator assembly in the container 104. The volume 216 may also be bounded by cowl elements, which may comprise a base plate 236 and end plates fitted at the longitudinal extents of the radiator units 206, 208. This ensures that air driven by the fluid drivers 220 enters the volume through the radiator units 206, 208.

The fluid drivers 220 (e.g. fans) are positioned at the opening 218 and are configured to drive air from the volume 216 through the fans 220 and out of the opening 218. This in turn draws air through the radiator units 206, 208 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 having a blade diameter (i.e. a tip- to-tip distance) 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 6x2 array in the opening 218. An overall height of the V-core radiator assembly 202 may be approximately 2305 mm including the height of the fans 220 (225 mm) and the frame 230.

Exemplary methods and apparatus are configured to maximise or increase the distance 226 by reducing the thickness 214 of the radiator unit 206, 208. This is counter-intuitive because the thicker the radiator units 206, 208, the greater the surface area of the heat dissipation elements and the greater the heat transfer from the coolant to the air passing over the heat dissipation elements. However, the inventors have appreciated that increasing the distance 226 increases the area at the opening 218 of the V-core radiator assembly 202 and this allows a larger area of fluid driver to be used. This in turn may increase the air flow through the radiator units 206, 208 and/or may increase the uniformity of airflow through the radiator units 206, 208, thereby improving cooling performance.

Further, fan sizes are standardized and the use of standard fan sizes is preferable for operational reasons, such as cost and maintenance. This restricts the possible arrangement of the fans 220 at the opening 218. In known arrangements, as shown in Figure 4, fans 420 are arranged in an offset array configuration. That is, part of a fan 420a is nestled within a region between adjacent fans 420b, 420c both on an opposite side of the radiator assembly. This configuration is necessary because the width of the opening is too small to permit the standardised 630 mm fans 420 to be placed alongside each other across the width of the opening.

Exemplary radiator assemblies 202, 204 may be dimensioned such that they can be removed from the container 104 in a modular fashion. That is, exemplary radiator assemblies 202, 204 may be removed from the container 104 in one piece and without the need for dismantling the radiator assembly. A plurality of pipes and/or hoses 238 are connected to the radiator units 206, 208 of the radiator assemblies 202, 204 and are configured to circulate the coolant therethrough. The pipes and/or hoses 238 and associated inlets for the radiator units 206, 208 may be fitted with quick release connectors, such as a Snaplock Camlock connector. Therefore, pipes and/or hoses 238 may be disconnected from the radiator units 206, 208 quickly. When the pipes and/or hoses 238 have been disconnected, the radiator assembly may be lifted using a forklift or other lifting equipment, for example by insertion of tines into the holes 232, 234. The radiator assembly 202, 204, including the fluid drivers 220, may then be removed from the container 104 via the aperture in the door.

Figures 5a and 5b show exemplary arrangements of fluid drivers, in this case fans, within the aperture 218. Figure 5a shows an arrangement of six 630 mm fans 500 arranged in a 3x2 array. As can be seen from Figure 5a, two fans 500 are positioned adjacent to each other across the width of the opening 218, which was not possible in the radiator assembly of Figure 4. Using the arrangement of Figure 5a allows for 49.6% coverage of the opening 218 by the fans 500. Figure 5b shows an arrangement of two 1 120 mm fans 502 longitudinally aligned in a one-dimensional array. Using the arrangement of Figure 5b allows for 53.2% coverage of the opening 218.

Figure 6 shows test data of air flow rate over through the radiator units 206, 208 using the 3x2 array of 630 mm fans shown in Figure 5a. The shading on the radiator unit surfaces indicates the air flow rate. Figure 6 shows that there is a high degree of uniformity of air flow in a central region 600 and lower region 602 of the radiator unit 206. This is borne out by the average flow rates of 1 .46 m/s in the central region 600 and 1 .31 m/s in the lower region 602. These average flow rates are very similar to one another. An upper region 604 of the radiator unit 206 has a higher average air flow rate at 2.07 m/s. However, this is to be expected because, as indicated by the darker shading at the top of the radiator unit, a high air flow rate is seen near to the fans.