Case Study – Engineering a 1000kW Custom-Contained Power Module

The Challenge

Many industrial projects have power needs that cannot be met by a simple generator set on a concrete pad. The core challenge was to engineer a fully self-reliant power module that was as durable and easy to deploy as it was powerful. Our client required a robust power solution for a demanding application with several key challenges:

• Environmental Protection: The generator needed to be completely shielded from harsh environmental conditions to ensure maximum uptime and asset longevity.
• Operational Constraints: The location had specific spatial and operational requirements that made a traditional installation impractical.
• Rapid Deployment: The client needed a “drop-in-place” solution to minimize complex on-site civil works and electrical hookups.
• System Integration: All supporting systems—including fuel storage, exhaust, and safety containment—had to be integrated into a single, transportable unit.

The Solution

The Generator Source team approached this challenge with a comprehensive, four-stage process, transforming a powerful 1000kW MTU generator into a fully contained power solution.

1. Consultation and Engineering Design
Our process began with a deep dive into the client’s specific needs. We worked closely with them to define the exact operational parameters, environmental factors, and footprint requirements. This allowed our engineers to design a custom enclosure and system layout tailored to the 1000kW MTU genset.

2. Custom Enclosure Fabrication
We contracted for a custom-built, industrial-grade steel container. Unlike a standard shipping container, this enclosure was engineered from the ground up to meet the generator’s exact specifications for airflow, structural support, access points, and subsystem integration.

3. Full System Integration
With the enclosure fabricated, our technicians began the expert assembly process. This critical phase involved integrating all necessary subsystems directly into the module:

• MTU 1000kW Generator: The generator set was securely mounted within the enclosure.
• Exhaust System: A custom, insulated exhaust system was installed to safely manage emissions and heat.
• Fuel Storage & Containment: The design incorporated a dedicated, double-walled fuel tank and a comprehensive containment system to prevent any potential leaks or spills.
• Electrical and Controls: All necessary switchgear, controls, and wiring were expertly installed and connected within the module.

4. Final Assembly and Testing
Our technicians meticulously managed the final assembly, ensuring every component was perfectly integrated. Before delivery, the entire power module underwent rigorous quality assurance checks and load bank testing to guarantee flawless performance upon arrival at the client’s site.

The final product was a secure, durable, and highly reliable 1000kW power module. This custom-contained approach delivered several key benefits:

• Guaranteed Performance: By engineering the solution from start to finish, we ensured all components work together seamlessly, providing the client with ultimate peace of mind.
• Superior Asset Protection: The robust steel enclosure shields the generator from weather, debris, and unauthorized access, significantly extending its operational life.
• Simplified Deployment: As a single, integrated unit, the power module drastically reduced on-site installation time and complexity.
• Operational Flexibility: The self-contained design allows the asset to be deployed in a wide range of environments and can be relocated if future needs change.