1250kVA Bespoke Standby Power for a Global Polymer Manufacturer

Project scope

At the heart of the solution is a bespoke 1250kVA containerised generator, designed specifically around the operational requirements of the manufacturing facility.

One of the most significant elements of the project was fuel autonomy. The client required the generator to be capable of operating continuously for up to seven days, so CPS incorporated a 20,000-litre bunded fuel tank directly within the container.

Integrating such a large fuel volume within the enclosure created a significant design challenge. The generator, fuel system, controls, fire protection and associated equipment all needed to fit within a carefully managed footprint while still allowing suitable access for maintenance and servicing.

Acoustic performance was another major consideration. With offices located close to the installation, the complete containerised system was designed to meet strict sound requirements while maintaining the airflow and ventilation required by a generator of this size.

Environmental performance was equally important. The generator incorporates an SCR emissions aftertreatment system with AdBlue to achieve Stage V emissions requirements. This was particularly significant for a standby generator above 1MW, where the client required a solution designed around current air quality and emissions standards.

The site’s coastal location introduced an additional requirement. To help protect the enclosure against corrosion, the complete container received C5 marine-grade treatment internally and externally. The external finish was also matched to the building, helping the sizeable installation blend more naturally into its surroundings.

The container was further equipped with motorised louvres, internal fire dampers, a complete fire alarm and fire suppression system, water jacket heating, anti-condensation heating and panel heaters.

Safety access was incorporated directly into the enclosure, including roof-mounted safety railings and a dedicated access ladder with a protective cage.

CPS produced the complete design package, including 3D General Arrangement drawings and electrical schematics, and worked closely with the client’s Project Manager, Electrical Manager and Site Manager throughout delivery.

Despite the complexity of the build, CPS completed manufacture and prepared the generator for witness testing in approximately 14 weeks, significantly quicker than the approximately 22-week industry lead time identified for a project of this nature.

Specialist lifting support was provided by McGovern during the installation, helping ensure the large containerised system was safely positioned on site.