WO2012118491A1

WO2012118491A1 - Stackable containerized modular generator

Info

Publication number: WO2012118491A1
Application number: PCT/US2011/026692
Authority: WO
Inventors: Antoine Saab
Original assignee: C-Tech International Llc
Priority date: 2011-03-01
Filing date: 2011-03-01
Publication date: 2012-09-07

Abstract

The stackable containerized modular generator (10) includes an electrical alternator and engine in a single modular shipping container (12). The container (12) includes additional components, e.g., exhaust stack units (44, 46), for assembly when the generator unit (10) is deployed in the field. Each generator unit (10) includes standard attachment fittings (30) at the upper and lower corners, with additional fittings (34) at intermediate points along the upper and lower edges (26). Thus, the containers (12) may be stacked vertically in a longitudinally staggered array to save space, with end fittings (30) of one generator unit (10) joined to intermediate fittings (34) of the next generator unit (10) above or below. The container units (12) may be stacked as many as five high with appropriate bracing (48). Each unit includes retractable platforms (52) extendible from the roof (24).

Description

STACKABLE CONTAINERIZED MODULAR GENERATOR

TECHNICAL FIELD

The present invention relates generally to portable electrical generators, and more particularly to a stackable containerized modular generator that provides a generator installed in a relatively small modular container having standardized external dimensions to facilitate shipping. The container includes all required equipment for operation of the generator, and is configured to provide for stacking of multiple generator units to reduce land area requirements.

BACKGROUND ART

Portable generators are commonly used in various areas as temporary electrical power plants or to provide additional power to supplement the capacity of an existing electrical power plant. In many cases the engine driving the generator and the generator itself are housed together in a portable shipping container to facilitate their transportation and installation and to assist in reducing noise output during operation. Such containerized generator units also provide protection from the elements for the enclosed equipment. When such a modular unit arrives at its destination, little more is required than to anchor it in position, connect the appropriate electrical cables and install any other ancillary components (e.g., exhaust stacks for the engine), provide fuel for the engine, and start the unit to provide useful electrical power.

Generally, a number of such portable units are required in any given installation to provide the electrical power required for the operation (industrial plant, etc.). These units are generally arranged in fairly closely packed rows, but even so, the number of units required for a large power output will take up considerable land area. In many cases, if not most, such portable containerized generator units are installed in congested areas on or near industrial complexes or sites, urban areas, etc. Accordingly, the land area available for such an array of modular generators is very limited and/or the use of such land is very costly and must be considered along with other costs of production for the electrical power being produced by the units. In some instances, it may not be possible to install a sufficient number of such portable generator units required to meet the electrical power demands, in the area available.

Thus, a stackable containerized modular generator solving the aforementioned problems is desired. DISCLOSURE OF INVENTION

The stackable containerized modular generator includes both an electrical alternator (which may comprise a dc generator in lieu of the alternator) and an engine (diesel or other reciprocating engine, gas turbine, etc., using any practicable fuel) to drive the alternator in a single modular shipping container. The container also houses the various components required for the operation of the system, e.g., fuel tank and fuel pump, electrical controller, and a breaker system permitting parallel operation of multiple units, etc. The container also provides room for additional equipment during shipping and storage, such as the exhaust stack(s) required when the unit is deployed. The stackable containerized modular generator also includes various features enabling the units to be stacked atop one another, thereby greatly reducing the land area requirements for the construction of an electrical generating facility having a fairly large electrical output

Each of the containers of the modular generator includes additional anchor or connector points at the floor and roof along each side. These additional connector points are located between the center of the container and each end of the container. These additional anchor or connector points allow the modular units to be stacked atop one another in a longitudinally staggered array with the inboard connector points of one unit connecting to the end connector points of another unit stacked therewith. This allows one end of the lower unit to protrude longitudinally beyond the end of the unit resting thereon to allow clearance for the exhaust stack(s) of the lower unit

Multiple units may be stacked together. For example, as many as five such units may be stacked when appropriate bracing is provided for the overhanging ends of the upper units. Each unit further has a retractable platform that may be extended from the roof of each side to provide access to the unit immediately above. These platforms are normally retracted to reduce the widths of the units for shipping, but may be extended laterally to allow technicians to enter any of the stacked units for maintenance or other purposes.

These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a perspective view of two of the stackable containerized modular generators according to the present invention, showing one containerized generator stacked atop the other as they would appear when readied for operation. Fig. 2 is a perspective view of the two stacked containerized modular generators of Fig. 1 from the opposite side thereof, illustrating additional features and the storage of certain internal components.

Fig. 3 is a side elevation view showing a series of five of the stackable containerized modular generators stacked atop one another, and bracing therefor.

Similar reference characters denote corresponding features consistently throughout the attached drawings.

BEST MODES FOR CARRYING OUT THE INVENTION

The stackable containerized modular generator provides a complete electrical generating unit within a single modular shipping container, and allows a series of such containers to be stacked atop one another to reduce land area requirements for an electrical generating plant incorporating a large number of such units. Figs. 1 and 2 of the drawings illustrate an exemplary installation of two of the containerized modular generator units 10. Each unit 10 comprises a modular shipping container 12 having the general form of a hollow rectangular parallelepiped. Each container 12 has a first end 14, an opposite second end 16, a first side 18, an opposite second side 20, a floor 22, and a roof 24. The ends 14, 16, sides 18, 20, floor 22, and roof 24 define a plurality of longitudinal edges 26 and vertical and lateral edges 28, a corresponding plurality of corners 30, and an interior volume 32.

Each of the corners 30 has a conventional corner attachment fitting disposed thereon. The attachment fittings will be seen to be collocated with the corners of the units 12, and as they are conventional, they are not shown in greater detail. These corner attachment fittings are used conventionally to secure the respective containers 12 aboard a ship, railway flatcar, semitrailer, etc. Such containers 12 are often stacked directly atop one another, particularly when carried aboard a ship, and thus have corner attachment fittings at both their upper and lower corners 30, as in the exemplary shipping container units 12 of Figs. 1 through 3. However, in addition to the conventional corner attachment fittings, each of the generator units or containers 12 further includes two spaced apart intermediate attachment fittings 34 disposed along each of the longitudinal edges 26. A vertical reinforcement member 36 extends between corresponding upper and lower intermediate attachment fittings 34, to provide additional load bearing support for additional containerized modular generator units 10 that may be secured atop one or more such units. 4

Conventionally, containerized modular generator units are deployed in the field in a horizontal array, i.e., they are not stacked atop one another because such conventional units have no means for operating when stacked directly atop one another. Both conventional modular containerized generator units and the modular containerized generator units 10 described herein are powered by some form of internal combustion engine burning some form of fuel, e.g., a diesel engine. Such engines universally produce combustion exhaust byproducts that must be removed from the container 12. This is accomplished both conventionally and by the modular containerized generator units 10 by an exhaust stack extending from the top of the generator unit 10. As conventional containerized generators have no means for offset stacking, they cannot be placed one atop another, as there would be no means for removing the exhaust gases from the lower unit(s).

The intermediate attachment fittings 34 and vertical reinforcement members 36 of the modular containerized generator units 10 permit the units 10 to be stacked atop one another in a longitudinally staggered or offset array, as shown in Figs. 1 through 3 of the drawings. This provides clearance for the exhaust stacks that extend from one end of the roof 24 of each of the containerized generator units 10, thus enabling the units to be stacked. The stacking is accomplished by placing a first or lowermost containerized generator unit 10 in me desired location, e.g., on a concrete pad or other foundation, and securing it by means of the conventional comer attachment fittings 30. A second unit 10 is then stacked atop the first unit, but is staggered or offset longitudinally, as shown in Figs. 1 and 2 of the drawings. The second or upper unit is attached to the first or lower unit by securing the two lower corner attachment fittings 30 at the first end 14 of the upper unit to the upper intermediate fittings 34 located toward the first end 14 of the lower unit, and securing the two lower intermediate fittings 34 toward the second end 16 of the upper unit to the upper corner fittings 30 at the second end 16 of the lower unit This results in the second end 16 of the upper unit being canti levered from the second end 16 of the lower unit, and a portion of the roof 24 of the lower unit being exposed, as shown particularly in Fig. 1 of the drawings. As the exhaust stack exits the roof 24 of each of the units 10 through the roof 24 adjacent or near the first end 14 thereof, this longitudinal offset or staggering of the stacked units allows the exhaust stack of each lower unit to extend upwardly without interference from a unit 10 stacked thereabove.

Each of the stackable containerized modular generator units 10 may be installed and operated as a stand-alone, independent electrical power generating station, if so desired. The internal volume 32 of each container 12 includes a conventional electrical alternator selectively driven by a conventional engine (e.g., diesel engine, Otto cycle ignition engine, gas turbine, etc.), or a dc electrical generator or other electrical power generating source, with the electrical power generating source being designated by the reference numeral 38 and shown as a rectangular outline within the interior volume 32 of the lowermost modular container 12 in Fig. 2. Other conventional components required for electrical power generation and distribution, e.g., a fuel tank, control system, electrical circuit breaker system, etc., are also included within each modular container 12. An exhaust stack storage area 40 is also provided within the interior volume 32 of each modular generator unit or container 12, e.g., between the conventional radiator 42 within the interior volume 32 and the second end 16 of the unit, as shown in the lower unit in Fig. 2. Thus, each of the stackable containerized modular generator units 10 comprises a kit, including all of the components required for operation and/or for attachment to another like unit being contained therein.

The exhaust stack storage area 40 has sufficient volume to provide for the storage of a complete exhaust stack assembly. Each exhaust stack assembly comprises two relatively longer exhaust stack sections 44 and a single shorter exhaust stack section 46. The second end 16 of each unit, behind which the exhaust stack sections 44 and 46 are stored when the generator unit 10 is not deployed, is removable or openable for access to the exhaust stack sections 44 and 46. When one of the modular generator units 10 has another like unit 10 installed thereon, a full length exhaust stack assembly comprising two longer lengths or sections 44 and a shorter top section 46 is installed on the lower unit, the total length of the assembled exhaust stack extending slightly above the generator unit 10 stacked thereon. The uppermost unit 10 may have only one of the shorter top exhaust stack sections 46 installed thereon, as shown in the drawings.

It will be seen in Fig. 3 of the drawings that the stacking of the modular containerized generator units 10 is not limited to only two such units. In Fig. 3, a series of five such units is illustrated, with four units being stacked atop one another and atop a lowermost unit. Each of the units 10 is identical to one another, with the sole difference being the use of only a shorter exhaust stack segment 46 installed atop the uppermost unit as it is not necessary to disperse the exhaust gases at a height above any other of the modular generator units 10. However, it will be noted that the higher the total stack of modular containerized generators 10, the less stable the stack will be. While this is not a concern for a stack of only two or perhaps even three such units, it becomes a concern for taller stacks, such as the five-unit array shown in Fig. 3. Accordingly, appropriate support bracing 48 may be provided for taller stacks of the containerized modular generators 10, as shown in Fig. 3 of the drawings. In addition to the various components described above, some means must be provided for access to the various units 10 for inspection, refueling, maintenance, adjustment, etc. Accordingly, each of the modular units 10 includes a built-in ladder SO extending up at least one of the two sides 18 and/or 20 adjacent the first end 14. Each of the units 10 further includes a retractable work platform 52 that extends laterally from the roof 24 to cantilever over each side 18 and 20 when extended. A folding guardrail 54 may be provided for additional safety, as required or desired. The guardrails 54 illustrated in Figs. 1 through 3 are relatively low, but they may be provided with additional height as required or desired.

The stackable containerized modular generators 10 are very useful for installations where a significant amount of additional electrical power may be required, e.g., factories and industrial plants where insufficient electrical power is available from the conventional electrical grid, or perhaps as a supplementary electrical power source to supply additional electrical power to the grid during periods of very high demand. It will be seen that in the examples noted above that in the majority of cases the land available for such an installation of a large number of containerized electrical generators may be at a premium. Factories and industrial plants will generally wish to minimize the amount of real estate required for their facility, in order to keep costs down. Supplementary electrical power is generally required in major urban areas, where relatively large areas of land for an installation of a large number of containerized generators are either very costly or unavailable. Accordingly, the ability of the stackable containerized modular generators to be stacked atop one another greatly reduces the required land for a given electrical output, thereby reducing the total overhead costs involved in setting up and operating such a power station comprising multiple stackable generators.

It is to be understood that the present invention is not limited to the embodiments) described above, but encompasses any and all embodiments within the scope of the following claims.

Claims

1. At least one stackable containerized modular generator, comprising:

at least one container having the general configuration of a hollow rectangular parallelepiped, the container having a first end, a second end opposite the first end, a first side, a second side opposite the first side, a floor, and a roof, each of the ends, each of the sides, the floor, and the roof defining a plurality of edges and comers, the container defining an interior volume;

an alternator and an engine selectively driving the alternator to generate electricity, the alternator and the engine being housed within the at least one container

a corner attachment fitting disposed at each of the comers of the container; and two spaced apart intermediate attachment fittings disposed along each of the edges of the container.

2. The stackable containerized modular generator according to claim 1, wherein said at least one container comprises a plurality of containers, each of the containers having said alternator housed therein and having said corner attachment fittings and said intermediate attachment fittings, each of the containers being adapted for attachment together to form a longitudinally staggered stack using said corner attachment fittings and said intermediate attachment fittings.

3. A kit, comprising:

a stackable containerized modular generator according to claim 1 ;

an exhaust stack storage area disposed within the interior volume of the container; and a plurality of exhaust stack sections selectively stored within the exhaust stack storage area of the container.

4. The stackable containerized modular generator according to claim 1, further including at least one retractable platform selectively laterally extendible from the roof of the container.

5. The stackable containerized modular generator according to claim 1, further including a vertical reinforcement member extending between corresponding intermediate attachment fittings.

6. The stackable containerized modular generator according to claim 1, further including:

a plurality of long exhaust stack sections

a single short exhaust stack section; and

an exhaust stack storage area disposed within the interior volume of the container, the long exhaust stack sections and the short exhaust stack section being selectively stored within the exhaust stack storage area of the container.

7. The stackable containerized modular generator according to claim 1, wherein the container is a modular shipping container.

8. A plurality of stackable containerized modular generators, comprising:

a plurality of containers, each of the containers having the general configuration of a hollow rectangular parallelpiped, each of the containers having a first end, a second end opposite the first end, a first side, a second side opposite the first side, a floor, and a roof, each of the ends, each of the sides, the floor, and the roof defining a plurality of edges and corners, the container defining an interior volume;

a plurality of alternator and engine assemblies, the engine selectively driving the alternator to generate electricity, each of the assemblies being housed in a corresponding one of the containers;

a corner attachment fitting disposed at each of the corners of each of the containers; and

two spaced apart intermediate attachment fittings disposed along each of the edges of each of the containers, each of the containers being adapted for attachment together to form a longitudinally staggered stack using the corner attachment fittings and intermediate attachment fittings thereof.

9. The stackable containerized modular generator according to claim 8, further including: an exhaust stack storage area disposed within the interior volume of each of the containers; and

a plurality of exhaust stack sections selectively stored within the exhaust stack storage area of each of the containers.

10. T e stackable containerized modular generator according to claim 8, further including at least one retractable platform selectively laterally extendible from the roof of each said container.

11. The stackable containerized modular generator according to claim 8, further including a vertical reinforcement member extending between corresponding intermediate attachment fittings of each said container.

12. The stackable containerized modular generator according to claim 8, further including:

a plurality of exhaust stack assemblies, each of the assemblies having a plurality of long exhaust stack sections and a single short exhaust slack section; and .

an exhaust stack storage area disposed within the interior volume of each said container, each said container having a corresponding one of the exhaust stack assemblies selectively stored within the exhaust stack storage area of said container.

13. The stackable containerized modular generator according to claim 8, wherein each said container is a modular shipping container.

14. A stackable containerized modular generator kit, comprising:

at least one container having the general configuration of a hollow rectangular parallepiped, the container having a first end, a second end opposite the first end, a first side, a second side opposite the first side, a floor, and a roof, each of the ends, each of the sides, the floor, and the roof defining a plurality of edges and corners, the container defining an interior volume;

a corner attachment fitting disposed at each of the corners of the at least one container;

two spaced apart intermediate attachment fittings disposed along each of the edges of the at least one container; an electrical alternator disposed within the interior volume of die at least one container

an engine disposed within the interior volume of the at least one container, the engine selectively driving the electrical alternator,

an exhaust stack storage area disposed within the interior volume of the at least one container, and

a plurality of exhaust stack sections selectively stored within the exhaust stack storage area of the at least one container.

15. A stackable containerized modular generator, comprising a plurality of the stackable containerized modular generator kits according to claim 14, each of said containers being attached to a corresponding said container immediately above it to form a longitudinally staggered stack, the corner attachment fittings and intermediate attachment fittings being releasably connected to each other to attach said adjacent containers together.

16. The stackable containerized modular generator according to claim 14, further including at least one retractable platform selectively extendible laterally from the roof of the at least one container.

17. The stackable containerized modular generator according to claim 14, further including a vertical reinforcement member extending between corresponding pairs of said intermediate attachment fittings.

18. The stackable containerized modular generator according to claim 14, further including:

a plurality of long exhaust stack sections;

a single short exhaust stack section; and

an exhaust stack storage area disposed within the interior volume of the at least one container, the long exhaust stack sections and the short exhaust stack section being selectively stored within the exhaust stack storage area of the at least one container.

19. The stackable containerized modular generator according to claim 14, wherein the at least one container is a modular shipping container.