One example of this is when a customer had a requirement for an additional standby generator at one of their critical Data sites and wished to explore if any of their existing assets could be better utilized. An inner-city site was identified where only one of two existing 850kVA embedded generators was required due to reduced site load and utility and UPS improvements since the original installation. An assessment of the generator’s performance was required however the addition of a Light Rail Tram system running directly outside the entrance required coordination with the Operator and relevant City authorities to ensure a safe and non-intrusive work environment was established.

Using an external load bank, the engine and alternator were put through a series of exercises based on the proposed new site load characteristics and the nameplate rating with all of its performance profile documented. A report was issued to the Consultant for both analysis and later comparison when the repackaging was completed. Once the generators potential was confirmed detailed risk assessments and method statements were produced detailing each stage of the generator to decommission process and the actual removal from site.

Realpower managed communications between Rail and City authorities on technical issues such as overhead clearances, protection of the rail lines, vehicle and pedestrian traffic management processes on the Clients behalf. This included securing of permissions, liaising with and direct supervision of subcontractors.

Preliminary works were carried out preceding the removal in order to reduce risks and interruptions to a minimum. The time for removal was scheduled midweek at 02.00 and once the overhead tramlines were de-energised and permits issued, the generator was removed from the power room, loaded and transported off site within 35 minutes.

Realpower managed communications between Rail and City authorities on technical issues such as overhead clearances, protection of the rail lines, vehicle and pedestrian traffic management processes on the Clients behalf. This included securing of permissions, liaising with and direct supervision of subcontractors.

Preliminary works were carried out preceding the removal in order to reduce risks and interruptions to a minimum. The time for removal was scheduled midweek at 02.00 and once the overhead tramlines were de-energised and permits issued, the generator was removed from the power room, loaded and transported off site within 35 minutes.

The generator was thoroughly cleaned, prepared for shipping and installation into its new enclosure by an approved generator packaging provider. During the process Realpower managed all of the container design changes required by evolving site requirements. This included relocating the generator control panel to better suit operators on site, and repositioning the load cable entry point from high level to under floor.

The top entry fuel tank was specifically designed for the site so that all piping, bends and joints were minimised with any flexible lines of a double steel braided hydraulic swaged type. This increase in performance allowed the engine to run directly from the remote bulk tank thus eliminating the requirement of a fuel transfer system and was validated during the site acceptance load bank test.

To increase longevity and serviceability, the fuel tank sits on galvanised cross beams to ensure any potential corrosion is minimised in the event of water entering the bund containment area.

Other fuel tank features included:

• Mechanical overfill prevention valve
• Lockable fill cabinet with all refuelling carried out within the bund catchment area
• High fuel level audible and visual alarm
• Double skin containment area with both audible and visual alarms
• Spill catchment tray at tanker connection point
• Contents indication gauge
• Audible and visual low contents level alarm
• High/high and low / low probe for remote customer level alarms
• Non ferrous mechanical protection over walkways and connection points

From initial enquiry, Realpower became a trusted project partner to provide the full spectrum of generator support services required to deliver an operational solution. With the generator solution now operating in full emergency standby function, Realpower continue to play a part by providing the necessary preventive maintenance and reactive service required by a mission critical facility.