Modular power generation facilities using shipping container-based modules

• US 10,340,697 B2
• Filed: 10/19/2017
• Issued: 07/02/2019
• Est. Priority Date: 10/19/2016
• Status: Active Grant

• Current Assignee: PowerSecure, Inc. (Southern Company)
• Original Assignee: PowerSecure, Inc. (Southern Company)
• Inventors: Paine, Miles, Dickinson, Will, Saunders, John, Brown, Bill, Ferrick, Bobby, Courliss, Jeff, Moore, Justin
• Primary Examiner(s): Deberadinis, Robert L
• Application Number:
  US15/788,521
• Publication Number:
  US 20180109163A1
• Time in Patent Office: 621 Days
• CPC Class Codes: B65D 88/022 in multiple arrangement, e.g. stackable, nestable, connected or joined together side-by-side
• CPC Class Codes: B65D 88/121 ISO containers
• CPC Class Codes: B65D 90/0013 Twist lock
• CPC Class Codes: B65D 90/0026 Corner fittings characterised by shape, configuration or number of openings
• CPC Class Codes: E04H 2001/1283 Small buildings of the ISO containers type
• CPC Class Codes: E04H 5/02 Buildings or groups of buildings for industrial purposes, e.g. for power-plants or factories buildings forming part of cooling plants E04H5/10
• CPC Class Codes: E04H 5/04 Transformer houses; Substations or switchgear houses
• CPC Class Codes: F01N 13/017 the purifying devices are arranged in a single housing
• CPC Class Codes: F01N 13/18 Construction facilitating manufacture, assembly, or disassembly
• CPC Class Codes: F01N 2450/30 Removable or rechangeable blocks or cartridges, e.g. for filters
• CPC Class Codes: F01N 2590/10 for stationary applications
• CPC Class Codes: F01N 3/206 Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents F01N3/2066 takes precedence
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• CPC Class Codes: F01N 3/2842 specially adapted for monolithic supports, e.g. of honeycomb type F01N3/2853 - F01N3/2871 take precedence
• CPC Class Codes: H02J 3/381 Dispersed generators
• CPC Class Codes: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Systems, methods, and building block modules for modular power generation facilities are disclosed. A multi-stack modular power generation facility includes first and second pluralities of primary modules and first and second control systems. The first modules are positioned in a first stack to form a first vertical enclosure; the second modules are positioned in a second stack to form a second vertical enclosure; and the first and second modules each include gen-set modules, each with an engine-generator, and a switchgear module ganged to the gen-set modules. Each control system communicates with the respective gen-set modules to coordinate the engine-generators as a unit and to control the loading of each of the generators in response to a power load demand. The second plurality of primary modules are disposed immediately adjacent the first plurality of primary modules such that the second vertical enclosure abuts the first vertical enclosure.

Claims

1. A multi-stack modular power generation facility, comprising:

(a) a first plurality of primary modules, wherein the first plurality of primary modules are positioned in a first vertical stack of modules and are attached together to form a substantially modular first vertical enclosure for the generation of electricity, wherein each primary module includes eight primary corners and an interior space at least partially enclosed by a top wall, a floor, a side wall, and an end wall, and wherein the primary modules include;

(i) one or more gen-set modules, each having an engine-generator disposed in the interior thereof, and

(ii) a first switchgear module having first switchgear disposed in the interior thereof, wherein the first switchgear is ganged to at least one of the one or more gen-set modules in the first vertical stack of primary modules;

(b) a first control system in communication with each of the gen-set modules in the first vertical stack of primary modules to coordinate the engine-generators of the one or more gen-set modules as a unit and to control the loading of each of the generators in response to a power load demand, wherein the first control system is disposed in one or more of the primary modules of the first vertical stack with at least part of the first control system being disposed in the first switchgear module;

(c) a second plurality of primary modules, wherein the second plurality of primary modules are positioned in a second vertical stack of modules and are attached together to form a substantially modular second vertical enclosure for the generation of electricity, wherein each primary module includes eight primary corners and an interior space at least partially enclosed by a top wall, a floor, a side wall, and an end wall, and wherein the primary modules include;

(i) one or more gen-set modules, each having an engine-generator disposed in the interior thereof, and

(ii) a second switchgear module having switchgear disposed in the interior thereof, wherein the second switchgear is ganged to at least one of the one or more gen-set modules in the second vertical stack of primary modules; and

(d) a second control system in communication with each of the gen-set modules in the second vertical stack of primary modules to coordinate the engine-generators of the one or more gen-set modules as a unit and to control the loading of each of the generators in response to a power load demand, wherein the second control system is disposed in one or more of the primary modules of the second vertical stack with at least part of the second control system being disposed in the second switchgear module;

(e) wherein the second plurality of primary modules are disposed immediately adjacent the first plurality of primary modules such that the second vertical enclosure abuts the first vertical enclosure.

2. The multi-stack modular power generation facility of claim 1, wherein, in each vertical stack, all of the primary modules have a common width.

3. The multi-stack modular power generation facility of claim 2, wherein a lowermost primary module, of each vertical stack of primary modules, is mounted on, and attached to, a base frame or foundation.

4. The multi-stack modular power generation facility of claim 2, wherein, in each vertical stack, each gen-set module further includes a dedicated fuel tank disposed in the interior thereof.

5. The multi-stack modular power generation facility of claim 2, further comprising one or more secondary modules, wherein each secondary module is disposed at an end of, but on the same level as, a respective primary module of the vertical stack of primary modules.

6. The multi-stack modular power generation facility of claim 5, wherein each secondary module has a width equal to the common width of the primary modules.

7. The multi-stack modular power generation facility of claim 6, wherein the one or more secondary modules include a fuel tank module, wherein each fuel tank module is disposed at the end of a respective gen-set module, and wherein each fuel tank module houses a fuel tank, in an interior thereof, that provides fuel to the engine-generator in the respective gen-set module.

8. The multi-stack modular power generation facility of claim 7, wherein each fuel tank module includes sound baffles, disposed in the interior thereof, to muffle sounds of combustion and flow of air in or out of the respective gen-set module.

9. The multi-stack modular power generation facility of claim 6, wherein the one or more secondary modules include a sound baffle module, wherein each sound baffle module is disposed at the end of a respective gen-set module, and wherein each sound baffle module houses sound baffles, in an interior thereof, to muffle sounds of combustion and flow of air in or out of the respective gen-set module.

10. The multi-stack modular power generation facility of claim 2, further comprising a staircase module having eight primary corners, wherein the staircase module is disposed alongside, and attached via the respective primary corners to, at least one primary module in the first vertical stack of primary modules.

11. The modular power generation facility of claim 10, wherein the staircase module is one of a plurality of staircase modules positioned in a vertical stack of staircase modules, wherein each staircase module is attached to a primary module beside it via side attachment fittings that are each connected to one corner on the staircase module and a corresponding corner on the primary module beside the staircase module.

12. The multi-stack modular power generation facility of claim 2, wherein in each vertical stack, each primary module is adapted from an intermodal shipping container having four posts, a pair of top side rails, a pair of bottom side rails, a front sill, a rear sill, a top front rail, and a top rear rail, all of which are connected together by shipping container corner castings, wherein the shipping container corner castings form the eight primary corners.

13. The multi-stack modular power generation facility of claim 12, wherein, in each vertical stack, each primary module is attached to a body above or below it via the corner castings and corresponding twist lock fasteners.

14. The multi-stack modular power generation facility of claim 12, wherein the primary modules in the first vertical stack are attached to the primary modules in the second vertical stack via side attachment fittings that are each connected to one corner casting on a first primary module and a corresponding corner casting on a second primary module.

15. The multi-stack modular power generation facility of claim 12, wherein portions of at least two of the walls of each primary module are corrugated shipping container walls.

16. The multi-stack modular power generation facility of claim 2, wherein each primary module includes at least one walk-through opening accessing the interior thereof, and wherein the at least one walk-through opening of each primary module in the first vertical stack is aligned with the at least one walk-through opening of the primary module immediately adjacent thereto in the second vertical stack, thereby providing access from the interior of each primary module in the first vertical stack to the interior of the immediately adjacent primary module in the second vertical stack.

17. The multi-stack modular power generation facility of claim 2, wherein each primary module in the first vertical stack is attached via the respective primary corners to the primary module immediately adjacent thereto in the second vertical stack.

18. The multi-stack modular power generation facility of claim 2, wherein the switchgear in the first switchgear module is operatively connected to the switchgear in the second switchgear module.

19. The multi-stack modular power generation facility of claim 18, wherein an exterior wall of the first switchgear module is penetrated by a cable slot through which interconnect cables may pass for connection to the second switchgear module.

20. A multi-level modular power generation facility, comprising:

(a) a first plurality of primary modules, wherein the first plurality of primary modules are positioned side by side in a row of modules, on a first level, and are attached together to form a substantially modular first level enclosure for the generation of electricity, wherein each primary module includes eight primary corners and an interior space at least partially enclosed by a top wall, a floor, a side wall, and an end wall, and wherein the primary modules include;

(i) one or more gen-set modules, each having an engine-generator disposed in the interior thereof, and

(ii) a first switchgear module having first switchgear disposed in the interior thereof, wherein the first switchgear is ganged to at least one of the one or more gen-set modules on the first level;

(b) a first control system in communication with each of the gen-set modules in the first level to coordinate the engine-generators of the one or more gen-set modules as a unit and to control the loading of each of the generators in response to a power load demand, wherein the first control system is disposed in one or more of the primary modules of the first level with at least part of the first control system being disposed in the first switchgear module;

(c) a second plurality of primary modules, wherein the second plurality of primary modules are positioned side by side in a row of modules, on a second level, and are attached together to form a substantially modular second level enclosure for the generation of electricity, wherein each primary module includes eight primary corners and an interior space at least partially enclosed by a top wall, a floor, a side wall, and an end wall, and wherein the primary modules include;

(i) one or more gen-set modules, each having an engine-generator disposed in the interior thereof, and

(ii) a second switchgear module having switchgear disposed in the interior thereof, wherein the second switchgear is ganged to at least one of the one or more gen-set modules on the second level; and

(d) a second control system in communication with each of the gen-set modules in the second level to coordinate the engine-generators of the one or more gen-set modules as a unit and to control the loading of each of the generators in response to a power load demand, wherein the second control system is disposed in one or more of the primary modules of the second level with at least part of the second control system being disposed in the second switchgear module;

(e) wherein the second plurality of primary modules are stacked on top of the first plurality of primary modules such that the second level enclosure is disposed on top of the first level enclosure.