Equipment Design

Nine disciplines of physical equipment, designed together — because the interfaces between them are where projects fail on site.

The physical equipment in a power system is more than the genset. The enclosure, silencer, fuel tank, fuel-polishing skid, switchgear, P&ID, HVAC ducting and acoustic treatment all have to work as one piece. We design all nine disciplines under one roof, because if they’re designed separately by separate vendors they don’t talk to each other and the interfaces become the customer’s problem.

The nine disciplines

1. Enclosure / container

• Containerised (ISO 20/40 ft) or skid-mounted (custom)
• Hot-rolled steel structure (IPE / HEA / HEB / UPN / W-shape / C-shape)
• Cold-formed trapezoidal sheet for floor / roof / wall panels
• Sound-attenuated walls (modular acoustic panels)
• Service doors, intake / exhaust louvers, lifting points (with FEA validation)
• Standards: EN 1993-1-1 (Eurocode 3), EN 1993-1-3 (cold-formed), AISC 360-22, AISI S100-16, EN 1090-2 (CE marking), EN ISO 3834 (welding)

2. Exhaust silencer & stack

• Multi-chamber silencer design (residential / industrial / critical-grade attenuation)
• Stack thermal + flow analysis (EN 13384-1 / -2), wind + seismic loading (DIN 4133)
• Insulation, thermal expansion compensators, supports
• Standards: EN 13384, EN 1856, ASME B31.1, ISO 6798, DIN 4133

3. Fuel tank — standard-flexible

• Workshop-fabricated steel (EN 12285-1 / -2 / -3)
• KIWA-certified (BRL-K903 installer, BRL-K744/04 mobile, BRL-K514 steel, K756 vertical, K796 horizontal)
• UK BS 799-5 (1100 L+ stationary)
• US UL 142 / UL 2085 (2-hour fire rating)
• Large above-ground API 650, low-pressure API 620
• TR: TS 12820 (fuel station)
• Bunding (110 % capacity), EN 13160 leak detection, vent / fill / drain / level gauge

4. Fuel polishing

• Multi-stage filtration: particulate (5 µm → 1 µm), water (coalescing), biological (UV / chemical)
• Continuous-circulation loop vs batch
• Tank-cleaning regime — schedule + procedure
• Monitoring: water content (Karl-Fischer), particulate count, fuel-quality test
• Standards: ASTM D975, ISO 12937, EN 590

5. Single-line diagram & synchronisation

• Multi-unit paralleling switchgear
• Synchroniser, governor + AVR tuning, droop / isochronous coordination
• ATS make / break strategy (open transition, closed transition, soft load transfer)
• Grid synchronisation (anti-islanding, fault-ride-through where required)
• Standards: IEEE 1547, VDE-AR-N 4110/4120, G99/G100 (UK), local grid codes

6. Acoustics — three paths

• Intake: louver insertion loss, splitter attenuator, ducting silencer
• Room: acoustic panel transmission loss, vibration isolation, structural breaks
• Exhaust: silencer chamber design (target 30–50 dB(A) attenuation)
• Structural: enclosure wall STC, floor mass, sealing details
• Standards: ISO 3744, ISO 8528-10, EU Outdoor Noise Directive 2000/14, ANSI S12.18

7. HVAC, louvers, ducting

• Intake / exhaust louver sizing (free area, pressure drop, water-tightness class)
• Ducting (galvanised / stainless / insulated as required), ducting transitions
• Make-up air balance, exhaust gas dispersion, recirculation prevention
• For cold climates: jacket-water heater, battery warmer, fuel-line trace heating
• For hot climates: oversized radiator, supplementary cooling (chiller / evaporative)
• Standards: ASHRAE 90.1 + Handbook, EN 13779, AMCA 210, SMACNA

8. P&ID — process & instrumentation diagram

• Fuel system (storage + day tank + supply + return)
• Cooling system (closed-loop coolant, radiator, expansion tank)
• Compressed-air system (where used for starting)
• Lube-oil system
• Instrumentation tags (KKS / IEC 81346 — optional per project)

9. Switchgear

• Form 4 segregation, arc-resistant (IEC 62271 Type 2B)
• Withdrawable ACBs / MCCBs sized for short-circuit and selectivity
• Cable termination, busbar sizing, earth bar
• Protection relays (overcurrent, earth fault, differential as required)
• HMI + SCADA interface
• Standards: IEC 62271-200, IEC 62208, IEC 61439, UL 1558, IEC 61641

Multi-standard design — the differentiator

Equipment Design is where ES4PS most strongly demonstrates its standards-flexibility. The same physical piece of equipment can be designed to satisfy different regulators. We have done all of them.

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