German Data Centre Packaging

34 Acoustically Packaged Diesel Generators for German Data Centre

AVK, a leading supplier of power generation systems, secured a major contract to supply 34 MTU emergency standby diesel generator systems, with a total capacity of 110.6 MVA, to a new hyperscale data centre in Germany.

They needed a manufacturer with advanced design capabilities and the capacity to produce a bespoke acoustic enclosure and 16,500 litre belly tank for each unit.

ADE Power were able to produce 34 custom-designed acoustic enclosures and accompanying fuel tanks, enabling AVK to fulfil strict project deadlines and site regulations while ensuring consistent quality across all units.

The Situation

Our client, AVK, faced a complex challenge: they needed to acoustically package their 34 MTU diesel generators (32 x 3300 kVA units & 2 x 2500 kVA units) and supply them complete with a total of 561,000 litres of fuel storage.

• Design and manufacture all enclosures attenuated to a noise level of 72 dB(A) at 1 metre.
• Design and manufacture the accompanying belly tanks to strict German DIBt regulations.
• Meet tight project deadlines.
• Ensure consistent & high quality across all units.

AVK needed an experienced partner with proven experience in high-volume generator enclosure manufacturing, who could handle the entire scope of the project from design to fit-out. The challenge was not just in the scale of the project, but also in the need for precision, consistency, and regulatory compliance across all 34 enclosures & tanks.

Our Solution

We approached this project with a comprehensive solution that leveraged our expertise in custom acoustic enclosure design and manufacturing. Our solution included:

• Bespoke Enclosure Design: Our in-house engineering team utilised the latest 3D software to design the enclosures, each specifically attenuated to a noise level of 72 dB(A) at 1 metre. The enclosures were equipped with motorised air inlet and outlet dampers to manage both airflow and noise.
• Belly Tank Design: We designed the 16,500 litre belly tanks in strict compliance with German DIBt regulations. The tanks are crucial for safe and secure fuel storage and had to meet precise safety and environmental standards.
• Fabrication and Painting: We fabricated and painted all 34 enclosures and belly tanks at our Pontefract & Hellaby facilities in the UK.
• Enclosure Fit-Out: We fitted out each enclosure with the client's standby generators, LV switchgear including internal busbars, lube oil tanks, fire suppression systems, fuel systems, and other auxiliary equipment including small light and power.
• Quality Control: Throughout the manufacturing process, our quality team's rigorous quality control measures ensured consistency across all 34 units.
• Project Management: We managed the entire process from design to dispatch, ensuring that all components were completed in line with the overall project timeline.

By taking on the entire scope of enclosure and tank design, manufacture, and fit-out, we provided AVK with a complete packaging solution that fulfilled all their requirements.

The Results

Our comprehensive solution yielded significant benefits for our client:

• Timely Delivery: AVK was able to deliver all 34 packaged generators and fuel tanks to the data centre in Germany and install them on-site in accordance with the timeline.
• Consistent Quality: By having the capacity to manufacture all the enclosures and tanks, we ensured consistent quality across all units. This consistency was crucial for the overall performance and reliability of the emergency power system.
• Regulatory Compliance: All units were designed and manufactured in compliance with strict site and German DIBt regulations, ensuring they met all necessary safety and environmental standards.
• Simplified Project Management: AVK benefitted from more straightforward project management, as they only needed to coordinate with a single supplier rather than multiple vendors.
• Enhanced Quality Control: The single-source approach allowed for more effective quality control throughout the entire process, reducing the risk of inconsistencies or defects.
• Noise Reduction: The acoustic treatment of the enclosures successfully achieved noise levels of 72 dB(A) at 1 metre, meeting the project's stringent noise reduction requirements.
• Comprehensive Solution: By providing a complete solution from design to fit-out, we simplified AVK's supply chain and reduced potential points of failure in the project.

This project demonstrates our ability to deliver complex, large-scale solutions for critical standby power generation projects. By providing a complete service - from design and manufacture to fit-out and quality control - we allowed AVK to fulfil their scope of works efficiently and effectively.

The success of this project has further strengthened our relationship with AVK, positioning us as a trusted partner for future high-volume generator enclosure projects. As the demand for data centres globally shows no signs of slowing down, we are well-positioned to support these projects with our proven expertise in custom acoustic enclosure and fuel tank manufacturing.

To learn more about how we can support your power generation enclosure needs, or to discuss a potential project, contact us today.