Generator Housing Units Case Study
(Anonymous) Manufacturer and distributor of Generator Housing Units (Gensets) for the mining, oil and gas industry sectors in some of Australia’s most remote and challenging environments.
When transitioning their service offering from the mining sector, our client was faced with a number of manufacturing and structural challenges to modify their current ‘Gensets’ to meet the stringent and tight regulations of Queensland’s Oil and Gas sector.
Having observed the clients ‘Genset’ at a recent trade show and following a closer site inspection, Metlink observed that current operations were over-servicing the market by building bespoke canopies to suit a wide and varied product offering. Metlink was able to quickly identify a number of critical design features that would need to undergo change to achieve not only compliance, but also deliver economies of scale in manufacturing.
The uniquely designed and manufactured ‘Gentsets” achieved full compliance to operate in the Oil and Gas sector, providing economies of scale in manufacturing and users with easy access to control panels, fuel tanks, engines, gauges and electrical equipment in a safe and controlled environment.
The new “gensets” were reconfigured to better house remote computer positioning data systems eradicating excessive boxed housing for electrical smarts. Within the unit, adjustable panels and rail systems were put in place to allow the technicians to assist with electrical placements. Drop down shelving was incorporated for operatives when working on laptops for ease of use, along with improved safety features for housing cabling and doors that opened upwards to create a sunshade for the technicians.
The improved design using folded and fully welded corners created sealed units that dramatically improved soundproofing to comply with noise retention regulations.
Having established a ‘wish list’ from the clients’ field technicians, electrical and mechanical engineers, using 3D modelling software Metlink began to re-design major components of the ‘Gensets’ to achieve a more refi ned and unique suite of products that provided a faster turnaround to market and accommodated a multitude of different diesel engines and electrical set-ups.
Metlink designed three different sized ‘Gensets’ (small, medium and large) with standard canopies which not only fulfilled a common engineering focus for manufacturing and met with industry compliance, but also created unique and adaptable engine mounts to house any size engine, enabling units to be shipped out and assembled on-site with greater speed and efficiency.
Made of powder coated mild steel, Metlink saved its client a considerable amount of money in the re-design of the base structure and bottom base sump of the incumbent ‘Gensets”. Replacing the fully-welded base containing box beams and fl at plates, Metlink, used its’ state of the art turret punching machines to fold the pan and achieve the intricate corners and side structures that were then stitch welded, saving a considerable amount of welding in the overall design and therefore weight in base and on the top of the unit.