Energy security in emergencies at one of the UK’s main airports: designing a generator with acoustic insulation and fire protection

Genesal Energy has designed a bespoke power solution for Manchester Airport, one of the busiest in the United Kingdom, with the aim of strengthening its backup system in the event of grid failures.

The project involved the design and manufacture of a fully customised 770 kVA generator set, integrated into a 20ft container and adapted to the client’s requirements in terms of dimensions, acoustic insulation and fire protection.

In critical infrastructures such as airports, where any interruption can cause significant operational issues, having a reliable auxiliary power system is essential. These units must guarantee uninterrupted operation of facilities, especially in strategic areas such as lighting, communications, security and signalling systems.

Adapted to a highly demanding environment

One of the main challenges of the project was fitting the generator into a reduced-size room without sacrificing the power needed to supply the airport’s critical loads. To achieve this, the genset was integrated into a compact 20ft DV container with a reinforced external design and two adjoining modules: one for sound attenuation and the other for fire protection, complying with EI60 classification.

In addition, motorised louvres were installed at the air inlet and outlet, together with fire dampers, automatic fuel shut-off valves and other measures to guarantee compliance with safety standards and airport regulations.

Maximum autonomy and silent operation

The generator, powered by a Volvo engine with 700 kVA Prime output, is designed to operate continuously at full load for at least 6 hours, thanks to a 1,700-litre fuel tank. Acoustically, it was designed as an oversized MD 250 model (-40 dB), enabling it to operate below 75 dB(A) even under full load, minimising any noise interference within the airport environment.

In critical infrastructures such as airports, where any interruption can cause significant operational issues, having a reliable auxiliary power system is essential.

The solution also includes an oil heater with thermostat, a double breaker in the power panel for both the genset and the load bank, and exterior LED luminaires (IP69K), ready for extreme conditions.

This development is an example of how customised engineering allows the design of reliable, safe power systems adapted to environments with the highest technical and operational requirements, such as international airports.

Features

• 770 kVA (Standby) / 700 kVA (Prime) generator set.
• Installed at Manchester Airport (United Kingdom).
• Integrated into a 20’’ DV container adapted to limited space.
• EI60 fire protection: fire dampers and automatic valves.
• Oversized sound attenuation module.
• Noise level below 75 dB(A).
• Large-capacity fuel tank (1,700 L).
• Deep Sea DSE8610 control panel.
• Motorised air inlet and outlet louvres.
• Double breaker in power panel (genset + load bank).
• LED exterior luminaires (IP69K).
• Oil heater with thermostat.