Executive Summary
A European clean ammonia producer operating a facility on the Gulf Coast required a permanent power solution for a single‑engine, standalone application. When the project reached the power generation phase more than two years into construction, original suppliers could not meet the required timeline for a custom, medium‑voltage package. Total Energy Solutions (TES) stepped in as a generator brand‑agnostic solutions integrator to specify, package and deliver a 2,000 kW (~ 2,500 kVA) custom diesel generator set that encompassed a 12,000‑gallon fuel tank, a hurricane-rated enclosure engineered to withstand 180 mph winds, sound attenuation to ~ 75dB at 10 ft) and integrated fire suppression, delivering resilience, noise control and safety in one package. Despite the client’s periodic changes in points of contact and a temporary site shutdown, the TES team navigated specification gaps, coordinated multiple manufacturers and delivered the fully packaged system four weeks ahead of target completion, ultimately establishing resilient, compliant power with enhanced serviceability for long‑term operations.
Project Scope
Power generation planning began later than ideal. Operationally, the power package needed to serve as a permanent power solution for a single‑engine, standalone application in a coastal environment. The physically large components required specialized, coordinated logistics and milestone-driven execution to protect schedule integrity.
The client initially planned a six-month lead time on a complex, custom gen set, though a realistic schedule was at least 12 months. By the time the power generation phase began, OEM suppliers could not deliver on time. At this critical juncture, TES was engaged to bring the expertise and flexibility required to realign the project and restore schedule certainty.
The written specifications contained gaps that further threatened compliance and schedule integrity, raising risks of delayed commissioning, exposure to severe weather without resilient backup power, and downstream operational impacts.TES proposed a brand-agnostic generator approach, surveying multiple qualified manufacturers and integrators to assemble the right combination of generator, engine, enclosure, tank and auxiliary systems aligned with the client’s expectations for functionality and timing. Without the constraints of OEM contractual limitations, TES was uniquely positioned to educate and guide the client through the pros and cons of each option to enable the most informed decision.
Integrated Solution
TES assumed the role of solutions integrator, guiding the client to refine specifications and close gaps while preserving compliance and constructability. The package centered on a 2,000 kW medium‑voltage diesel generator with a custom enclosure and fuel system engineered for coastal resilience.
The solution preserved the single‑engine architecture while improving resilience, serviceability and compliance. Key elements included:
- Enclosure: With a footprint approximately 61′ long by 13′ wide, the enclosure was engineered to a ~ 75 dB noise level at 3 ft, wind‑rated to 180 mph and with a height of 17′ 2″.
- Engine and cooling: The Baudouin diesel engine and radiator were housed inside the enclosure, forming the backbone of the single-engine power architecture.
- Fuel system: The packaged assembly incorporated a 12,000-gallon tank with built-in fuel polishing and venting to ensure reliable performance and compliance.
- Safety: The system included integrated fire suppression to mitigate and control potential incidents.
- Access and serviceability: External platforms and stairs enabled safer, faster maintenance and servicing.
- Electrical and protection: The packaged circuit breaker and auxiliary systems were fully aligned with the project’s medium-voltage requirements to ensure safe and reliable operation.
Implementation and Timeline
As a best-in-class solutions provider with the unique flexibility to evaluate multiple manufacturers and subcontractors, the team applied an unbiased-sourcing, options‑based approach paired with rigorous milestone communications. This enabled schedule certainty, specification integrity and better lifecycle serviceability than a single‑brand path could offer.
The program was executed with clear milestones and transparent dialogue. Despite shifting points of contact on the client’s team and a temporary site-wide shutdown, TES sustained momentum and adapted quickly when work resumed.
- November 2023: Initial RFQ received; quotation turned around within days
- February 2024: Client approval; submittals provided
- June 2024: Submittals approved
- October 2024: Manufacturing began and packaging commenced; engine and generator sourced from a single manufacturer; fuel tank, enclosure, and other components fabricated and integrated; final packaging performed at a dedicated facility
- August 2025: Completed package delivered to site
- December 2025: Commissioning completed by TES technicians
Outcomes
The client realized tangible benefits across every stage of delivery, from accelerated schedules to long-term operational assurance.
√ Informed decision-making: Nimble brand‑agnostic sourcing avoided generator OEM limitations and enabled an options‑based selection aligned with the client’s goals and schedule.
√ Schedule assurance: A fully packaged system was delivered four weeks ahead of the target completion date.
√ Operational resilience: The gen set package provides comprehensive permanent power, backup power and emergency backup power for the unit.
√ Environmental fit: The corrosion‑resistant design is suited to coastal conditions, while the hurricane‑rated enclosure helps keep power online during severe weather.
√ Noise control: The enclosure is engineered to ~ 75 dB at 3 ft for quieter operation.
√ Serviceability and safety: External platforms and stairs significantly improve access at a negligible project cost.
The hydrogen-based ammonia facility was commissioned in December 2025
Lower-carbon ammonia is anticipated in 2026, expanding the global availability of low-carbon–intensity ammonia. The facility is positioned to reduce emissions in hard-to-decarbonize sectors, spanning traditional fertilizer and industrial markets and extending into new end uses such as power and maritime transport. Designed to capture ~1.7M metric tonnes of CO₂ annually and produce up to 1.1M metric tonnes of blue ammonia per year, its future-forward infrastructure is pre-sized to double capacity within the existing plot.
Total Energy Solutions delivers certainty where it matters most: for capital-intensive, safety-critical and schedule-driven facilities across chemicals, refineries, LNG terminals, data centers and other infrastructure where downtime isn’t an option. Learn more about Total Energy Solutions’ integrated solutions for the world’s most demanding operations at http://totalenergysolutions.com
