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Diesel to hybrid

Same site. Same engine. A fraction of the run hours.

If you already have a diesel set running a site, adding battery storage and an inverter charger is usually the cheapest improvement available — and it uses the generator you have already paid for.

The problem with a diesel on its own

A generator sized for your peak load spends most of its life nowhere near it. Overnight, at weekends, and through any quiet period, it is running at a fraction of its rating — and diesels are poor at that.

  • Efficiency falls away below about 40% load. You burn fuel that produces very little useful output.
  • Wet stacking. Unburnt fuel and oil accumulate in the exhaust system. Left long enough it needs an engine strip to put right.
  • Bore glazing. Cylinder walls polish rather than bed in, and oil consumption climbs.
  • Hours accumulate regardless. Services are counted by running hours, not by useful work done.
  • Noise, all night, whether or not anything is drawing power.

What conversion involves

Three components, and none of them replaces the generator.

ComponentWhat it does
Battery storageCarries the base load with no engine running. Sized against your overnight and quiet-period consumption, not your peak.
Inverter chargerThe heart of it. Supplies the site from the battery, and charges the battery hard from the generator when it does run.
Control systemDecides when the engine starts, at what state of charge, how long it runs, and when it does not need to bother at all.

And solar, where there is room

If the site has roof space, a spare corner of yard, or a container roof, solar makes the arithmetic considerably better. On a summer week it can keep the battery topped up well enough that the engine does not start at all.

How the engine's life changes

Before: running continuously, mostly lightly loaded, accumulating hours around the clock.

After: starting when the battery calls for it, running at high load where it is efficient, charging fast, and stopping. Fewer starts, harder work while running, and long silent periods in between.

That is better for the engine as well as for your fuel bill. An engine that runs hard and stops is healthier than one that idles indefinitely.

What it saves, and the honest caveat

The savings come from four places: fuel, refuelling visits, servicing intervals, and engine life. On a site with a low base load and occasional peaks the effect can be dramatic. On a site running near full load all day it will be modest.

Sites where it usually works well

  • Security and monitoring compounds — very low load, running continuously, the worst case for a bare diesel
  • Welfare and site offices — heavy peaks morning and lunchtime, almost nothing in between
  • Remote installations where every refuelling visit costs real money in travel and time
  • Anywhere with a noise constraint, particularly overnight
  • Sites with emissions obligations written into a contract or a planning condition

Where it works less well

  • Sites running near capacity for most of the working day
  • Very short-duration projects where there is no time to recover the capital
  • Sites with no secure space for a battery enclosure

How we approach it

  1. Meter the site. A period of real data — load profile, base load, peaks and their duration.
  2. Model the conversion against that data. Battery size, expected run hours, fuel saved, payback.
  3. Specify and quote, with the assumptions written down so you can challenge them.
  4. Install and commission, integrating with your existing set and switchgear rather than replacing it.
  5. Verify. Meter again afterwards and compare against the model. If we were wrong, you will know.

Running a diesel that barely breaks sweat?

Let us meter it. The data will tell you whether conversion is worth doing.

Arrange a site survey