APPLICATION
Diesel Generator Hybrid Retrofit
Retrofit existing diesel generators with solar PV and battery storage to cut fuel costs by 40-70%.
Diesel Generator Hybrid Retrofit
Transform Your Existing Gensets
Upgrade your diesel generator fleet with a hybrid retrofit solution that integrates solar panels and battery energy storage without replacing existing assets. Our retrofit kit works with all major generator brands and can be installed with minimal downtime.
Typical results: 40-70% fuel reduction, 50-80% lower maintenance intervals, and 3-5 year payback period.
System Configuration
| Generator Compatibility | All major brands, 50kVA-2000kVA |
| Solar PV Addition | 50kWp – 2MWp |
| Battery Storage | 100kWh – 5MWh (LiFePO₄/Li-ion) |
| Control System | PLC-based hybrid controller with remote SCADA |
| Installation Downtime | 2-5 days per unit |
| Fuel Savings | 40-70% vs diesel-only |
| Maintenance Reduction | 50-80% fewer service intervals |
| Warranty | 5 years on major components |
50%
Average Fuel Saving
500+
Units Retrofitted
3-5yr
Payback Period
<1wk
Installation Time
Retrofit Existing Diesel with Solar + Battery
You already have a diesel generator. Maybe several. They’re working, they’re paid for, and replacing them outright is wasteful. The good news: you don’t have to. A hybrid retrofit adds solar PV and battery storage alongside your existing diesel plant.
The diesel keeps running. The solar+battery just takes over a much larger share of the work. Fuel savings are assessed for the specific site. Maintenance extends. Engine life increases. You keep the assets you already own and add the assets that pay back fastest.
How a Retrofit Works
Before: Diesel-Only
Diesel runs 24/7 at variable load. Inefficient at <40% load. Wears out from continuous runtime.
After: Hybrid System
Solar+battery carries daytime load. Diesel runs only when battery low or peak demand. Fuel use is evaluated for the specific site.
What We Add to Your Existing System
☀ Solar PV Array
Sized to provide 50-80% of your daytime load. Roof-mount, ground-mount, or carport – we work with your site.
Typical: 200kWp – 2MWp
🔋 Battery Storage
LiFePO₄ batteries sized for your night-time load. Smooths solar variability. Black-starts if diesel fails.
Typical: 500kWh – 4MWh
📊 Hybrid PCS
Bidirectional inverter. Manages solar+battery. Auto-starts diesel on low SoC. Synchs with your existing generator.
Typical: 100kW – 1MW
💻 EMS Software
Energy management system. Optimizes when to use solar, battery, and diesel. Reports savings. Remote monitoring.
Optional: cloud SCADA included
Retrofit Reference Configuration
Industrial Water Pumping – 800kVA Existing Diesel
A remote water pumping station running three 400kVA diesel generators in parallel can be retrofitted with solar and storage while keeping the existing diesel as backup. Remote sites with high delivered fuel costs see the fastest payback.
Retrofitted with: 600kWp solar canopy + 1.2MWh battery + 500kW hybrid PCS. Existing diesel kept as backup.
Typical results after retrofit:
- Fuel consumption reduced by roughly 60-70%
- Diesel runtime cut from 24 hr/day to a few hours per day
- Diesel service intervals extended significantly
- Payback typically 2-3 years
- Substantial annual CO₂ reduction
Retrofit Project Process
A typical retrofit follows these steps over 12-20 weeks:
- Site survey (1-2 weeks): Load measurements, existing generator assessment, solar resource study, civil works review
- Engineering design (2-4 weeks): System sizing, single-line diagrams, equipment specifications, ROI model
- Manufacturing (4-8 weeks): Container fabrication, equipment integration, factory testing
- Logistics (2-6 weeks): Sea/air/road shipping to site, customs clearance, on-site delivery
- Installation (2-4 weeks): Container placement, cable connections, solar array mounting
- Commissioning (1-2 weeks): System testing, operator training, handover documentation
- Ongoing support: Remote monitoring, scheduled maintenance, performance reporting
Common Retrofit Challenges & Solutions
Every retrofit is unique, but most projects encounter a common set of challenges. Here’s how we address them:
- Existing diesel age: Older generators may need refurbishment or replacement as part of the hybrid project. We assess and recommend the most cost-effective approach.
- Available space: Solar arrays need land area (or roof area). We work with your site to find the best placement-ground, roof, or canopy.
- Grid interconnection: If connecting to grid for export, the utility’s technical requirements must be met. We handle the application and approval process.
- Permits and approvals: Local permits, environmental approvals, and grid operator sign-offs. Our team manages the documentation and submissions.
- Financing: Hybrid retrofits qualify for green financing in many markets. We can connect you with lenders who specialize in energy efficiency projects.
Frequently Asked Questions
How is this different from a standard retrofit?
It focuses on the genset as the core, wrapping it with PV and storage and controls to convert a dirty baseload generator into a clean hybrid plant.
What fuel savings are typical?
50 to 70 percent diesel reduction, while extending generator life by lowering run hours and smoothing load.
Can multiple gensets be retrofitted?
Yes. Parallel genset fleets are managed as one dispatchable block by the energy management system.
Is it suitable where there is no grid?
Absolutely. It is designed for off-grid and bad-grid sites, with optional grid-tie when a utility connection becomes available.