Power Packager & Generator Set Removable Insulation Systems

---

Core Engine & Genset Components Insulated

Industrial generator packages concentrate extreme thermal energy within compact, enclosed footprints. ATC fabricates modular, multi-piece removable insulation systems designed for rapid servicing, routine maintenance, and zero-degradation thermal performance:

Genset Component	Thermal & Operating Challenge	ATC Custom Engineered Solution
Exhaust Manifolds (Dry & Water-Cooled)	Surface temperatures exceeding 1,200°F (650°C), thermal expansion stress, and fluid-spray fire risks.	Segmented removable manifold blankets with oil-resistant silicone/PTFE outer jackets and stainless wire mesh inner linings.
Turbocharger Turbine Housings	Extreme localized heat concentration, vibration fatigue, and proximity to sensitive electrical wiring.	Contoured, form-fitting turbo blankets designed for rapid removal during turbo rebuilds or wastegate inspections.
Exhaust Bellows & Flex Connectors	Continuous multi-directional vibration, axial thermal growth, and high exhaust gas velocity.	Multi-layer flexible expansion jackets that absorb mechanical movement without tearing or thermal bypass.
Emissions Aftertreatment (SCR, DOC, DPF)	Catalysts require precise, elevated internal temperatures to achieve required NOx and particulate reduction.	High-efficiency thermal blankets maintaining catalyst operating temps while protecting external enclosure components.
Exhaust Silencers & Primary Piping	Massive radiant heat release inside generator enclosures, increasing ventilation cooling loads.	Thermal-acoustic combo blankets reducing enclosure ambient temperatures by up to 50°F and dampening decibel levels.

Reciprocating Engine OEM Model Coverage

ATC maintains an extensive library of precision CAD templates for major reciprocating engine manufacturers used in continuous power generation, emergency standby, and mobile packaging applications:

Engine Manufacturer	Target Engine Series & Models	Standard Kit Configurations
Caterpillar® (CAT)	3500 Series: 3508, 3512, 3516, 3516B, 3516C, 3520 Gas Engines: G3516, G3520 C-Series: C15, C18, C27, C32	Complete exhaust manifold kits (8 to 16 pieces), twin/quad turbocharger covers, exhaust risers, flex connections.
Cummins®	High-Horsepower: QSK19, QSK38, QSK50, QSK60, QSK78 Legacy & Marine: KTA19, KTA38, KTA50, QSV series	Precision-tailored manifold sections, turbo blankets, exhaust crossover lines, aftertreatment thermal wraps.
INNIO® Jenbacher	Type 2, 3, 4, 6 & 9: J312, J320, J420, J620, J920	Combined heat and power (CHP) engine insulation, biogas/landfill gas manifold sets, exhaust heat recovery jackets.
Waukesha®	VHP Series: 7042, 7044, 9390 mobiles & Gas: 275GL, VGF series	Heavy gas compression engine blankets, water-cooled manifold covers, turbo blankets for remote field skids.
MTU® / Rolls-Royce	Series 2000 & Series 4000: 12V4000, 16V4000, 20V4000	Mission-critical data center generator insulation, modular manifold blankets, exhaust silencer covers.
Other Generator OEMs	Kohler® / Rehlko®, Generac® Industrial, Mitsubishi®, MAN®	Custom OEM specification blankets built to original drawing tolerances or templated from field equipment.

Data Center & Mission-Critical Generator Applications

Hyperscale cloud facilities, colocation hubs, and AI computing data centers depend on massive multi-megawatt backup generator arrays. In high-density generator enclosures and modular power modules, unmanaged radiant exhaust heat can trigger premature cooling fan failure, overheat control PLCs, and trip emergency sensors.

ATC supplies custom data center genset insulation systems engineered for:

• Extreme Enclosure Ambient Temperature Reduction: Keeping ambient air temperatures inside acoustic enclosures well within safe operating parameters for batteries and sensitive switchgear.
• Instant Standby Readiness: Blankets designed to handle rapid cold-start to full-load temperature shocks (ambient to 1,000°F+ in seconds) without thermal fatigue.
• ACOUSTIRAP® Sound Attenuation: Integrating specialized acoustic barrier septums to help facilities achieve strict boundary noise ordinances (STC 55).

CHP, Cogeneration & Gas Compression Skids

In distributed energy and pipeline applications, thermal efficiency directly dictates system ROI:

• Combined Heat & Power (CHP): Retaining maximum exhaust gas thermal energy between the engine exhaust ports and the heat recovery steam generator (HRSG) or heat exchanger.
• Biogas, Landfill Gas & Renewable Gas Engines: Protective outer barrier fabrics that resist corrosive chemical trace gases (H2S, siloxanes) and frequent washdowns.
• Natural Gas Compression Skids: High-vibration thermal blankets engineered for pipeline transmission compressors, gas gathering skids, and wellhead reciprocating engines.

Engineering Materials & Technical Specifications

Specification Parameter	ATC Power Packager Standard
Continuous Temperature Rating	Rated from 500°F (260°C) up to 1,800°F (980°C) continuous exposure (2,000°F peak).
Outer Jacketing Fabrics	Heavyweight silicone-impregnated fiberglass, PTFE/Teflon® coated glass cloth, stainless steel knitted wire mesh.
Hot-Side Inner Lining	304/316 Stainless Steel knitted wire mesh, high-purity silica cloth (1,800°F+), Inconel® mesh for extreme vibration.
Thermal Insulation Core	High-density E-glass needled fiberglass mat (6 to 11 lbs/cu.ft.), silica mat, or aerogel thermal composite.
Fastening & Attachment Hardware	Stainless steel lacing anchors, tie wire, stainless extension springs, high-temp silicone straps with quick-release D-rings.
Safety & Compliance	Complies with OSHA touch-safety standards (< 140°F / 60°C outer surface), ASTM E84 / UL 723 Class A flame and smoke ratings.

OEM Packaging & Contract Manufacturing Services

Advanced Thermal Corp. serves as a tier-1 partner to generator manufacturers, packagers, and skid fabricators across North America:

• “Made-to-Print” Production: We manufacture directly from your 3D CAD models, STEP files, or engineering prints with tight dimensional tolerances.
• High-Volume Blanket Manufacturing: Dedicated production lines in Wood Dale, IL and Jacksonville, TX capable of scaling from single prototypes to repeating production runs.
• Private Label & Custom Branding: Custom part numbering, branded labeling, and serial-number tracking matching your packaging BOMs.
• On-Site Digitization: When CAD drawings are not available, our field engineering teams utilize 3D scanning technology to template engine exhaust geometries on site.

Power Generation & Packager Installation Gallery