Winter 2026/27 preparation checklist: how to keep your production running. Autonomous energy supply

Autonomous energy supply is not a one-off purchase but a multi-stage project. From the first assessment of your needs to the moment the unit enters commercial operation, a certain period of time passes — and this time can be either planned in advance or adapted to an existing horizon. Below are options for different timing scenarios plus a complete seven-step checklist.

Autonomous energy supply. Three scenarios for different planning horizons

Dieselmash has solutions for three typical situations — depending on how much time you have until your desired launch date.

SCENARIO 1. FAST-TRACK PROJECT (2–3.5 MONTHS)

Possible through our production reserves, priority slots, and the standard DvGA product line without custom modifications. Design and manufacturing run in parallel; some components are drawn from stock. Cost is slightly above baseline (due to logistics and priority handling), but the horizon shortens by 6–8 weeks. Suitable if the key preconditions (gas, site, technical specs) are already in place.

SCENARIO 2. PLANNED PROJECT (4–6 MONTHS)

The optimal option when you have time for the full cycle. All stages proceed at their normal pace, without acceleration. Economically the most efficient scenario — minimal logistics costs, maximum time to design for your specific needs, smooth commissioning without time pressure. For projects aimed at the 2027/28 heating season, this is the scenario that starts now.

SCENARIO 3. HYBRID SOLUTION (for alternative fuel) — CHP on natural gas NOW + CHP on alternative fuel later

If your facility can use alternative fuel cheaper than natural gas (biogas, producer gas, pyrolysis gas, etc.), but also has access to natural gas, and an autonomous energy source is critically needed by the current heating season — consider a hybrid. Equipment for producing alternative fuel has a long manufacturing cycle — 6–8 months. Dieselmash offers a fast-track CHP running on natural gas to cover your energy needs right away. In parallel, the alternative fuel equipment is manufactured; once it is installed and running, the supplied CHP is upgraded and switched to alternative fuel. The option to operate on natural gas remains available.

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Dieselmash ready-made solutions

We manufacture a full product line from which we select a solution for your specific project.

COGENERATION UNITS (CHP)

■  DvGA-315 — for small facilities: agricultural complexes, district heating in small towns, greenhouses, processing plants

■  DvGA-500 — base model for a mid-sized industrial enterprise

■  DvGA-630 — for large projects and industries with high thermal and electrical loads

■  DvGA-750 — for large district heating utilities and combined enterprises

All models run on natural gas; biogas versions are available for the agri-industrial sector; producer and pyrolysis gas versions — for processing industries.

MODERNISATION OF EXISTING SOURCES

If you already have a boiler house, it is often more efficient not to build from scratch but to integrate the CHP into the existing infrastructure. This saves 3–4 weeks on thermal loop design and reduces CAPEX. Such projects have been successfully implemented, for example, for district heating utilities in Khmelnytskyi region and Kamianets-Podilskyi.

Dieselmash has dedicated production slots for priority projects and a reserve stock of base engines. This makes it possible to offer options beyond the standard cycle — for a specific request and a specific launch horizon.

Full project cycle: how long autonomous energy supply takes

The full project cycle — from the first discussion to the commercial launch of a CHP unit — takes 2–6 months. This is the standard timing for any industrial equipment project involving a gas connection.

Breakdown by stages:

■  Design and obtaining technical specifications — 2–6 weeks

■  Unit manufacturing at the plant — 1–10 weeks

■  Delivery to the site and installation — 1–2 weeks

■  Commissioning and test runs — 1–3 weeks

■  Acceptance tests — 1 week

These are indicative timelines for a standard project. Options for tighter planning horizons are described above.

The project timing is a physical process: gas pipeline design, approvals from the gas utility, cabinet and piping manufacturing. Understanding the real cycle helps you calmly choose the scenario that fits you: full, fast-track, or hybrid.

Step 1. Energy consumption audit

Before choosing equipment, you need accurate data on what you actually consume. Not estimates like "about 500 kW" but specific meter readings:

■  Electricity consumption — kWh by month for the last 12 months

■  Heat consumption — Gcal by month for the last 12 months, separately for heating and process needs

■  Load profile — how many hours per day the facility operates at base load, how many at peak

■  Contracted capacity and limits — how much you are allowed to consume per your utility contract

■  Tariff structure — how much you pay during day and night hours, whether peak surcharges apply

This data is easy to collect: it is in your invoices for electricity and heat. It takes 2–3 working days.

A typical mistake is calculating "our average consumption". The correct approach is to look at distribution by hours and months. Summer and winter profiles at an industrial facility can differ by a factor of 3–4.

Step 2. Choosing a solution: CHP, diesel, or a combination

GAS COGENERATION UNIT (CHP)

Suitable if you have a gas connection at 0.1–4 bar pressure, 24/7 operation (4,000+ hours per year), and a need for heat for heating or process purposes. Economics: fuel is three times cheaper than diesel, plus heat is produced in parallel. Payback — 1.5–2 years in the base scenario.

DIESEL GENERATOR

Suitable if there is no gas or connection is economically impractical; if you need a backup source with 500–1,000 hours per year; if the site is remote (drilling rigs, oilfields, river vessels). Economics: low CAPEX, high OPEX. Optimal for backup and seasonal applications. Additional benefit — shorter supply cycle (2–3 months).

CHP + DIESEL COMBINATION

Suitable for large enterprises where the CHP covers the base load and the diesel covers peak loads or gas network failures. CAPEX is higher, but so is reliability — this is a standard architecture for critical infrastructure (hospitals, data centres, food production).

Don't confuse backup with base energy supply. A 500 kW diesel generator running 24/7 costs UAH 65–70 million per year in fuel alone. It is not suitable for base supply — too expensive.

Step 3. Feasibility study — real payback based on your tariffs

A feasibility study is not a "seller's marketing calculation" but an objective assessment of whether the unit will pay off in your specific case.

What a feasibility study contains:

■  Calculation of annual electricity and heat consumption

■  Fuel cost (gas at industrial price in your region)

■  Cost of purchased electricity and heat — at your actual tariffs

■  CAPEX — turnkey unit cost plus infrastructure

■  OPEX — annual expenses on fuel, oil, service, staff payroll, depreciation

■  Annual savings and payback period

■  Sensitivity — how payback changes with rising or falling prices for gas and electricity

Realistically, a feasibility study takes 3–5 working days with data from Step 1.

According to a specific study dated 01.07.2026 for a 500 kW CHP on natural gas at UAH 30/Nm³ and an electricity tariff of UAH 12/kWh, the payback was 1.7 years. Your result will differ — but within 1.5–2.5 years for most industrial facilities with continuous operation.

Step 4. Design and technical specifications (2–6 weeks)

Design begins after the contract is signed. What happens at this stage:

■  Development of the unit design for the customer's site — foundation, ventilation, exhaust system, thermal loop

■  Obtaining technical specifications for gas pipeline connection (from the gas utility) — this is the critical path, taking 2–6 weeks depending on the region

■  Obtaining technical specifications for grid connection (for grid synchronisation or selling surplus power)

■  Coordinating environmental standards for industrial installation

■  Developing and approving the gas supply project

What the customer needs at this stage:

■  Cadastral certificate for the plot under the unit

■  Construction permit (if required by regional norms)

■  Active contract with the gas supply company

Gas pipeline design is often the "bottleneck" of the whole project. If you don't have an active contract with the gas utility or there are disputes over the balance boundary — it's better to find out early. Such issues can be resolved in parallel with equipment selection.

Step 5. Unit manufacturing at the plant (1–10 weeks)

After obtaining technical specifications and approving the design, manufacturing begins. At the Dieselmash plant in Pervomaisk:

■  Manufacturing and running-in of the engine (base engine of series 6GChN25/34 or 8GChN25/34)

■  Assembly of the generator module and cooling system

■  Manufacturing of the automation cabinet and synchronisation system

■  Assembly of the heat recovery loop (exhaust gas heat exchangers, circulation pumps)

■  Final assembly and factory tests under load

All critical components have a supply lead time of several months. The automation control system (HEINZMANN), turbochargers (PBS TURBO), power electronics — are ordered at the moment the contract is signed. This is why the production cycle cannot be arbitrarily accelerated: its duration is determined by component supply lead times from the manufacturers.

At the same time, we have reserved production slots and some engines in stock, which makes it possible to offer accelerated implementation for priority projects.

Step 6. Delivery to the site and installation (1–2 weeks)

After manufacturing and factory tests are completed, the unit is shipped to the site:

■  Transportation (for a standard 500 kW CHP — usually one trailer)

■  Installation on the foundation — the foundation must be ready in advance, by the time the unit arrives

■  Thermal loop installation — connection to the heating or process system

■  Electrical installation — connection to the main switchboard

■  Gas pipeline connection — usually from the connection point to the unit

■  Installation of the exhaust system with silencer and stack

What the customer needs at this stage:

■  Ready foundation (concrete pouring — 2–4 weeks, better to plan in advance)

■  Thermal main from the boiler house to the site laid

■  Power cable from the unit to the main switchboard ready

■  Permits for installation works

Step 7. Commissioning and commercial launch (1–3 weeks)

Final stage before commercial operation:

■  First cold engine start — check of the oil, fuel, and cooling systems

■  Grid synchronisation — setting up parallel operation with the utility grid

■  Test runs with stepped loads — 25%, 50%, 75%, 100%

■  Automation tuning — power regulation, response to load jumps

■  72-hour test run under load (usually required for acceptance)

■  Training of the customer's operating personnel

■  Signing of acceptance test certificates

Commercial launch is not "flip the switch and it works". It is tuning the operating mode to the specific load schedule of the facility. A well-tuned CHP reaches its rated efficiency after 100–200 operating hours.

Where to start

Three parallel actions that can be started in the next two weeks — regardless of which scenario fits you:

First — gather data for the feasibility study (Step 1). No commitments, no budget. You need 12 months of electricity and heat bills. It takes 2–3 days.

Second — check the state of your gas contract. Do you have an active contract with the gas utility? Do you know the gas pressure at the connection point? Is there a limit? If not — these questions can be resolved in parallel with equipment selection.

Third — request a preliminary feasibility study. We do it in 3–5 working days with basic data. It gives you an understanding of the real economics for your specific facility — and lets you choose the appropriate scenario for your timing.

Autonomous energy supply is not a one-off purchase but a project that fits into your production strategy for the next 20–25 years (that's how long the unit serves). The right question is not "will I be on time by date X" but "which solution fits my facility and my horizon".

Dieselmash manufactures cogeneration units of the DvGA series based on our own engines 6GChN25/34 and 8GChN25/34. We have solutions for the full planned cycle, for fast-track options, and for hybrid schemes. Let's discuss your specific case — a calculation for your situation is free and comes with no commitments.

Describe your situation: operating hours, gas availability, heat demand, desired launch date. Within 3–5 working days we will prepare a feasibility study with a payback calculation and options by delivery timing — planned, fast-track, or hybrid.

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