Container type diesel generator set: types, specifications, working principle and application

2024 Author: Howard Calhoun | [email protected]. Last modified: 2023-12-17 10:16

The main purpose of such installations is to provide uninterrupted power supply to large industrial facilities in the event that ordinary power lines are not connected to them. Such equipment is also often used as a backup source in emergency situations. Assembled container-type diesel generator sets are ready-to-work units.

General device and principle of operation

The mechanism of the device is not much different from any other. All generators are built on the principle of operation, in which mechanical energy is converted into electrical energy during the operation of the engine of the device. This process is carried out using special equipment. If you look for the differences between container-type diesel generator sets (DGU) from others, then they can be found in the configurationaggregates. All components are assembled by specialists at the factory and delivered to the consumer in finished form. The container can be installed not only indoors, but also at a certain distance in an open area. The connection procedure is quite simple and involves connecting power cables to the power supply system of a building or other facility.

The container type diesel generator set includes the following items:

1. Engine. Most often, a single diesel engine is used, but in some cases, another one is added to seriously increase the power of the generator.
2. Ventilation system. Serves for removal of products of combustion of fuel outside the room. Also cools engines with fresh air from outside.
3. Alarm and emergency prevention system. A combined mechanism that provides several vital functions at once. The system automatically copes with the resulting fires by injecting a powder mixture and turns on emergency lighting if necessary. In addition, the device can independently turn off the motors and cut off the power supply.
4. Container. The main element in which all other parts of the installation are located. It is presented in the form of a metal frame sheathed with corrugated board and reinforced with stiffeners. In some cases, the body material has anti-vandal properties.

Types of installations by mobility

In thisThe classification considers three main options currently used.

1. Stationary units. Such installations have the widest range of available capacities. The location is usually open, and the scope is quite extensive. Can be used wherever uninterruptible power is required without any reservations, i.e. military bases or continuous cycle industries.
2. Mobile units. Portable diesel generator sets are mounted on a special chassis at the factory, which allows subsequent transportation. The convenience lies in the fact that it will not be difficult for the owner to move the DGU from one industrial facility to another, even over a considerable distance. Such installations are commonly used in exploration expeditions, in the repair and maintenance of roads, in agricultural enterprises, as well as for construction or emergency power supply.
3. Portable units. In most cases, they are very compact diesel generator sets. They are most disposed to frequent relocation if necessary. They are the best choice for summer residents and owners of country cottages, that is, they are mainly used for domestic purposes.

Purpose and scope

There are many prerequisites for choosing a diesel generator set as a power source. These units are mainly used in places with no availableelectricity and in areas with difficult climatic conditions. The permissible temperature range during active operation is in the range from -50 to +50 degrees Celsius. Due to the increased risk of danger at various construction sites, metallurgical plants, mining and other industries, container-type diesel generator sets have become so widely used. As an auxiliary power source, the units are most often used where continuous work processes are carried out - in hospitals, at broadcasting stations and agricultural complexes.

Power plants in containers are completely autonomous and are able to easily serve remote and rotational camps, industrial buildings and office space. For each case, manufacturers can design a container station, taking into account individual requirements for power, dimensions and other parameters. Oftentimes, compact diesel generator sets are the best choice for temporary events such as outdoor music concerts.

Description of container block

All equipment assembled must pass certain tests and meet minimum acceptable standards. In particular, the container has a sufficiently high class of protection against fires and explosions. No less requirements are imposed on the place of installation of the unit. There is a list of certain rules and regulations, regardless of the type of diesel generator setsin a container. Such a list is given below.

1. Mobility of installation. Any unit must be able to be transported to another location if necessary.
2. Anti-vandal system. If it is planned to place the installation outside the protected premises or territory, then it will not be possible to do without special protection against opening. Mechanical damage can lead to depressurization, violation of the temperature regime and damage to the equipment.
3. Dimensions are not strictly regulated and depend solely on the wishes of the client. In most cases, you need to strike a balance between optimal physical size and the required power.
4. Insulation and heating. As a rule, its own autonomous system is provided, because diesel fuel begins to thicken at low temperatures. Thus, in some operating modes, the engine wears out faster and becomes less productive. The thickness of insulation made of mineral materials is at least 10 centimeters.
5. Ventilation system. At a minimum, this assembly must include ventilation grilles, smoke exhaust mechanisms and emergency sources of fresh air entering the container.
6. Depreciation smoothing. During operation, the units emit strong vibration. In order to compensate for this effect, when designing portable diesel generator sets, engineers do not allow a rigid connection of parts with the container body. For these purposes, special vibration pads are used, which serve as shock absorbers for the engine.

Device specifications

As an example, you can take any modern unit. Statistics from the GENMOTORS plant show that AD diesel generator sets have become very popular in recent years. They are built on the basis of the TSS Diesel engine and are intended to be used as the main source of electricity. The kit comes with a battery and a muffler. The unit is pre-filled with oil and coolant, with which the DGU passed a two-hour run-in during testing for operation stability.

The specifications of the model are as follows:

• rated and maximum power - 120 kW and 132 kW respectively;
• three-phase alternating current;
• rated voltage - 230/400V;
• Power Factor - 0.8;
• rated current - 216A;
• motor speed - 1500 rpm;
• rated frequency - 50Hz;
• fuel consumption - 25 liters per hour;
• fuel tank capacity - 260 liters.

Weight depends on performance. With the open version, it is 1370 kg, and in the casing and container, the weight will be 2000 and 3470 kg, respectively. Maintenance of the model should be carried out every 250 hours or once every six months. Warranty is given by the manufacturer for 12 months or 1000 hours.

FG Wilson Diesel Gensets

No less popular modelsare innovative solutions from the English company Wilson. The volume of DGU production per year exceeds 50 thousand copies. Various companies use FG series units in 170 countries, including Russia. On the territory of our country, such devices are mostly needed in remote areas of Siberia, where climatic conditions require a special quality of equipment. However, in other northern and southern regions of the Russian Federation, such DGUs are also used.

Wilson's range of diesel generator sets includes small and medium power models as well as a range of high capacity power plants up to 2200kVA. The products use engines from Perkins. Each installation is equipped according to all modern standards and meets any necessary standards. In particular, fuel filters, an electric starter, a control and protection system, water cooling, a charging generator, starter batteries and an industrial silencer are used. Representatives of Wilson declare an increased motor resource of all models, maximum reliability and reliability, as well as excellent maintainability.

Installation process of the unit

The whole procedure generally takes no more than one or two days. This period is valid provided that the portable diesel generator set has already been moved to its final destination, and all preparatory work has been completed. Installation is carried out in six main stages:

1. Preparation of a reliable and solid foundation. Experts recommend making the foundation of a reinforced concrete pad. Thickness notshould exceed 20-25 centimeters. Before installing the container, it is required to carefully check the horizontal level and the strength of the resulting structure.
2. Connecting the facility's power supply system and installing grounding. Some of these units reach a power of 300 kW or more. For this reason, special safety precautions must be observed during operation. The station and all equipment must be grounded, and personnel must be protected from electric shock.
3. Connecting an emergency warning system, as well as pouring the powder mixture into fire extinguishing installations.
4. General briefing for all service personnel.
5. Conducting a test run. Commissioning.
6. Getting a generator set for warranty service.

User Requirements

At the initial briefing, specialists will definitely tell you in detail about all the nuances during the use of the unit. Warranty service is provided only if all the basic rules and regulations for the operation of a diesel generator set have been observed. Proper use of the unit allows you to extend its service life by one and a half or two times.

Safety requirements clearly state that hand-held fire extinguishers should be placed in close proximity to the plant. At the same time, it is necessary to fill fire extinguishers on a regular basis and monitor their condition. The relevant state services and inspections will conduct their own checks, based on the resultswhich will allow the installed generator to operate.

Additional equipment and options

In some situations, the basic configuration may not be enough for certain purposes pursued by a potential buyer. Then the majority of manufacturers are ready to meet and, as part of an individual order, somehow expand the functionality of a container-type diesel generator set. A summary of these improvements is provided below:

• low noise muffler;
• auto start system;
• additional lamps for lighting;
• system for remote monitoring of the container;
• second fuel tank with a capacity of 500 to 2000 liters;
• creating an additional door to the container;
• installation of advanced fire extinguishing and alarm systems;
• internal heating by convector;
• cabinet with auxiliary automation;
• battery charging system;
• wiring power cables in a sealed way;
• climate control system inside the container;
• second power shield for intermediate power connection;
• mechanism for pre-start heating of diesel generator;
• fuel supply system from an additional tank to the main one;
• a set of special noise reduction gratings.

Diesel generators for locomotives

The required installation capacity in a given mode of transport depends primarilyturn on the crankshaft speed. The diesel locomotive is equipped with a diesel generator set in combination with a traction generator that generates electricity and transmits traction to electric motors. The design of the unit must be as protected as possible, and the device itself must have its own ventilation system and forced fresh air. The design of diesel generator sets in a diesel locomotive from different manufacturers is fundamentally no different. However, the overall dimensions and technical specifications may vary depending on the intended use of the particular unit.