The main purpose of such installations is to provide uninterrupted power 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. The assembled container-type diesel generator sets are completely ready-to-use units.
General arrangement and principle of operation
The mechanism of action of the apparatus 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 device’s engine. This process is carried out using special equipment. If you look for differences between container-type diesel generator sets (DGUs) from others, you can find them in the configuration of the units. All components are assembled by specialists at the factory and delivered to the consumer in a 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 the connection of power cables to the energy supply system of a building or other facility.
The complete set of the container-type diesel generator set includes the following elements:
- Engine. Most often, a single diesel engine is used, but in some cases, for the sake of a serious increase in generator power, one more is added.
- Ventilation system. Serves to divert the products of combustion of fuel outside the premises. Also cools the engines with fresh air from the outside.
- Alarm and emergency system. A combined mechanism that provides several vital functions at once. The system automatically copes with fires caused by the injection of powder mixture and includes emergency lighting if necessary. In addition, the device can independently turn off the engines and cut off the power supply.
- 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 case material has anti-vandal properties.
Types of mobility plants
This classification considers three main options that are currently used.
- Stationary units. Such installations have the widest range of available capacities. The location is usually open, and the scope is quite extensive. They can be used wherever uninterrupted power is required without any reservations, that is, at military bases or production facilities with a continuous cycle.
- Mobile units. Portable diesel generator sets are mounted at a factory on a special chassis, which allows for subsequent transportation. Convenience lies in the fact that it will not be difficult for the owner to move the diesel generator set from one industrial facility to another even at a considerable distance. Such installations are usually used in geological exploration expeditions, in the repair and maintenance of roads, in agricultural enterprises, as well as for construction or emergency power supply.
- Portable units. In most cases, they are very compact diesel generator sets. They are most disposed to frequent movement 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. The main application of these units found in places with a lack of available electricity and in areas with difficult climatic conditions. The permissible temperature range during active use 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 received such widespread use. As an auxiliary power source, aggregates are most often used where continuous working processes are conducted - in hospitals, broadcasting stations and agricultural complexes.
Power plants in containers are completely autonomous and can easily service remote and shift camps, industrial buildings and office premises. For each case, manufacturers can design a container station, taking into account individual requirements for capacity, dimensions and other parameters. Often, compact diesel generator sets are the best option when servicing any temporary events, such as outdoor music concerts.
Container Block Description
All assembled equipment must pass certain tests and meet the minimum acceptable standards. In particular, the container has a fairly high class of protection against fires and explosions. No less requirements are presented to the installation site of the unit. There is a list of certain rules and regulations, regardless of the type of diesel generator sets in the container. Such a list is provided below.
- Mobility of installation. Any unit must be able to transport to another place if necessary.
- Anti-vandal system. If it is planned to place the installation outside the protected premises or territory, then without special protection against opening it will not work. Mechanical damage can lead to depressurization, violation of the temperature regime and damage to equipment.
- Dimensions are not strictly regulated and depend solely on the wishes of the client. In most cases, a balance is required between the optimal physical dimensions and the required power.
- Thermal insulation and heating. As a rule, their 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 efficient. The thickness of the insulation of mineral materials is at least 10 centimeters.
- Ventilation system. At a minimum, this unit must include ventilation grilles, smoke exhaust mechanisms and emergency sources of fresh air into the container.
- Depreciation smoothing. When functioning, the units emit a strong vibration. In order to compensate for this effect, engineers in the design of portable diesel generator sets do not allow 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 some modern unit. Statistics from the GENMOTORS plant indicate that diesel generator sets HELL have become very popular in recent years. They are built on the basis of the TSS Diesel engine and suggest the use as the main source of electricity. Complete with installation is a battery and silencer. The unit was pre-filled with oil and coolant, with which the diesel engine passed a two-hour run-in during testing for stability.
Technical characteristics of the model are as follows:
- rated and maximum power - 120 kW and 132 kW, respectively;
- alternating three-phase current;
- rated voltage - 230/400 V;
- Power factor - 0.8;
- rated current - 216 A;
- engine shaft speed - 1500 rpm;
- rated frequency - 50 Hz;
- 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 the 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 generator sets
No less popular models are 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 special quality equipment. Nevertheless, in other northern and southern regions of the Russian Federation, such DGUs are also used.
The Wilson range of diesel generator sets includes low- and medium-power models, as well as a number of high-performance power plants up to 2200 kVA. The products use engines from Perkins. Each installation is equipped to all modern standards and meets any necessary standards. In particular, fuel filters, an electric starter, a control and protection system, water cooling, a charge generator, starter batteries and an industrial silencer are used. Representatives of Wilson say about the increased engine life of all models, maximum reliability and reliability, as well as excellent maintainability.
Unit Installation Process
The whole procedure takes as a whole no more than one or two days. This period is relevant 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:
- Preparation of a reliable and solid foundation. Experts recommend making the foundation of a reinforced concrete pillow. The thickness should not exceed 20-25 centimeters. Before installing the container, you must carefully check the horizontal level and strength of the resulting structure.
- Connection of the power supply system of the facility and installation of grounding. Some of these units reach 300 kW or more. For this reason, special safety measures must be observed during operation. The station and all equipment must be grounded, and personnel must be protected from electric shock.
- Connecting an emergency warning system, as well as pouring powder mixture into fire extinguishing installations.
- General briefing of all staff.
- Carrying out a trial start. Commissioning works.
- DGU statement for warranty service.
Operating requirements
At the initial briefing, the specialists without fail will tell you in detail about all the nuances during the use of the unit. Warranty service is provided only if all basic norms and rules for the operation of a diesel generator set have been complied with. Proper use of the unit allows you to extend its service life by one and a half or two times.
Safety requirements clearly prescribe the placement of manual fire extinguishing devices in the immediate vicinity of the installation. In this case, it is necessary to refuel fire extinguishers on a regular basis and monitor their condition. The relevant public services and inspections will conduct their own inspections, the results of which 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, most manufacturers are ready to meet and, as part of an individual order, expand in some way the functionality of a container-type diesel generator set. A brief list of such improvements is presented below:
- low noise muffler;
- automatic start system;
- additional lamps for lighting;
- container remote monitoring system;
- a 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 due to convector;
- cabinet with auxiliary automation;
- system for charging the battery;
- hermetic wiring of power cables;
- climate control system inside the container;
- second power shield for intermediate power connection;
- mechanism for pre-start heating of the diesel generator;
- fuel supply system from an additional tank to the main one;
- a set of special noise reduction grilles.
Diesel locomotive generators
The required power of the installation in this type of transport depends primarily on the speed of the crankshaft. The locomotive is equipped with a diesel generator set in combination with a traction generator that generates electricity and transfers traction to electric motors. The design of the unit should be as protected as possible, and the device itself should have its own ventilation system and forced blowing with 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 purpose of the particular unit.