#containerized generator set

In today's competitive manufacturing industry, an efficient and stable power supply is essential to ensure the continuous operation of production lines. As a reliable backup and main power supply, diesel generators are widely used in various production scenarios. However, there are a wide variety of diesel generator sets with different performance available on the market. How do manufacturing enterprises choose the generators that best suit their own production line needs? Below are some key factors that should be considered.

Before choosing a diesel generator, manufacturing enterprises need to analyze the actual demand of the production lines in detail. It’s necessary to understand the electrical load characteristics of the production line, the type and amount of electrical equipment, the operation mode of the production line, and future expansion plans and so on.

Electrical load characteristics: Equipment on the production line usually includes continuous operation equipment and intermittent operation equipment. Equipment such as lighting, ventilation and monitoring systems that need to operate continuously require a stable power supply. Equipment such as machine tools, welders and cranes are used intermittently according to the production takt. Thus, when selecting a diesel generator, you need to consider if the generator can meet the power demands of the equipment, especially during peak load hours.

Electrical equipment types and quantity: List all equipment such as motors, heaters and cooling equipment that need to be powered by diesel generators as well as their rated power. Please note that the actual operating power of the equipment is often lower than the rated power. It is also necessary to consider the power factor (PF) for conversion.

Production line operating modes: Different production lines have different operating modes, such as three shifts, two shifts or single shift. This affects the use time and load curve of the diesel generator sets, which in turn affects the choice of their power capacities and quantities.

Future expansion plan: When investing in diesel generators, keep in mind that their power capacities not only meet the current needs, but also can cope with possible future increases in electrical equipment or production line expansion. Thus, consider a 20-30% margin above the required power for future power requirements.

Factors need to consider when selecting diesel generators for manufacturing industry

Based on the demand analysis of the production lines, manufacturing enterprises should consider the following key factors when selecting diesel generator sets:

Generator power capacity: It’s necessary to understand the prime generators and standby generators. A prime generator set is any standard genset that is used as the primary power source for the equipment it is powering. It is intended for continuous operation, which is usually best utilized in situations where you are away from a utility source of power such as the mains power from a house or other building. Standby Power (emergency power) is to be used when the main source of power fails. It is the maximum output power that the unit can achieve in a short period of time, such as 30 minutes, which is used to deal with sudden high load. Thus, the prime power should be considered to ensure that the generator can meet the daily electricity demand of the production line.

Peak power requirements: Pay special attention to whether the production line has an instantaneous high-power demand, such as starting a large motor. This may require a diesel generator with a higher standby power or reducing the start shock by means such as soft starting.

Fuel Efficiency and emission standards: With the improvement of environmental protection requirements, choosing diesel generators with high fuel efficiency and low emissions can not only reduce operating costs, but also respond to the call for green production. This helps enterprises improve their social image and reduce environmental pollution.

Noise level: Noise level is an important consideration for generators that need to be installed near production lines or in densely populated areas. Choosing a diesel generator with a noise reduction design can reduce the impact on the surrounding environment, improve the working environment of employees and the quality of life of surrounding residents.

Reliability and durability: The reliability and durability of diesel generator sets are directly related to the continuous operation of the production lines and the production efficiency of the enterprises. Therefore, priority should be given to generator sets with well-known brands, such as Cummins and Perkins. These brands usually have an excellent quality assurance system and after-sales service network, which can provide timely maintenance services when the equipment fails.

Automation and intelligence: With the development of intelligent technology, more and more diesel generator sets are equipped with automatic control systems and remote monitoring functions. These functions can realize remote monitoring, fault diagnosis and automatic start and stop of the unit, improve operation and maintenance efficiency and reduce labor costs.

Generator maintenance and service: Consider the easy maintenance feature and after-sales service quality of the generator. Make sure the diesel generator has a rapid response in emergency situations and ensure uninterrupted power supply. Moreover, choose models with easy access to spare parts to reduce downtime caused by spare parts shortages.

Dongfeng Cummins' National IV electronically - controlled engines occupy a leading position in the market, thanks to their advanced electronic control technology, unique system and technology integration, and cutting - edge emission technology. To better assist drivers in leveraging the advantages of these engines, we will now introduce the operating knowledge of the EBP Intelligent Energy - Saving System.

EBP, commonly referred to as the fuel - saving switch, is mainly utilized in tractors and trucks. The EBP Intelligent Energy - Saving System is equivalent to an engine equipped with three - gear selection keys. Drivers can make free selections based on different road conditions and load weights, enabling the engine to operate within the optimal fuel - economy range and thereby achieving fuel - saving goals.

Instruction for Using the Cummins EBP Intelligent Energy - Saving System (Applicable to Dongfeng Cummins ISLe8.9/ISL9.5 Series Engines)

The Intelligent Energy - Saving System is a device designed to enable users to achieve the best fuel economy under light - load, medium - load, heavy - load conditions, and various road conditions.

Usage Instructions for Unloaded, Half - loaded, and Fully - loaded Conditions

For trucks: Unloaded means the total weight of the truck and its cargo is less than 15 tons; half - loaded means the total weight is between 15 tons and 25 tons; fully - loaded means the total weight exceeds 25 tons.

For tractors: Unloaded means the total weight of the tractor and its cargo is less than 20 tons; half - loaded means the total weight is between 20 tons and 30 tons; fully - loaded means the total weight exceeds 30 tons.

Operation Method

Pushing the switch upward activates the E (Unloaded) driving mode.

Keeping the switch in the middle position selects the B (Half - loaded) driving mode.

Pushing the switch downward engages the P (Fully - loaded) driving mode.

Properly using the EBP driving modes according to different driving conditions can lead to better fuel economy.

Special Suggestion: One gear higher can be selected according to the working conditions. For instance, in hilly road conditions, select the B mode when the vehicle is unloaded, and choose the P mode when it is half - loaded or fully - loaded.

Precautions for Use

Press the switch before starting the vehicle to check if it functions properly.

It is advisable to switch the mode when the vehicle is stationary. If you need to switch while driving, make sure to completely release the accelerator pedal first.

If you feel that the engine power is insufficient, check if the Intelligent switch is set to the E or B gear.

With the improvement of people's living standards, there are more and more household appliances, such as rice cookers, microwaves, kettles, refrigerators, air - conditioners, washing machines, etc. It can be said that every household has them. But what if there is a power outage? These appliances won't work properly, and our lives will be greatly disrupted. How can we avoid this?

We can use household mini - generators to provide convenience in power consumption. So, how to choose a good household mini - generator?

Consider the noise level

Since it is for household use, when choosing a household mini - generator, we need to check whether the noise will affect the neighbors. Generally, the seller will demonstrate the performance of the generator in advance. A good household generator can reduce noise by about 80%.

Choose a generator with a moderate price

Due to different brands, there are significant differences in power, and consequently, the price differences of household mini - generators are also very obvious. At this time, many consumers are attracted to low - priced household generators, which are likely to be shoddy products. This is largely related to the chaotic situation in the domestic generator market, which has made the household generator market rather messy. Therefore, the price of a household generator is mostly proportional to its quality. When choosing a household generator, one should select a product with a moderate price.

Choose a generator with a suitable power

If the household generator is used to power appliances such as refrigerators, TVs, and air - conditioners, a generator with a power slightly larger than the total power of these appliances should be selected. This helps to reduce the load on the generator and also protects household appliances from damage caused by unstable power.

Finally, when choosing a household generator, one should select products from regular manufacturers and through regular sales channels. This way, one can pay taxes legally and be a good citizen. At the same time, there will be sufficient evidence for future rights protection to help consumers obtain legitimate rights and interests.

In modern times, diesel generators have become standard equipment across various industries. When grid power fails or becomes insufficient, diesel generator sets provide continuous and stable power supply for businesses or factories. A diesel generator set consists of three main components: a diesel engine, an alternator, and a control system. So, what exactly is an alternator?

About AC generators  

Alternators can be categorized into two main types: DC generators and AC generators. AC generators are further subdivided into synchronous generators and asynchronous generators. In modern power stations, synchronous generators have become the most widely used type due to their unique excitation methods and ability to provide both active power and reactive power simultaneously. In contrast, asynchronous generators feature simpler construction and easier operation. However, their lack of independent excitation windings prevents them from supplying reactive power to loads and requires them to draw lagging magnetizing current from the grid. This necessitates parallel operation with other synchronous machines or connection with multiple capacitors, limiting their applications primarily to small automated equipment and DC power supply needs for urban trams, electrolysis, and electrochemical industries.

Working principle of alternator/AC generator  

An AC generator is a key component of a diesel generator. It is used to convert mechanical energy into electrical energy and responsible for generating the electrical power that is output by the generator. An AC generator mainly comprises multiple alternating N-S pole permanent magnets made of magnetic material (called rotor) and an armature coil made of silicon cast iron with multiple series-wound coil groups (called stator).

The working principle is that the rotor, driven by the diesel engine, axially cuts magnetic flux lines. The alternately arranged magnetic poles in the stator create alternating magnetic fields in the coil core. With each full rotation of the rotor, the direction and magnitude of magnetic flux change multiple times. This magnetic field variation induces alternating current in the coils, which is then output through the stator windings. To protect electrical equipment and maintain normal operation, the current produced by the generator requires regulation and control through voltage regulators.

How to choose the right alternator?  

Most modern AC generators are brushless types with rotating excitation systems. When selecting an alternator for your diesel generator set, ensure that it is mechanically compatible with the diesel engine. Electrically, the alternator should provide required kW output at specified voltage, frequency, ambient temperature, and altitude, while being capable of withstanding transient loads without exceeding maximum allowable voltage dips. Typically, an Automatic Voltage Regulator (AVR) is provided as part of the alternator to ensure compatibility. Brushless AC generators use rotating exciter generators to produce the excitation current and voltage required for magnetizing the main rotor. The AVR controls rotor excitation based on sensed generator output voltage. The alternator speed must match the diesel engine speed - lower speeds require more rotor poles to maintain fixed 50Hz or 60Hz frequency regardless of rotational speed.

There are typically two connection methods between diesel engines and AC generators: flexible connection using couplings, and rigid connection using high-strength bolts to join the generator's rigid connecting plate with the engine flywheel. Currently, rigid connection is more prevalent in practical applications. After installation, various sensors (e.g., water temperature sensors) monitor the diesel engine's operating status and display data to operators. When parameters reach or exceed preset limits, the control system issues warnings. If operators fail to respond promptly, the system automatically shuts down for protection. Sensors play crucial roles in receiving and feeding back information, while the unit's control system analyzes data and executes protective measures.

With the increasing power demand and rising stability requirements, generator sets, as critical backup power equipment, make their manual starting function particularly important. It is not only the cornerstone for ensuring continuous power supply to critical loads but also serves as the direct means for operators to restore power when automation systems encounter difficulties. Below are the safety guideline for manual starting and stopping of generator sets.

I. Necessary preparations before manual starting generator set  

Safety check and system status confirmation

First, perform a safety check. Ensure there are no flammable materials around the generator set, ventilation is adequate, and the exhaust pipeline is unobstructed. Carefully inspect the genset's exterior for any damage and check the control panel for any illuminated alarm indicators. Meanwhile, confirm that safety equipment such as the emergency stop button and protective covers are in proper working condition.

Next, confirm the system status. Set the generator set's control switch to the Manual position to disengage automatic mode. If a manual power transfer is required, set the Automatic Transfer Switch (ATS) to Manual or Generator Priority mode.

Fuel and lubrication system preparation  

Ensure the diesel fuel tank has sufficient fuel, with the level at least above one-third. In addition, check the engine oil level, confirming it is within the marked range, typically between the L (Low) and H (High) marks.

Cooling system and battery check  

Check if the radiator coolant or antifreeze is sufficient, and ensure the water temperature gauge needle is at its initial position. Close the battery switch, then measure the battery voltage. Diesel engines typically require 24V, while gasoline engines require 12V.

Load and line connection

Before starting, connect the load equipment to the generator set, but keep the circuit breaker in the OFF position to avoid inrush current impacting the equipment. Additionally, carefully inspect the output cables for any damage and ensure the grounding wire is securely connected.

II. Manual starting generator operation steps  

Pre-start warm-up and starting method  

Pre-start warm-up (Applicable in winter or low-temperature environments): First, open the fuel valve. Then, press and hold the preheat button (if the unit is equipped with a preheating device) for 30 seconds to 1 minute to raise the engine block temperature. During this time, closely observe whether the preheat indicator light illuminates to confirm the preheating system is working normally.

Starting operation: Insert the start key into the ignition switch on the control panel and turn it clockwise to the START position. Hold it there for 3-5 seconds, listening carefully for the exhaust sound or observing the tachometer to determine if the engine has successfully ignited. If the starting attempt is unsuccessful, wait 10 seconds before repeating the operation to avoid excessive battery discharge.

Post-start checks and abnormal situation handling

After starting the generator set, pay attention to changes in various indicators. Typically, oil pressure should rise above 0.3 MPa within 10 seconds of starting, indicating the lubrication system is normal. In addition, the water temperature should gradually rise to the range of 60-90°C (specific values may vary by model). Furthermore, the generator output frequency should stabilize at 50Hz or 60Hz, and the voltage should remain at the rated value, such as 380V or 220V.

If the oil pressure does not rise or the water temperature rises abnormally, stop the engine immediately and check the oil pump or cooling system to ensure equipment safety. If the frequency fluctuation exceeds ±5%, adjust the engine speed control knob to restore stability.

Manual power transfer

After confirming the generator set is running stably, manually close the output circuit breaker to transfer the load from the mains supply to the generator power. During this process, continuously monitor whether the load current is within the rated range to prevent damage from overload operation.

III. Manual stopping generator set operation process  

Load unloading and engine shutdown  

Before stopping, first disconnect all non-critical loads to gradually reduce the generator set's load. Subsequently, turn the output circuit breaker to the OFF position, completely disconnecting the generator from the load.

Turn the control switch to the STOP position. The engine will begin idling, typically for a period of 3-5 minutes. During this time, closely monitor the water temperature, ensuring it drops below 70°C, and note if the oil pressure returns to zero. Once these conditions are met, the engine will shut down automatically. In case of an emergency, immediately press the red emergency stop button, the engine will stop rapidly. After stopping, be sure to check the cause of any fault (e.g., high water temperature, low oil pressure), eliminate safety hazards, and then reset the relevant buttons.

Post-stop Inspection and Maintenance

After stopping the generator set, close the fuel valve to prevent fuel leakage. Then, carefully inspect all components of the generator set for signs of oil or water leaks, and record the operating parameters in detail. If the generator set will be out of service for an extended period, it is recommended to start and run it once every two weeks to prevent component corrosion.

IV. Safety precautions  

When operating the generator set, a series of safety regulations must be followed. Before starting, ensure you stay clear of the exhaust pipe to prevent burns from hot gases. Furthermore, strictly avoid opening the control cabinet or inspection covers while the genset is running to ensure equipment safety. Operators must wear insulated gloves, safety goggles, and anti-slip shoes to ensure personal safety.

The generator fuel pump is the "heart" of the engine's fuel supply system. It is a device that continuously draws fuel from the fuel tank and provides the fuel system with fuel at a specified pressure and flow rate. Based on the functions of the generator fuel pump, it can be known that the performance of the fuel pump will directly affect the working performance of the engine. Therefore, it is necessary to carry out corresponding preparatory work before using the fuel pump.

To ensure the normal use of the generator, debugging the fuel pump is the primary preparatory work. We must install and debug it on a dedicated test bench according to the fuel pump calibration data sheet. Currently, the flowmeter method is mostly used, and the specific steps are as follows:

Preparation before debugging

The fuel pump and injector have been debugged on the test bench. The generator is in good technical condition and has entered the hot - running state.

The fuel pump is correctly connected to the driving device, and clean fuel is injected into the gear pump.

Disconnect the throttle valve control rod from the connecting rod to enable free movement.

Install the tachometer on the connecting device of the fuel pump timer drive shaft.

Check whether the instruments used (such as pressure gauges and tachometers) are working properly.

Idle speed adjustment

Unscrew the plug from the cover of the PTG governor spring assembly. Adjust the idle speed of the generator to (600 ± 20) r/min by rotating the idle - speed adjustment screw. After the idle - speed adjustment, screw the plug back.

For the generator fuel pump equipped with an MVS governor, the idle - speed adjustment screw is located on the governor cover. After the idle - speed adjustment, tighten the lock nut to prevent air from entering.

High - speed adjustment

Usually, when the fuel pump debugged on the test bench is installed in the generator, high - speed adjustment is not required. If adjustment is needed, the method of increasing or decreasing the high - speed spring washers is still used.

The disconnection point speed of the generator governor should be 20 - 40 r/min higher than the rated speed to ensure that the governor does not play a limiting role before the rated speed.

The maximum no - load speed of the generator is generally 10% higher than the rated speed.

It is hoped that the above - shared content can help everyone debug and use the fuel pump more easily. Many users face difficulties in the later use, maintenance, and upkeep of the generator set due to insufficient in - depth understanding of the generator. Therefore, a professional enterprise is needed to provide technical support and guidance for later use and maintenance.

Diesel generators are renowned for their reliability, durability, fuel efficiency and low maintenance. They are commonly used as emergency backup power supply or used in remote areas where the power grid is unavailable. When buying a diesel generator set for an application in a noise-sensitive location, you need a noise-reducing solution. Silent type generators often come either containerized or with a canopy. In this article, we’ll explore the containerized diesel generators and their applications.

What is a containerized diesel generator?

A containerized diesel generator is a power generator that produces electricity by burning diesel fuel and has been built within a standard ISO shipping container. This containerized approach has many advantages, such as mobility, easy deployment, and scalability. Containerized diesel generators are used as a backup or single power source for companies and factories that require a large amount of power. They are ideal for emergency or continuous power and can can reach a high-power output of 3000kW.

Advantages of containerized diesel generators

A canopied generator is built to protect the inside of the generator from the elements. Those units being housed within a soundproof canopy can attenuate noise effectively and are commonly used in residential, commercial and industrial applications. Compared to canopied generator sets, containerized diesel generators have the following benefits:

Easy transport

A containerized diesel generator is packaged and delivered as a complete unit within a standard ISO container, which is easy for transportation to the most remote worksites. Forklift slots and lifting eyes are also integrated, which also facilitate transportation and on-site installation. These generators can be easily transported from one worksite to the next.

Low noise level

The interior of the container adopts high frequency, medium frequency, low frequency PUR type flame retardant sound-absorbing cotton to effectively reduce the different noises emanating from various parts of the unit. The internal box-type silencer helps to attenuate exhaust noise in the roof and air in/outlet effectively. Generally, acoustically enclosed or canopied generators range from 75-85 dB(A) at one meter.

Easy installation and maintenance

The robust design of the containerized generator sets enables them to withstand harsh environments. They can operate reliably even in the hottest environments - validated at ambient temperatures of up to 50 degrees Celsius. This type of diesel generators is weatherproof and dustproof. The secure container keeps the generator in a safe, clean environment, requiring less routine checks and maintenance. The integrated ladder and 2 end doors and 2 lateral doors also simplify installation, access and maintenance of generator.

Applications of containerized diesel generators

Containerized diesel generators have been widely used in various fields due to their portability, easy installation and maintenance, high performance and other advantages. These generator sets can be used in various applications such as remote locations, disaster recovery, events, back-up power and construction sites where there is a need for reliable power supply.

Remote locations

Containerized diesel generators are suitable for use in remote locations, such as temporary camps, construction sites, military bases and areas without reliable access to the grid. It can be utilized to power a wide range of heavy duty tools and equipment.

Disaster recovery

Containerized generator are easy to transport and install, which are ideal for disaster recovery. They can provide reliable power and aid recovery after a natural disaster.

Construction sites

The durable and robust containerized generator sets are ideally suited for independent power producer (IPP), mining, oil and gas, or any project where harsh conditions, challenging environments and the demand for reliable, continuous remote power exist.

This article continues to introduce the knowledge of the crankshaft connecting rod mechanism and the crankcase ventilation device of diesel generators.

Crankshaft - flywheel group

There are seven main bearings. The fourth bearing is equipped with thrust washers. The thrust washers should be installed according to the specified method; otherwise, an incorrect axial clearance will be obtained. After installation, check the thrust clearance of the crankshaft, and the axial clearance of the crankshaft must be between 0.15 - 0.344 mm.

The front crankshaft oil seal is installed on the front oil - seal seat, and the front oil - seal seat is installed at the front end of the diesel engine block, as shown in Figure 3.10. The rear oil seal is installed on the rear oil - seal seat, and the rear oil - seal seat is installed on the flywheel housing.

When pressing in the front and rear oil seals, use special tooling to ensure that the oil seals are installed in place reliably. When tightening the front and rear oil - seal seats, tighten the bolts diagonally and cross - wise, and tighten them in two steps. The first step is to tighten to 10 - 13 N.m, and the second step is to tighten to 20 - 30 N.m. The sealing surface of the rear oil seal is mated with the timing gear. When installing the rear oil seal, first tighten the timing gear on the crankshaft with bolts to facilitate the assembly of the flywheel and prevent the O - ring from misaligning.

The flywheel is positioned and assembled with the rear flange of the crankshaft. During assembly, keep the mating surface clean and intact. Tighten the flywheel fastening bolts diagonally and cross - wise, and tighten them evenly in three steps as required in Table 2 - 5.

First step: Tighten to 150 N.m.

Second step: Tighten to 300 N.m.

Third step: Tighten to (520 - 560) N.m.

Note: After each tightening, rotate the crankshaft to check its flexibility.

The crankshaft pulley damper is connected to the crankshaft with bolts. Tighten the bolts diagonally and cross - wise, and also tighten them in three steps according to the requirements in Table 2 - 5.

When the engine is working, a part of the combustible mixture and exhaust gas leaks into the crankcase through the piston rings. The gasoline vapor that leaks into the crankcase will condense and dilute the engine oil, deteriorating its performance. The exhaust gas contains water vapor and sulfur dioxide. The water vapor will condense in the engine oil to form foam, which will disrupt the oil supply. This phenomenon is particularly serious in winter. Sulfur dioxide reacts with water to form sulfurous acid, and sulfurous acid reacts with oxygen in the air to form sulfuric acid. The presence of these acidic substances not only deteriorates the engine oil but also corrodes the parts. Due to the leakage of the combustible mixture and exhaust gas into the crankcase, the pressure in the crankcase will increase, and the engine oil will leak out from the crankshaft oil seal, the crankcase gasket, etc. The engine - oil vapor that leaks into the atmosphere will increase the engine's pollution to the atmosphere. Installing a crankcase ventilation device on the engine can avoid or mitigate the above - mentioned phenomena. Therefore, the functions of the engine crankcase ventilation device are: 1) to prevent the engine oil from deteriorating; 2) to prevent the crankshaft oil seal and the crankcase gasket from leaking.

The oil - gas separator is installed on the tappet - chamber cover on the right side of the front section of the engine block. When the engine is working, the oil - gas mixture that leaks into the crankcase enters the oil - gas separator through the pipeline. The oil - gas separator separates the oil and gas sucked from the crankcase, allowing the liquid oil to flow back to the oil pan and discharging the gaseous oil - gas mixture. This can reduce the consumption of engine oil.