How to Design a Containerized Diesel Generator Set?

Containerized diesel generator sets are compact, high-efficiency, and easy-to-transport power supply devices that are widely used in locations requiring emergency backup power or temporary power sources, especially in remote areas with unstable grid power or no access to the grid. As a self-sufficient power solution, the containerized diesel generator set not only needs to meet power output requirements but also needs to consider various environmental factors, equipment configuration, and safety protections to ensure its stability and efficiency in different operating conditions.

This article will explore the key elements in the design of containerized diesel generator sets, from power output and interface configuration to noise reduction, protection, fuel tank and drainage design, providing practical guidance for designers to make informed decisions in actual projects.

 

The primary task of a containerized diesel generator set is to provide stable power output, making power output design one of its core elements. During this process, designers need to consider not only the load requirements of the equipment but also ensure interface compatibility with other systems to support future expansions and maintenance.

 

Containerized diesel generator sets typically use efficient diesel engines in conjunction with generators, providing power output in various capacities. Common power ranges vary from tens of kilowatts to several hundred kilowatts, with the specific power selection depending on the actual load demand. The design should fully consider the generator's load characteristics, such as rated power, overload capacity, and maximum starting current, to ensure the generator can operate stably and handle sudden load fluctuations.

Additionally, the generator set's control system should be equipped with automatic load adjustment functions to ensure quick power output adjustments during load changes, preventing the generator from overloading or shutting down due to uneven or rapid load variations.

 

Designers need to define the interface standards between the diesel generator set and other electrical equipment to ensure the power and control systems can connect effectively. The electrical interfaces inside the container should reserve appropriate connection ports, typically including high and low-voltage power output interfaces, to allow connections to other equipment. Control and monitoring system interfaces should also account for potential future equipment expansions and technology upgrades.

The containerized diesel generator set must address compatibility issues, such as connections with distribution systems, automation monitoring systems, and remote operation systems, minimizing additional engineering costs and operational complexity during future equipment upgrades or expansions.

 

The noise produced by diesel generator sets during operation is another major challenge that must be considered in the design. This is particularly crucial in noise-sensitive areas such as residential districts, hospitals, and schools, where effectively reducing noise is vital to protect the environment and personnel. Noise reduction design is not only an environmental issue but also involves the operational safety, health, and comfort of the equipment.

 

Generally, diesel generator sets produce high noise levels, especially under heavy loads, where noise can exceed 85 decibels or more. Prolonged exposure to noise levels above 85 decibels can harm human health. Therefore, noise reduction in containerized diesel generator sets requires the use of efficient sound-absorbing materials and soundproof enclosures to reduce noise propagation.

During the design process, the enclosure is typically made from multi-layer composite materials with sound-absorbing functions, and the container is fitted with soundproof cotton or sound-absorbing panels. At the same time, air circulation should be considered to avoid overheating the generator due to the use of noise reduction materials. By installing efficient soundproof walls and absorption modules inside the container, noise levels can be reduced to a reasonable range, typically between 70-75 decibels, meeting most workplace noise requirements.

 

In addition to noise reduction, ventilation design is also an essential factor influencing the performance of the diesel generator set. Diesel generators produce significant amounts of heat during operation, and poor heat dissipation may lead to overheating, affecting the stability and lifespan of the unit. Therefore, the ventilation system design of the container must plan the airflow path carefully to ensure adequate cooling.

Typically, special attention is paid to the intake and exhaust ports of the containerized diesel generator set to ensure smooth air flow. The intake should be positioned away from dusty or sand-prone areas, and the exhaust port should be properly arranged to expel hot air effectively while minimizing environmental impact.

 

Containerized diesel generator sets are usually equipped with a daily fuel tank to store diesel, ensuring the unit can operate continuously without external refueling for a certain period. The design of the fuel tank directly impacts the generator's endurance, safety, and ease of maintenance.

 

The capacity of the daily fuel tank is typically designed based on the required operating time. Generally, the fuel tank should support at least 8 hours of operation. To reduce refueling frequency, the tank capacity can be appropriately increased, especially in remote areas or locations with limited fuel supply, as a larger fuel tank can significantly extend the generator's autonomous running time.

 

Water or contaminants may accumulate inside the daily fuel tank. Therefore, the design should include a drainage system to remove any water or impurities. The bottom of the fuel tank should feature a drainage outlet for timely expulsion of contaminated or water-accumulated fuel. The drainage system should also include a filtration device to prevent contaminants from entering the fuel, ensuring the proper operation of the generator set.

The waste disposal system is also crucial, as it prevents contaminants from affecting the diesel system and ensures that the generator's fuel system remains in good condition over the long term. Additionally, drainage and waste pipes should be positioned safely outside the container to avoid any leaks or contamination.

 

The design of the containerized diesel generator set must take into account the potential exposure of the equipment to harsh environmental conditions. Whether in extreme cold, extreme heat, or windy and dusty environments, protective measures are key to ensuring the long-term stable operation of the equipment.

 

When designing containerized diesel generator sets, specific protective measures should be taken based on the climate conditions of different regions. For example, the humid and rainy climates of the southern regions require enhanced waterproof and anti-corrosion designs, while the cold northern climates demand efficient heating systems inside the container to prevent difficulty in starting the diesel engine.

 

To enhance fire safety, many designs incorporate automatic fire extinguishing systems, ensuring that firefighting equipment activates promptly in the event of a fire. Commonly used fire suppression systems include FM-200, CO2, or other clean agent systems that can effectively extinguish fires without the use of water. Furthermore, the container should be equipped with fire alarms and temperature sensors to provide early warning and automatically trigger emergency protocols.

 

The low-voltage distribution system and operating space design of containerized diesel generator sets are crucial for the ease of operation and maintenance. A well-designed distribution system not only ensures a stable power supply to external loads but also facilitates daily monitoring and maintenance of the equipment.

 

The low-voltage distribution system is an indispensable part of containerized diesel generator sets, primarily used to distribute the power generated by the unit to external loads or equipment. The low-voltage distribution panel should be installed in an easily accessible location and be equipped with necessary protective devices, such as circuit breakers and overload protectors, to ensure the safety of the power system.

 

When designing the container, adequate consideration must be given to the space requirements of operation and maintenance personnel. The control panels, distribution boxes, and monitoring devices should be positioned for ease of operation, and enough space should be reserved to allow for daily inspection, maintenance, and replacement of components.

 

Compared to open-frame diesel generator sets, containerized models offer distinct advantages and are suitable for different applications.

 

Compactness: The containerized design integrates the diesel generator set, control system, fuel tank, noise reduction features, and other functional modules into a single enclosed container, providing excellent protection and making it suitable for various harsh environments.

Ease of Transport and Installation: The standardized design of containerized sets makes them easy to transport and allows for quick installation and commissioning, reducing on-site construction time and costs.

 

High Flexibility: Open-frame diesel generator sets typically offer more space for maintenance and expansion, making them suitable for areas that require regular servicing or large equipment spaces.

Lower Cost: Without the protective casing, open-frame generator sets are less expensive to manufacture, making them ideal for permanent installations.

 

Containerized diesel generator sets have become the ideal choice for emergency power and independent power systems in industries such as construction, telecommunications, energy, and many others due to their high integration, excellent protection, effective noise reduction, and ease of transport and installation. In the design process, key factors such as power output and interface configuration, noise reduction and ventilation systems, fuel tank capacity and drainage, protective safety measures, and maintenance space must be carefully considered to ensure stable and efficient operation in complex environments.

Compared to traditional open-frame generator sets, containerized generator sets offer significant advantages in safety, mobility, and environmental adaptability, making them particularly suitable for remote projects, field construction, and temporary power supply needs. With proper design and optimization, these systems can enhance reliability, extend service life, and reduce operating and maintenance costs effectively.