Installation Guide for Containerized Diesel Generator Sets

Containerized diesel generator sets are highly favored in many scenarios requiring backup or temporary power due to their convenience and efficiency. However, compared to indoor units, the installation of containerized generator sets has unique requirements and steps. This article will provide a detailed introduction to the installation points of containerized diesel generator sets, covering the entire process from site preparation to final commissioning, ensuring that you can complete the installation smoothly and allow the generator set to operate safely and efficiently.

Site preparation is a crucial first step before installing a containerized diesel generator set. This not only affects the stability and safety of the generator set but also directly impacts the efficiency of subsequent installation and operation. The following are some key points for site preparation to ensure that you provide an ideal installation environment for the generator set.

Ground Levelness: First, the installation site must be level and free of standing water. The ground's load-bearing capacity is also very important and must be able to support at least 1.5 times the total weight of the generator set, including the container, generator set, fuel tank, and all other components. If the site is uneven or the load-bearing capacity is insufficient, it may cause unstable operation of the unit and even damage the equipment.

Surrounding Environment: Check the surrounding environment to ensure that the installation location is far from flammable and explosive areas, at least 5 meters away from buildings. This is for safety reasons to prevent accidents such as fires. Also, avoid obstacles that may affect the operation and maintenance of the unit, such as high-voltage lines and trees.

Concrete Foundation: The foundation is the key to the stable operation of the containerized generator set. The size of the foundation should not be smaller than the base area of the container, with a thickness of at least 300 millimeters, and the concrete strength grade should reach C25 or above. During foundation construction, anchor bolts or pedestal brackets should be embedded to securely fix the container to the foundation later.

Levelness and Drainage: The levelness error of the foundation surface should be controlled within 3 millimeters per meter to ensure the stability of the unit during operation. Also, drainage ditches should be set around the foundation with a slope of no less than 2% to prevent rainwater accumulation, which can affect the service life of the unit.

Vibration Isolation Pads or Dampers: Install rubber vibration isolation pads or dampers under the container. The vibration transmission rate should be controlled below 85%. This can effectively reduce the impact of the unit's operation vibrations on the foundation and surrounding environment, improving the stability and service life of the unit.

Lifting Equipment and Operation: Use professional lifting equipment for the lifting operation. The lifting points must be fixed according to the markings on the container to ensure the stability of the lifting process. During lifting, strictly control the tilt angle to no more than 5 degrees and then smoothly place the unit on the foundation.

Alignment and Fixing: After the unit is in place, carefully check whether the container is aligned with the foundation. After confirming that there are no errors, use bolts to securely fix the container to the foundation and grout the gaps to seal them, preventing rainwater and dust from entering.

In the installation process of containerized diesel generator sets, the installation of the foundation system is the cornerstone for ensuring the stable operation of the unit, while the installation of the electrical system, fuel system, and exhaust system are key to ensuring the normal operation of the unit.

Cable Introduction and Tray: Power cables are introduced into the container through waterproof conduit. There should be a certain amount of expansion allowance between the cable tray and the container to cope with the effects of thermal expansion and contraction. At the same time, the cable heads should be waterproofed to prevent moisture ingress that could cause short circuits or damage.

Grounding Connection: The grounding wire should be connected to the foundation grounding grid, with the grounding resistance controlled below 4 ohms. Good grounding can effectively prevent electrical faults and lightning strikes from causing harm to the unit and personnel.

Fuel Pipeline Layout: The external fuel pipeline should be no less than 3 meters away from the container and connected with seamless steel pipes and fire-resistant hoses. The slope of the fuel pipeline should be no less than 1%, sloping towards the fuel tank to ensure that fuel flows smoothly to the generator set.

Fuel Tank Accessories: The fuel tank should be equipped with a breather valve and a fuel level sensor. The breather valve can prevent excessive or insufficient pressure inside the fuel tank, while the fuel level sensor can monitor the fuel level in real-time, facilitating timely fuel replenishment.

Exhaust Pipe Installation: The exhaust pipe is led out through a reserved hole in the container, using high-temperature resistant corrugated pipes and mufflers. The height of the outdoor exhaust outlet should be no less than 3 meters, and a rain cap should be installed to prevent rainwater from backflowing into the exhaust system.

Support and Fixation: The support spacing of the exhaust pipe should not exceed 2 meters to prevent sagging of the exhaust pipe, which could affect exhaust efficiency. At the same time, ensure that the connections of the exhaust pipe are secure to prevent loosening due to vibration or thermal expansion and contraction.

In addition to the installation of the foundation system, there are other important installation requirements in the process of installing containerized diesel generator sets. These requirements involve ventilation and heat dissipation, noise control, grounding, and lightning protection to ensure the efficient operation and safety of the unit. The following are detailed explanations of these aspects.

Air Inlet and Outlet: The air inlet of the container is located at the lower side and is equipped with a dust-proof net to prevent dust from entering the unit. The exhaust outlet is located at the top, and its area should be no less than 1.2 times the heat dissipation requirement of the generator set. In high-temperature areas, forced exhaust fans can also be installed to improve heat dissipation efficiency.

Protection Level: The protection level of the forced exhaust fan should reach IP55 to prevent dust and water from entering the fan and affecting its normal operation.

Sound Insulation and Muffling: The interior of the container should be lined with sound insulation cotton no less than 50 millimeters thick, and mufflers should be installed on the exhaust pipes. Through these measures, ensure that the noise level at a distance of 1 meter from the unit does not exceed 75 decibels. If the noise is still too loud, a sound barrier can be added around the unit, with a height of no less than 1.5 times the height of the container.

Grounding Requirements: The container shell, generator set casing, and cable armor layer all need to be grounded. The cross-sectional area of the grounding wire should be no less than 25 square millimeters of copper wire to ensure the reliability and safety of the grounding.

Lightning Protection Measures: Install a lightning rod on the top of the container or connect it to the building's lightning protection network, with the impulse grounding resistance controlled below 10 ohms. This can effectively prevent lightning strikes from causing damage to the unit and surrounding equipment.

After completing the installation of the generator set, commissioning and testing are key steps to ensure that the unit can operate safely and stably. The work at this stage aims to verify whether the performance of the generator set meets the design requirements and whether the automation functions are normal. The following are the specific contents of commissioning and testing.

Test Content: Start the generator set and run it no-load for 30 minutes to check whether the voltage (allowable deviation ±2%), frequency (allowable deviation ±1 hertz), oil pressure, etc., are normal. Through the no-load test, the initial judgment of the unit's operating condition can be made.

Test Process: Gradually increase the load to 100% of the generator set's rated load in stages and run continuously for 2 hours. During the test, closely monitor the unit's temperature, vibration, and exhaust color. If any abnormal conditions are found, the unit should be shut down immediately for inspection and troubleshooting.

Function Test: Test the ATS (Automatic Transfer Switch) automatic switching function, remote monitoring function, and fault alarm function of the unit. Ensure that these automation functions operate normally, enabling the unit to start, switch, and alarm automatically in unattended conditions, thereby improving the reliability and operating efficiency of the unit.

After the installation and commissioning of the generator set, safety and maintenance are important guarantees for the long-term stable operation of the unit. Reasonable safety measures and regular maintenance work can not only extend the service life of the unit but also effectively prevent potential safety risks. The following are specific requirements for safety and maintenance.

Safety Distance: The distance between the container and the fence or building should be no less than 5 meters, and the distance from trees or overhead lines should be no less than 10 meters. The exhaust outlet should avoid personnel activity areas, fresh air inlets, and sensitive equipment to prevent exhaust from adversely affecting people and equipment.

Sealing and Reinforcement: Use waterproof sealant to seal gaps in the container door, cable holes, and other areas. Install rainproof louvers on the bottom ventilation openings. In coastal or windy areas, reinforce with expansion bolts or ground stakes to prevent the unit from being blown over. In areas with seismic intensity of 7 or above, take corresponding seismic measures to ensure the safety of the unit during an earthquake.

Fire Extinguishers and Fire Sand Boxes: Equip the outside of the container with more than two 8-kilogram dry powder fire extinguishers (MF/ABC) and set up a fire sand box nearby. In flammable areas, flame detectors can also be installed and connected to an automatic fire extinguishing system to increase the fire safety factor.

Operation and Maintenance Space: Reserve an operation space of no less than 1.5 meters wide on the side of the container door and a maintenance space of no less than 1 meter at the top. At the same time, the control panel, oil filter, battery, and other easily maintained parts should face the passage side for convenient daily maintenance and inspection work.

In summary, the installation of containerized diesel generator sets involves multiple links and details, which must be strictly carried out according to the relevant requirements. From site preparation to foundation construction, from electrical system connection to ventilation and heat dissipation, noise control, and finally to commissioning and testing, each step is crucial. Only by ensuring that every link is properly done can the containerized diesel generator set operate safely, stably, and efficiently, providing reliable power support for your production and living.