Containerized Diesel Genset

Overview

A containerized diesel genset packages a diesel engine, an AC alternator, fuel, cooling, exhaust and controls inside a sound-attenuated ISO container so the whole unit ships as one craneable module. This 500 kVA / 400 kW class set delivers 400/415 V three-phase power at 50 Hz, with a 60 Hz variant available by running the Diesel Engine at 1800 rpm. The container does three jobs at once: it protects the machinery from weather, it cuts radiated noise to around 75 dBA at one metre, and it gives a standard footprint for transport and craning. Typical duty is standby power for hospitals, data centres and telecom sites, prime power for construction and mining camps off the grid, and peak shaving where utility tariffs make on-site generation worthwhile.

Engine and prime mover

The prime mover is an inline-6 turbocharged diesel of roughly 12.5 L displacement. The Cylinder Block is a grey cast-iron monobloc carrying six wet Wet Cylinder Liner bores and the Crankshaft, a forged seven-bearing shaft running in tri-metal main bearings. Each Piston and Connecting Rod couples a cooling-gallery piston to a fracture-split connecting rod. The Cylinder Head is a crossflow casting with two intake and two exhaust valves per cylinder, fed by a Common Rail Injection common rail system that holds up to 1600 bar so injection timing and quantity stay independent of engine speed. A wastegated Turbocharger with an air-to-air charge cooler raises specific output and lets the set hold its rating up to 50 degC ambient. Speed is held at exactly 1500 rpm by the Electronic Governor Actuator, which trims fuel against an electronic reference so output frequency stays within 0.5%.

Fuel consumption runs near 95 L/h at 75% load and about 125 L/h at full load, so the 2,000 L Base Fuel Tank in the skid gives roughly 16 hours at full load before refuelling. The Fuel Transfer Pump lifts fuel into the 200 L Day Tank, whose Fuel Level Float Switch pair starts and stops transfer to keep a steady head at the injection pump.

Alternator and power output

Mechanical power crosses the flywheel housing into the AC Alternator, a brushless four-pole synchronous machine. The electromagnetic core reuses the shared stator-assembly and rotor-assembly nodes, the same building blocks that appear in motors elsewhere in this catalogue, which is exactly the kind of cross-product reuse the BOM graph is meant to show. Excitation is brushless: the Exciter and Rotating Rectifier sits on the same shaft, and its output is rectified by the rotating Rotating Rectifier Diode bridge to feed the main field without slip rings or brushes. The Automatic Voltage Regulator regulates terminal voltage to within 1% by controlling exciter field current, and the Alternator Terminal Box carries the output busbars and three Current Transformer units for metering and protection. At 0.8 power factor the set delivers 400 kW from its 500 kVA rating.

Cooling, exhaust and ventilation

Heat rejection is the constraint that sizes a container set. The Radiator Core and belt-driven Engine Cooling Fan reject full-load engine heat while the Coolant Water Pump circulates coolant through the block and head. Two Container Ventilation Fan units purge hot air so the enclosure never starves the engine of combustion air or overheats the alternator. Exhaust leaves through a Flexible Exhaust Bellows into a Residential Silencer giving 30 to 35 dB of attenuation, then up lagged piping through the roof.

Acoustic enclosure

The Acoustic Container Enclosure is a 20 ft ISO container shell lined with perforated Acoustic Lining Panel sections backed by mineral wool. Cooling air enters through a Weather Louver and an Intake Attenuator, and leaves through a matching discharge attenuator, so airflow is never blocked even though both paths are acoustically treated. Three gasketed Access Door panels give service access to the engine, the alternator and the control end. The combined treatment brings radiated noise down to about 75 dBA at one metre and 65 dBA at seven metres, low enough for many urban and near-residential sites.

Controls and starting

The Control and Switchgear holds the Genset Controller, which sequences cranking, builds voltage, synchronises and trips on fault. An Automatic Transfer Switch watches the mains and transfers load to the genset within seconds of a utility failure, then returns it to the utility on restoration once the mains has proven stable for a set delay. The Main Circuit Breaker protects the output, and the Instrument Set reports voltage, current, frequency and running hours. Cranking comes from a 24 V Starter Motor fed by two series Starting Battery units, which a Float Battery Charger floats from the mains while idle and the Charging Alternator tops up while running.