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Unveiling the Technology: How Industrial Diesel Generators Work

Industrial diesel generators, also referred to as diesel generators or gensets, are machines designed to generate electricity in industrial settings or at large commercial facilities and construction sites, and to provide backup power for critical applications. It operates on the principle of converting the chemical energy stored in diesel fuel into electrical energy through a combination of a diesel engine and an alternator or generator.

Alternators produce alternating current (AC) when rotated by the diesel engine and generators produce direct current (DC). Typically, industrial diesel generators are configured with alternators, and they produce three-phase AC electrical power. The heart of industrial diesel generators is an internal combustion engine, which burns diesel fuel to produce mechanical energy. Diesel engines are renowned for their reliability, durability, and fuel efficiency, making them a good solution for providing both continuous and standby power generation.

In this article, we’ll look at a few aspects of industrial diesel generators you need to consider, such as control systems used to operate them and noise attenuation, as well as how to select the right industrial diesel generator for your needs.

Control Systems for Industrial Diesel Generators

Industrial diesel generators are equipped with control panels that allow operators to start, stop, and monitor the generator. Controllers may be simple with features such as voltage regulation, frequency control, and safety shutdown mechanisms, or they may have sophisticated programmable logic control devices (PLCs).

A sophisticated PLC allows for remote monitoring and control of the generator system via computer interfaces, mobile apps, or web-based platforms. Operators can remotely check the generator’s status, start or stop it, and receive alerts or notifications in real-time. The distribution of power to various loads can be managed and critical systems can be prioritised during periods of high demand. It can also implement load-shedding strategies to prevent overloading and protect the generator. The generator can be automatically started or stopped in response to power outages or several other triggers, including low voltage or scheduled maintenance. Automatic shutdown can be initiated when grid power is restored or when certain conditions are met. Where multiple generators are used in parallel, the PLC can synchronise their operation to ensure they work together seamlessly, maintaining frequency and phase synchronisation.

Other features provided by sophisticated PLCs include fuel management, starter battery monitoring, fault detection and diagnostics, data logging, automatic test and exercise modes, and energy management.

Industrial Diesel Generators and Noise Attenuation

Large industrial diesel generators are noisy, with the general rule being that the larger they are, the noisier they will be. Noise attenuation for generators is typically required in situations where the noise generated by the generator will pose a significant disturbance. The noise level may be high enough to cause health and safety risks and legal compliance issues. Diesel generators can be made “silent” or less noisy through a combination of design and engineering measures aimed at reducing noise levels. These measures are known as noise attenuation or soundproofing.

The most effective way to reduce noise from industrial diesel generators is by enclosing them in a soundproof housing or enclosure. Enclosures are typically made of steel or aluminum and lined with acoustic insulation that absorbs and dampens sound waves to prevent them from escaping the enclosure. In addition to the enclosure itself, acoustic barriers or shields may be installed around the generator to further block noise. These barriers may be erected to create a soundproof zone around the generator. The design of the exhaust systems of diesel engines is critical to the amount of noise the genset produces. Careful exhaust design using mufflers or silencers can bring about significant reductions in the noise produced by exhaust gases.

Various other steps can be taken to reduce noise as much as possible, including vibration isolation, low-noise cooling fans, and electronic noise reduction.

Noise-attenuated industrial diesel generators are typically required at several sites and facilities. For example, construction sites in urban or suburban areas often require generators to power tools and equipment. Noise-attenuated generators are needed to help minimise noise experienced by occupants and residents close to the construction site. Outdoor events, concerts, festivals, and film productions invariably need noise-attenuated generators to prevent noise disturbance during these activities. Hospitals, clinics, and medical centers use industrial diesel generators for backup power during grid failures. Noise attenuation is critical in healthcare settings to ensure a quiet and stress-free environment for patients and medical staff.

Selecting the Right Industrial Diesel Generator for Your Needs

Industrial diesel generators are valued for their reliability and ability to provide a stable source of power in situations where grid power is unavailable or unreliable, or during emergency situations such as technical faults and natural disasters. They are commonly used in manufacturing plants, data centers, hospitals, construction sites, remote locations, and other environments where a consistent power supply is essential. Industrial diesel generators can range from several kilowatts to several megawatts in capacity, depending on the specific application and site requirements.

Selecting the right industrial diesel generator requires careful consideration of various factors to make sure that the generator meets your operational needs.

Determine the total electrical load (in kilowatts or megawatts) that the generator needs to support. Consider both the continuous power requirements and any peak or surge loads. Typically, some form of power-measuring data logger will be needed to draw an accurate load profile and establish what the peak demand of the facility is.

Identify which loads are critical to operations and which can be left unpowered during power interruptions (non-critical loads). Industrial diesel generators can use a significant amount of diesel so check that diesel fuel is readily available in your location.

Choose a generator of the correct capacity for the site’s power requirements. Both oversizing or undersizing an industrial diesel generator can lead to negative consequences. Oversized generators run inefficiently and running at very low load levels can damage the diesel engine, and undersized generators cannot supply enough power to meet the loads.

Determine whether a standby generator or a prime generator is required. Prime generators are designed for continuous use while standby generators are for intermittent, backup use. Make sure that the physical space available for the generator includes clearance for maintenance and sufficient ventilation. Ensure the generator’s location allows for safe fuel storage.

Specifying Industrial Diesel Generators Requires Experience and Expertise

Selecting the right industrial diesel generator is a crucial decision as it directly impacts your ability to maintain power during outages and other critical situations. If you don’t have the knowledge and experience, get professional assistance and then make an informed decision.

 

Purchase your generators from a recognised industry leader. We at PacB are a leader in the Southern African power-provision industry. When it comes to industrial diesel generators, specialist knowledge on unit sizing, fuel type, noise attenuation, system configuration, and programmable logic controllers (PLCs) is required. All these factors need to be thoroughly understood and matched to site-specific electrical architecture and power-provision requirements. We have expert knowledge and experience on power provision and generators. Initially focused on building state-of-the-art, large, industrial diesel generators, we have grown into an industry expert in renewable power generation and UPSes as well. Contact us today to ensure continuous electrical power.