High Power Diesel Generator Set

The high power diesel generator set made in China by Kecheng can meet the needs of heavy load start and continuous operation. It integrates the self-developed high-voltage intelligent controller to support multi-machine parallel connection and high-voltage monitoring, and the operation is stable and reliable. The protective structure of the equipment is sturdy and can adapt to different environmental conditions. The product strictly adheres to national technical standards. Core components are provided with a longer warranty period, and the greater the power, the longer the warranty time. It can be well adapted to the main, backup or peak shaving power supply in large factories, mines, heavy infrastructure, energy bases and other places, especially suitable for heavy-load application scenarios with high standards and continuous requirements for power supply. As a domestic factory, Kecheng is committed to providing professional power supply solutions for such critical demands.

The Kecheng 800-3000KW high-power diesel generator sets are core equipment developed in response to the demands of "industrial heavy-duty power supply + energy system guarantee", covering three power ranges: 800-1500KW (large), 1500-2000KW (super-large), and 2000-3000KW (heavy-duty) as follows:

Application scenarios (High-power dedicated adaptation)

1. Large-scale industrial manufacturing scenarios (800-2000KW)

• Applicable scenarios: Automotive vehicle manufacturers (stamping production lines, welding robot groups), metallurgical plants (blast furnace fans for steelmaking, steel rolling equipment), chemical industrial parks (large reaction vessels, circulating water pump clusters)

• Core value: Can withstand three times the rated starting current (compatible with heavy-duty motor equipment, such as a 2000KW unit can start a 6000KW motor), preventing the unit from going out. Supports 24-hour continuous full-load operation (annual operation time ≥ 8,000 hours) to ensure that the production line is not interrupted. It can be linked with the factory DCS system to achieve "load adjustment as needed", with an annual energy-saving rate of 8% to 12%.

2. Super-large data center scenarios (1500-3000KW)

• Applicable scenarios: Cross-border cloud computing centers (100,000 + cabinet server clusters, 10kV/35kV high-voltage power distribution), financial data centers (backup power supply for core trading systems, zero interruption requirements)

• Core value: The high-voltage models (10kV/35kV) are directly connected to the high-voltage power distribution system of the data center, reducing step-down losses (saving 5%-8% energy compared to low-voltage units). High power quality (voltage distortion rate ≤2%, frequency stability ≤±0.1Hz), protecting precision servers; Supports parallel connection of multiple units (such as three 1000KW units working in tandem), meeting the expansion requirements of data centers. The failure of a single unit does not affect the overall power supply.

3. Mining and resource development scenarios (1000-2500KW)

• Applicable scenarios: Open-pit mines (mining crushers, charging systems for mining trucks), underground coal mines (ventilators, drainage pumps, explosion-proof types), non-ferrous metal mines (mineral processing equipment, smelting furnaces)

• Core value: The explosion-proof model complies with the Ex dⅡB T4 standard and is suitable for flammable and explosive environments in mines; The engine adopts "heavy oil/diesel dual-fuel switching" (optional), which can reduce the cost of fuel transportation for remote mines. The body is made of high-strength manganese steel (impact-resistant and corrosion-resistant), capable of withstanding the harsh working conditions of mine dust and vibration, with an MTBF of ≥ 15,000 hours.

4. Port and heavy Infrastructure scenarios (800-2000KW)

• Applicable scenarios: International ports (container quay cranes, gantry cranes), cross-sea Bridges (bridge lighting, monitoring systems, wind-resistant equipment), railway hubs (high-voltage traction power supply backup for high-speed railway stations)

• Core value: Resistant to "frequent start-stop + fluctuating load" (such as intermittent operation of quay cranes), unit response speed ≤1 second, avoiding voltage fluctuations; The high-voltage output (10kV) is compatible with the high-voltage distribution network of ports, reducing the configuration of transformers. IP54 protection (IP65 for some models), suitable for high salt spray and humid environments in ports, no worries about downtime throughout the year.

5. Energy Base and Peak Shaving Scenarios (1500-3000KW)

• Applicable scenarios: Photovoltaic/wind farms (backup power sources for energy storage to make up for intermittent power generation gaps), gas power stations (peak shaving backup units to smooth out grid load fluctuations), independent power grids in remote areas (such as islands, plateaus, main power supply)• Core value: Peak shaving response time ≤10 seconds, which can quickly fill the load gap of the power grid (such as when wind power drops sharply); The power correction factor for the high-altitude model (at an altitude of 5,000 meters) is ≥0.85, and the start-up success rate for the low-temperature model (at -30℃) is ≥99%. Support the linkage with the power grid dispatching system to achieve "peak-valley electricity price optimization" and reduce energy operation costs.

Product advantages (High-power core competitiveness)

Technical parameters (Full power range of 800-3000KW)

Technical features (High-power exclusive design)

1. Enhanced power system

• Engine optimization:

① 800-1500KW: Yuchai YC6C adopts "high-pressure common rail (2000bar) + turbocharged intercooling", which increases combustion efficiency by 15% and extends the oil change cycle to 1000 hours.

② 1500-2000KW: Cummins QSK60 features a V-type 16-cylinder structure. The cylinder block is made of vermicular graphite cast iron (with a strength 70% higher than that of ordinary cast iron), capable of withstanding heavy load impacts.

③ 2000-3000KW: MAN D2876 with exhaust after-treatment system (SCR+DPF), meeting Euro V/US Tier 4 Final emission standards, and adapting to global environmental protection requirements.

• Generator technology:

①The high-voltage generator (6kV/10kV/35kV) is insulated with epoxy glass cloth tubes, with a temperature resistance grade of H (180℃) and a short-circuit withstand time of ≥2 seconds.

② Equipped with imported excitation systems (such as Stanford, Marathon), the voltage establishment time is ≤0.3 seconds, the voltage regulation rate is ≤±0.5%, and it has strong resistance to load shock.

2. High-voltage distribution integration technology

• High-voltage switchgear: Integrated with ABB/Siemens vacuum circuit breakers and relay protection devices (overcurrent, overvoltage, grounding protection), it complies with GB 50060 "Code for Design of 3-110kV High-Voltage Switchgear Installations" and can be directly connected to the user's high-voltage power grid.

• Grid connection control: Supports grid connection with State Grid/enterprise microgrid, equipped with PCC point (common connection point) monitoring device, complies with GB/T 19939 "Technical Requirements for Grid Connection Operation of Diesel Generators", and there is no inrush current during grid connection;

• Insulation monitoring: Real-time monitoring of the insulation resistance of high-voltage windings (≥100MΩ), automatic alarm when insulation drops, to prevent high-voltage breakdown accidents.

3. Intelligent Control System (KCPLC-06 High Voltage Version)

• Core functions:

① Full parameter monitoring: display high voltage/current, power factor, power generation, engine water temperature/oil pressure and other 30 + parameters, support data storage (1 year historical data);

② Multi-machine parallel operation: support 8 units parallel operation, load balance deviation ≤5% (such as 3 1000KW units with a total load of 2800KW, single load deviation ≤70KW);

③ Remote operation and maintenance: through 4G/satellite networking, it can realize remote start and stop, parameter check and fault push on mobile APP/PC, and support linkage with industrial DCS/power grid dispatching system.

④ Peak shaving optimization: automatically adjust the output power according to the peak and valley electricity price of the grid (full load at peak time, load reduction at valley time), saving 10% to 15% of the annual electricity bill.

4. Heavy-duty protection and environmental compatibility

• structure protection:

① The body frame is welded with 16Mn manganese steel (tensile strength ≥510MPa), the surface is sprayed with zinc + anticorrosive paint (rust resistance grade ≥10), salt spray test ≥1000 hours;

②  All electrical components of the explosion-proof type are Ex dⅡB T4 grade, and explosion-proof sealing joints are used for cable interfaces to avoid spark leakage;

• Adaptation to Extreme environments

① High-temperature environment (50℃) : Equipped with dual cooling towers for independent heat dissipation, the unit can operate at full load.

② Low-temperature environment (-30℃) : Install the "three preheating" system of engine oil preheater, coolant preheater and fuel heater, with a start-up success rate of ≥99%.

③ Plateau environment (5000 meters) : Optimize the intake system (increase the boost pressure by 20%), with a power correction factor of ≥0.85 to avoid power attenuation at high altitudes.

5. Long battery life and convenient maintenance

• Fuel system: Equipped with a large-capacity fuel tank of 3000-5000L (made of 304 stainless steel), providing a full-load range of 20-30 hours. Supports external oil tanks (DN100 flange interface) to achieve unlimited battery life. Dual-fuel versions (diesel/heavy oil) can be switched, and the cost of heavy oil is 30% lower than that of diesel.

• Maintenance and optimization:

① Large oil capacity (for models with a capacity of 800-1500KW, the oil capacity is 200-300L, and the oil change cycle is 1000 hours);

② The vulnerable parts (filters, belts) adopt standardized design, are compatible with international brands, and can be purchased locally.

③ The machine body is reserved with a large inspection door (width ≥1.5 meters), which is convenient for the operation of heavy maintenance tools. The inspection time is shortened by 30% compared with similar products.

Power selection (Precise matching of high power)

1.Core Selecting basis

2.Power recommendation for typical scenarios

Usage Method (Exclusive operation for High power)

1.Pre-startup inspection (carried out by a professional team, completed within 60 minutes)

2.Startup operation (available in high-voltage and grid-connected models, with two-person cooperation)

(1) High voltage non-grid-connected model (industrial main and backup power)

1. Preheating startup: the controller switches to "manual" mode, and starts the "three preheating" system (preheating in low temperature environment for 60-120 minutes, oil temperature ≥20℃);

2. Start the engine: press the "start" button (hydraulic start), observe the speed (gradually rise to 1500r/min), oil pressure (≥0.3MPa), water temperature (gradually rise to 70℃), and the parameters are stable for 10 minutes;

3. High voltage closing: Operation and maintenance personnel A confirms that the parameters are normal at the controller end, operation and maintenance personnel B operates in the high voltage switchgear: close the "disconnector" → close the "vacuum circuit breaker" → observe the high voltage voltmeter (6kV/10kV±5%);

4. Graded loading: according to "20%→50%→80%→100%" graded loading (10 minutes per stage interval), avoid impact load.

(2) Grid-connected models (Energy peak shaving/Data center)

1. Grid-connected preparation: the controller switches to the "grid-connected" mode, and sets the grid-connected parameters (voltage, frequency and phase are consistent with the grid);

2. Synchronous detection: the controller automatically detects the synchronicity of the unit and the grid (voltage difference ≤5%, frequency difference ≤0.1Hz, phase difference ≤5°), and automatically issues the grid connection instruction after meeting the conditions;

3. Automatic grid connection: The vacuum circuit breaker automatically closes, the unit is connected to the power grid, and the controller automatically adjusts the output power (according to the load demand of the power grid).

4. Operation monitoring: Real-time monitoring of grid-connected power and power factor (maintaining a lag of 0.8-0.9) to prevent overcurrent and overvoltage.

3. Operation monitoring (24-hour uninterrupted, with dedicated personnel on duty)

• Real-time monitoring: Record every 30 minutes: High voltage (6kV/10kV±5%), current (≤ rated current), frequency (50Hz±0.1Hz), engine water temperature (≤95℃), oil pressure (≥0.2MPa), insulation resistance (≥100MΩ);

• Exception handling:

① High-voltage insulation decline: Immediately reduce the load and shut down the machine, and inspect the generator windings (clean the dust and test the insulation);

② High water temperature of the engine: Clean the scale in the cooling system and inspect the cooling tower fan.

③ Grid-connected power fluctuation: Contact the power grid dispatching, adjust the output of the unit, and avoid disconnection from the grid;

• Emergency shutdown: In the event of "high-voltage short circuit", "engine runaway", or "severe oil leakage", immediately press the "Emergency Shutdown" button (cut off fuel and disconnect the high-voltage circuit breaker).

4. Shutdown operation (to avoid high-voltage accidents and component damage

1. Hierarchical unloading: For non-grid-connected models: Gradually reduce to 20% load → Unload to 0; Grid-connected models: Apply to the power grid dispatching for disconnection → The controller automatically reduces the load to 0→ Disconnect the grid-connected circuit breaker.

2. High-voltage tripping: Maintenance personnel B operates on the high-voltage switch cabinet: open the "vacuum circuit breaker" → open the "disconnector" → close the "grounding switch" (discharge).

3. Shutdown and cooling: Run the engine idle for 15 to 20 minutes (to cool the cylinder block and turbocharger), and then press the "Shutdown" button.

4. Safety closure: Close the fuel valve (for long-term shutdown), disconnect the power supply of the controller, check for any leakage or component damage in the high-pressure system, and record the operation data (power generation, fuel consumption, faults).

Safety and Protection (High Power and High Voltage Specifications)

1. Installation safety (High voltage and heavy duty specifications)

• Site selection and layout:

① The installation area should be kept away from open flames (≥15 meters) and flammable and explosive items (≥20 meters). The distance between the high-voltage switch cabinet and the unit should be ≥3 meters. A safety fence (≥1.2 meters in height) should be set up and a "High Voltage Danger" sign should be hung.

② The ground load-bearing capacity should be no less than 1.5 times the weight of the unit (for example, for a 20,000kg unit, it should be no less than 30,000kg /㎡). A reinforced concrete foundation (with a thickness of no less than 500mm) should be adopted, and spring vibration isolators should be installed between the foundation and the unit (to reduce vibration transmission).

③ High-voltage cable laying: Use cable trenches (with sand and bricks) or pass through galvanized steel pipes (wall thickness ≥5mm), and match the cable cross-section (for example, for 10kV/2000KW models, ≥120mm² copper cables are required) to avoid mechanical damage.

• High-voltage safety

① Grounding of the unit: The grounding resistance on the high-voltage side should be ≤10Ω, and on the low-voltage side, it should be ≤4Ω. It should be connected to an independent grounding grid (with a distance of ≥5 meters from the grounding grids of other equipment).

② Insulation test: After installation, use a 2500V megohmmeter to test the insulation resistance of the high-voltage winding (≥100MΩ). Only after passing the test can power be applied.

③ Lightning protection: Install lightning rods (protection radius ≥ 1.5 times the size of the unit) and lightning arresters (parallel on the high-voltage side) to prevent damage to high-voltage components by lightning strikes.

• Fire protection configuration:

①The installation area is equipped with 4 8kg ABC dry powder fire extinguishers, 2 CO₂ fire extinguishers (specifically for high-pressure equipment), and 1 fire sandpit (with a volume of ≥5m³).

② The fuel tank is independently set up (at least 15 meters away from the unit), equipped with an anti-seepage pool (laid with HDPE anti-seepage membrane), and fitted with a liquid level gauge and an emergency shut-off valve.

③ Develop a fire emergency response plan and organize a fire drill once every quarter (with the full participation of the operation and maintenance team).

2. Operational Safety (High Voltage and Heavy Duty Risk Control)

• Personnel requirements:

①Operators must hold the "High Voltage Electrician Certificate" and the "Special Equipment Operator Certificate (Heavy Duty Unit)", and pass the assessment after 32 hours of specialized training by Kecheng before taking up their posts.

② High-voltage operation requires the cooperation of two people (one person operates and one person supervises). Before operation, fill out the "High-voltage Operation Ticket", and after confirming that there are no errors, proceed.

③When operating, wear high-voltage insulating clothing, insulating shoes and insulating gloves (with a withstand voltage level of ≥10kV), and use insulating tools (which have passed the withstand voltage test and are within the validity period).

• Operating contraindications:

① Unlicensed personnel and those who have drunk alcohol are prohibited from operating the high-voltage system.

② Do not pull the disconnector under load (to avoid arc burns and equipment damage).

③ It is strictly prohibited to disassemble high-pressure components or touch high-temperature parts (such as exhaust pipe temperature ≥500℃) when the unit is in operation.

④ High-voltage operations are strictly prohibited during thunderstorms. The high-voltage power supply must be disconnected and grounded for discharge.

• Emergency response:

① High-voltage leakage: Immediately press the "Emergency Stop" button → put on insulating equipment → Use an insulating rod to disconnect the high-voltage switch → Ground discharge → locate the leakage point (such as cable damage, winding breakdown).

② Fuel leakage: Shut down the machine → Close the fuel valve → Start the exhaust system (explosion-proof model) → Clean with oil-absorbing cotton and fire-fighting sand → Check the leakage point (such as flange gasket, oil pipe rupture).

③ Fire accident: Shut down the machine → Disconnect the high-voltage power supply → Use dry powder/CO₂ fire extinguishers to put out the fire → Call 119→ Evacuate people → Isolate flammable materials around.

3. Maintenance of safety (Exclusive for high-voltage and heavy-duty components

• Preparations before maintenance:

① Disconnect the main power supply of the unit (both high-voltage and low-voltage switches are open), close the fuel valve, and hang a warning sign that reads "Under maintenance, do not start".

② For the high-voltage system, close the "grounding switch". After confirming that there is no electricity with a voltage detector, carry out maintenance.

③ Prepare maintenance tools (insulating wrenches, high-voltage testing instruments, heavy lifting equipment), spare parts (original high-voltage components from Kecheng, sealing gaskets), and protective equipment (insulating gloves, goggles, safety helmets).

• Maintenance operation specifications:

① Engine maintenance: When changing the engine oil, use a dedicated oil pump (heavy-duty models have a large oil volume), and hand over the old engine oil to a qualified institution for disposal. To adjust the valve clearance, a torque wrench (according to the original factory standard torque) is required.

② High-voltage generator maintenance: Clean the winding dust (using compressed air at 0.3MPa), test the insulation resistance (≥100MΩ), and replace the excitation carbon brush (wear ≤1/3).

③ Maintenance of high-voltage switch cabinets: Clean the contacts of vacuum circuit breakers (sand them with fine sandpaper and apply conductive paste), and calibrate relay protection devices (such as overcurrent setting and tripping time).

• Professional maintenance

① Complex maintenance such as engine depth inspection (cylinder pressure, injector atomization), high-voltage generator insulation repair, and grid connection system calibration must be carried out on-site by Kecheng after-sales engineers (high-voltage certified) (once a year, free service).

②After maintenance, a "load test" (loading to 80% of the rated power and running for 2 hours) must be conducted. Only when the monitoring parameters are normal and the high-voltage insulation is qualified can it be put into operation.

Maintenance Cycle Table (for High Power)