GENERATING SET

INSTALLATION
MANUAL
 FOREWORD

This installation manual will guide you to the factors to be considered in the
installation of your diesel generator system. It discusses location and mounting
of the generating set; size of room; ventilation and air flow; engine cooling water
supply or radiator location; exhaust outlet; fuel tank and fuel transfer system.

By following the suggestions in this installation manual, you will be able to plan
an economical, efficient generating set installation with operating characteristics
suitable to each particular application.

You can make you work easier by enlisting the aid of an FG Wilson Distributor
when planning your generating set installation. Getting his advice early may save
cost and avoid problems. He knows engines, electrical equipment, local laws and
insurance regulations. With his help, you can be sure your generating set
installation will fulfil your needs without unnecessary cost.

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 TABLE OF CONTENTS

PAGE
1. INSTALLATION FACTORS 1
2. MOVING THE GENERATING SET 1
3. GENERATING SET LOCATION 1
4. GENERATING SET MOUNTING 2
5. VENTILATION 3
6. ENGINE EXHAUST 6
7. EXHAUST SILENCING 9
8. SOUND ATTENUATION 10
9. ENGINE COOLING 10
10. FUEL SUPPLY 13
11. SELECTING FUELS FOR STANDBY DEPENDABILITY 18
12. TABLES AND FORMULAS FOR ENGINEERING STANDBY 19
GENERATING SETS:
Table 1 Length Equivalents 19
Table 2 Area Equivalents 19
Table 3 Mass Equivalents 19
Table 4 Volume and Capacity Equivalents 20
Table 5 Conversions for Units of Speed 20
Table 6 Conversions of Units of Power 20
Table 7 Conversions for Measurements of Water 21
Table 8 Barometric Pressures and Boiling Points of Water at Various Altitudes 21
Table 9 Conversions of Units of Flow 22
Table 10 Conversions of Units of Pressure and Head 22
Table 11 Approximate Weights of Various Liquids 22
Table 12 Electrical Formulae 23
Table 13 kVA/kW Amperage at Various Voltages 24
Conversions of Centigrade and Fahrenheit 25
Fuel Consumption Formulas 25
Electrical Motor Horsepower 25
Piston Travel 25
Break Mean Effective Pressure 25

13. GLOSSARY OF TERMS 26

 Copyright 1997 by FG Wilson (Engineering) Ltd

All rights reserved. No part of the contents of this manual may be reproduced, photocopied or transmitted
in any form without the express prior written permission of FG Wilson (Engineering) Ltd.
1. INSTALLATION FACTORS Never lift the generating set by attaching to the
engine or alternator lifting lugs!
Once the size of the generating set and the required
For lifting the generating set, lift points are
associated control panel and switchgear have been
provided on the baseframe. Shackles and chains of
established, plans for installation can be prepared.
suitable length and lifting capacity must be used
Proper attention to mechanical and electrical
and a spreader bar is required to prevent damaging
engineering details will assure a satisfactory power
the set. See figure 2.1. An optional "single point
system installation.
lifting bale" is available if the generating set will be
regularly moved by lifting.
Factors to be considered in the installation of a
generator are:
3. GENERATING SET
Access and maintenance location.
Floor loading. LOCATION
Vibration transmitted to building and equipment.
Ventilation of room. The set may be located in the basement or on
Engine exhaust piping and insulation. another floor of the building, on a balcony, in a
Noise reduction. penthouse on the roof or even in a separate
Method of engine cooling. building. Usually it is located in the basement for
Size and location of fuel tank. economics and for convenience of operating
Local, national or insurance regulations. personnel. The generator room should be large
Smoke and emissions requirements. enough to provide adequate air circulation and
plenty of working space around the engine and
alternator.
2. MOVING THE GENERATING If it is necessary to locate the generating set
SET outside the building, it can be furnished enclosed in
a housing and mounted on a skid or trailer. This
The generating set baseframe is specifically type of assembly is also useful, whether located
designed for ease of moving the set. Improper inside or outside the building, if the installation is
handling can seriously damage the generator and temporary. For outside installation the housing is
components. normally "weatherproof". This is necessary to
prevent water from entering the alternator
Using a forklift,the generating set can be lifted or compartment if the generating set is to be exposed
pushed/pulled by the baseframe. An optional "Oil to rain accompanied by high winds.
Field Skid" provides fork lift pockets if the set will
be regularly moved.

FIG 2.1. PROPER LIFTING ARRANGEMENT

1
4. GENERATING SET discharge duct, conduit for control and power
cables and other externally connected support
MOUNTING systems.

The generating set will be shipped assembled on a 4.2 Floor Loading

rigid base that precisely aligns the alternator and
engine and needs merely to be set in place (on Floor loading depends on the total generating set
vibration isolation pads for larger sets) and levelled. weight (including fuel and water) and the number
See figure 4.1 and size of isolator pads. With the baseframe
mounted directly on the floor, the floor loading is:
4.1 Vibration Isolation
Total Generating Set Weight
Floor Loading =
It is recommended that the generating set be Area of Skids
mounted on vibration isolation pads to prevent the With vibration isolation between the baseframe and
set from receiving or transmitting injurious or the floor, if the load is equally distributed over all
objectionable vibrations. Rubber isolation pads are isolators, the floor loading is:
used when small amounts of vibration transmission Total Generating Set Weight
is acceptable. Steel springs in combination with Floor Loading =
Pad Area x Number of Pads
rubber pads are used to combat both light and
heavy vibrations. On smaller generating sets, these Thus, floor loading can be reduced by increasing
isolation pads should be located between the the number of isolation pads.
coupled engine/alternator feet and the baseframe.
The baseframe is then securely attached to the If load is not equally distributed, the maximum floor
floor. On larger sets the coupled engine/alternator pressure occurs under the pad supporting the
should be rigidly connected to the baseframe with greatest proportion of load (assuming all pads are
vibration isolation between the baseframe and floor. the same size):
Other effects of engine vibration can be minimised Load on Heaviest Loaded Pad
Max Floor Pressure =
by providing flexible connections between the Pad Area
engine and fuel lines, exhaust system, radiator air

FIG 4.1 REDUCING VIBRATION TRANSMISSION

2
5. VENTILATION In providing ventilation, the objective is to maintain
the room air at a comfortable temperature that is
cool enough for efficient operation and full
Any internal combustion engine requires a liberal
available power, but it should not be so cold in
supply of cool, clean air for combustion. If the air
winter that the room is uncomfortable or engine
entering the engine intake is too warm or too thin,
starting is difficult. Though providing adequate
the engine may not produce its rated power.
ventilation seldom poses serious problems, each
Operation of the engine and alternator radiates heat
installation should be analysed by both the
into the room and raises the temperature of the
distributor and the customer to make sure the
room air. Therefore, ventilation of the generator
ventilation provisions are satisfactory.
room is necessary to limit room temperature rise and
to make clean, cool intake air available to the
engine. 5.1 Circulation

When the engine is cooled by a set mounted Good ventilation requires adequate flow into and
radiator, the radiator fan must move large quantities out of the room and free circulation within the room.
of air through the radiator core. There must be Thus, the room should be of sufficient size to allow
enough temperature difference between the air and free circulation of air, so that temperatures are
the water in the radiator to cool the water equalised and there are no pockets of stagnant air.
sufficiently before it re-circulates through the See figure 5.1. The generating set should be
engine. The air temperature at the radiator inlet located so that the engine intake draws air from the
depends on the temperature rise of air flowing cooler part of the room. If there are two or more
through the room from the room inlet ventilator. By generating sets, avoid locating them so that air
drawing air into the room and expelling it outdoors heated by the radiator of one set flows toward the
through a discharge duct, the radiator fan helps to engine intake or radiator fan of an adjacent set. See
maintain room temperature in the desirable range. figure 5.2.

FIG 5.1 TYPICAL ARRANGEMENT FOR ADEQUATE AIR CIRCULATION AND VENTILATION

3
5.2 Ventilators Both the inlet and exit ventilators should have
louvres for weather protection. These may be fixed
To bring in fresh air, there should be an inlet but preferably should be movable in cold climates.
ventilator opening to the outside or at least an For automatic starting generating sets, if the
opening to another part of the building through louvres are movable, they should be automatically
which the required amount of air can enter. In operated and should be programmed to open
smaller rooms, ducting may be used to bring air to immediately upon starting the engine.
the room or directly to the engine's air intake. In
addition, an exit ventilator opening should be
located on the opposite outside wall to exhaust
warm air. See Figure 5.3.

FIG 5.2 TYPICAL ARRANGEMENT FOR PROPER VENTILATION WITH MULTIPLE GENERATING SETS

4
5.3 Inlet Ventilator Size and silencer so that heat radiation from this source
may be neglected in calculating air flow required for
Before calculating the inlet ventilator size, it is room cooling.
necessary to take into account the radiator cooling
air flow requirements and the fan static pressure After determining the required air flow into the
available when the generating set is operating at its room, calculate the size of inlet ventilator opening
rated load. In standard room installations, the to be installed in the outside wall. The inlet
radiated heat is already taken into account in the ventilator must be large enough so that the
radiator air flow. negative flow restriction will not exceed a maximum
of
For generator room installation with remote 10 mm (0.4 in) H2O. Restriction values of air filters,
radiators, the room cooling airflow is calculated screens and louvres should be obtained from
using the total heat radiation to the ambient air of manufacturers of these items.
the engine and alternator and any part of the
exhaust system.
5.4 Exit Ventilator Size
Engine and alternator cooling air requirements for
FG Wilson generating sets when operating at rated Where the engine and room are cooled by a set
power are shown on specification sheets. Exhaust mounted radiator, the exit ventilator must be large
system radiation depends on the length of pipe enough to exhaust all of the air flowing through the
within the room, the type of insulation used and room, except the relatively small amount that enters
whether the silencer is located within the room or the engine intake.
outside. It it usual to insulate the exhaust piping

FIG 5.3 INLET AND EXIT VENTILATORS

5
6. ENGINE EXHAUST It is not normally recommended that the engine
exhaust share a flue with a furnace or other
equipment since there is danger that back pressure
Engine exhaust must be directed to the outside
caused by one will adversely affect operation of the
through a properly designed exhaust system that
others. Such multiple use of a flue should be
does not create excessive back pressure on the
attempted only if it is not detrimental to
engine. A suitable exhaust silencer should be
performance of the engine or any other equipment
connected into the exhaust piping. Exhaust system
sharing the common flue.
components located within the engine room should
be insulated to reduce heat radiation. The outer
The exhaust can be directed into a special stack that
end of the pipe should be equipped with a rain cap
also serves as the outlet for radiator discharge air
or cut at 60° to the horizontal to prevent rain or
and may be sound-insulated. The radiator
snow from entering the exhaust system. If the
discharge air enters below the exhaust gas inlet so
building is equipped with a smoke detection
that the rising radiator air mixes with the exhaust
system, the exhaust outlet should be positioned so
gas. See figures 6.2 and 6.3. The silencer may be
it cannot set off the smoke detection alarm.
located within the stack or in the room with its tail
pipe extending through the stack and then outward.
6.1 Exhaust Piping Air guide vanes should be installed in the stack to
turn radiator discharge air flow upward and to
For both installation economy and operating reduce radiator fan air flow restriction, or the sound
efficiency, engine location should make the exhaust insulation lining may have a curved contour to
piping as short as possible with minimum bends direct air flow upward. For a generating set
and restrictions. Usually the exhaust pipe extends enclosed in a penthouse on the roof or in a separate
through an outside wall of the building and outdoor enclosure or trailer, the exhaust and
continues up the outside of the wall to the roof. radiator discharges can flow together above the
There should be a sleeve in the wall opening to enclosure without a stack. Sometimes for this
absorb vibration and an expansion joint in the pipe purpose the radiator is mounted horizontally and
to compensate for lengthways thermal expansion or the fan is driven by an electric motor to discharge
contraction. See figure 6.1. air vertically.

SILENCER/PIPEWORK
WALL SLEEVE SUPPORTS
AND EXPANSION
JOINT

EXHAUST
RAIN CAP SILENCER

FIG 6.1 TYPICAL EXHAUST SYSTEM INSTALLATION

6
6.2 Exhaust Pipe Flexible Section and silencer and retained by a stainless steel or
aluminium sheath may substantially reduce heat
A flexible connection between the manifold and the radiation to the room from the exhaust system.
exhaust piping system should be used to prevent
transmitting engine vibration to the piping and the An additional benefit of the insulation is that it
building, and to isolate the engine and piping from provides sound attenuation to reduce noise in the
forces due to thermal expansion, motion or weight room.
of piping. A well designed flex section will permit
operation with ± 13 mm (0.5 in) permanent 6.4 Minimising Exhaust Flow
displacement in any direction of either end of the Restriction
section without damage. Not only must the section
have the flexibility to compensate for a nominal Free flow of exhaust gases through the pipe is
amount of permanent mismatch between piping and essential to minimise exhaust back pressure.
manifold, but it must also yield readily to Excessive exhaust back pressure seriously affects
intermittent motion of the Generating Set on its engine horsepower output, durability and fuel
vibration isolators in response to load changes. consumption. Restricting the discharge of gases
The flexible connector should be specified with the from the cylinder causes poor combustion and
Generating Set. higher operating temperatures. The major design
factors that may cause high back pressure are:
6.3 Exhaust Pipe Insulation
• Exhaust pipe diameter too small
No exposed parts of the exhaust system should be • Exhaust pipe too long
near wood or other inflammable material. Exhaust • Too many sharp bends in exhaust system
piping inside the building (and the silencer if • Exhaust silencer restriction too high
mounted inside) should be covered with suitable • At certain critical lengths, standing pressure
insulation materials to protect personnel and to waves may cause high back pressure
reduce room temperature. A sufficient layer of
suitable insulating material surrounding the piping

FIG 6.2 HORIZONTALLY MOUNTED EXHAUST SILENCER FIG 6.3 RADIATOR AIR DISCHARGING INTO
WITH EXHAUST PIPE AND RADIATOR AIR SOUND-INSULATED STACK CONTAINING
UTILISING COMMON STACK EXHAUST SILENCER

7
Excessive restriction in the exhaust system can be Flexible Sections:
avoided by proper design and construction. To Length (ft): 0.167 x Diameter (inches)
make sure you will avoid problems related to
The following formula is used to calculate the back
excessive restriction, ask The FG Wilson distributor
pressure of an exhaust system:
to review your design.
The effect of pipe diameter, length and the 2
CLRQ
restriction of any bends in the system can be P =
5
calculated to make sure your exhaust system is D
adequate without excessive back pressure. The
longer the pipe, and the more bends it contains, the where:
larger the diameter required to avoid excessive flow P = back pressure in inches of mercury
restriction and back pressure. The back pressure C = .00059 for engine combustion airflow of 100 to 400 cfm
should be calculated during the installation stage to = .00056 for engine combustion airflow of 400 to 700 cfm
make certain it will be within the recommended limits = .00049 for engine combustion airflow of 700 to 2000 cfm
for the engine. = .00044 for engine combustion airflow of 2000 to
5400 cfm
Measure the exhaust pipe length from your L = length of exhaust pipe in feet
installation layout. See figure 6.4. Take exhaust R = exhaust density in pounds per cubic foot
flow data and back pressure limits from the
generating set engine specification sheet. Allowing 41.1
for restrictions of the exhaust silencer and any R=
o o
elbows in the pipe, calculate the minimum pipe Exhaust temperature F * + 460 F
diameter so that the total system restriction will not
exceed the recommended exhaust back pressure Q = exhaust gas flow in cubic feet per minute*
limit. Allowance should be made for deterioration D = inside diameter of exhaust pipe in inches
and scale accumulation that may increase restriction * Available from engine specification sheet
over a period of time.
These formulae assume that the exhaust pipe is
Elbow restriction is most conveniently handled by clean commercial steel or wrought iron. The back
calculating an equivalent length of straight pipe for pressure is dependent on the surface finish of the
each elbow and adding it to the total length of pipe. piping and an increase in the pipe roughness will
For elbows and flexible sections, the equivalent increase the back pressure. The constant 41.1 is
length of straight pipe is calculated as follows: based on the weight of combustion air and fuel
burned at rated load and SAE conditions. See
45° Elbow: engine specification sheet for exhaust gas
Length (ft) = 0.75 x Diameter (inches) temperature and air flow. Conversion tables to other
units are provided in Section 12.
90° Elbow:
Length (ft) = 1.33 x Diameter (inches)

FIG 6.4 MEASURING EXHAUST PIPE LENGTH TO DETERMINE EXHAUST BACK PRESSURE

8
7. EXHAUST SILENCING Silencers normally are available in two
configurations - (a) end inlet, end outlet, or (b) side
inlet, end outlet. Having the choice of these two
Excessive noise is objectionable in most locations.
configurations provides flexibility of installation,
Since a large part of the generating set noise is
such as horizontal or vertical, above engine, on
produced in the engine's pulsating exhaust, this
outside wall, etc. The side-inlet type permits 90°
noise can be reduced to an acceptable level by
change of direction without using an elbow. Both
using an exhaust silencer. The required degree of
silencer configurations should contain drain fittings
silencing depends on the location and may be
in locations that assure draining the silencer in
regulated by law. For example, the noise of an
whatever attitude it is installed.
engine is objectionable in a hospital area but
generally is not as objectionable in an isolated
The silencer may be located close to the engine,
pumping station.
with exhaust piping leading from the silencer to the
outside; or it may be located outdoors on the wall
7.1 Exhaust Silencer Selection or roof. Locating the silencer close to the engine
affords best overall noise attenuation because of
The silencer reduces noise in the exhaust system by minimum piping to the silencer. Servicing and
dissipating energy in chambers and baffle tubes draining of the silencer is likely to be more
and by eliminating wave reflection that causes convenient with the silencer indoors.
resonance. The silencer is selected according to
the degree of attenuation required by the site However, mounting the silencer outside has the
conditions and regulations. The size of silencer and advantage that the silencer need not be insulated
exhaust piping should hold exhaust back pressure (though it should be surrounded by a protective
within limits recommended by the engine screen). The job of insulating piping within the
manufacturer. room is simpler when the silencer is outside, and the
insulation then can aid noise attenuation.
Silencers are rated according to their degree of
silencing by such terms as "low degree" or Since silencers are large and heavy, consider their
"industrial", "moderate" or "residential" and "high dimensions and weight when you are planning the
degree" or "critical". exhaust system. The silencer must be adequately
supported so its weight is not applied to the
• Low-Degree or Industrial Silencing - Suitable engine's exhaust manifold or turbocharger. The
for industrial areas where background noise silencer must fit into the space available without
level is relatively high or for remote areas requiring extra bends in the exhaust piping, which
where partly muffled noise is permissible. would cause high exhaust back pressure. A side-
inlet silencer may be installed horizontally above
• Moderate-Degree or Residential Silencing - the engine without requiring a great amount of
Reduces exhaust noise to an acceptable level headroom.
in localities where moderately effective
silencing is required - such as semi- Silencers or exhaust piping within reach of
residential areas where a moderate personnel should be protected by guards or
background noise is always present. insulation. Indoors, it is preferable to insulate the
silencer and piping because the insulation not only
• High-Degree or Critical Silencing - Provides protects personnel, but it reduces heat radiation to
maximum silencing for residential, hospital, the room and further reduces exhaust system noise.
school, hotel, store, apartment building and Silencers mounted horizontally should be set at a
other areas where background noise level is slight angle away from the engine outlet with a
low and generating set noise must be kept to a drain fitting at the lowest point to allow the disposal
minimum. of any accumulated moisture.

9
8. SOUND ATTENUATION the engine. Cooling devices are commonly coolant-
to-air (radiator) or coolant-to-raw water (heat
exchanger) types.
If noise level must be limited, it should be specified
in terms of a sound pressure level at a given
In the most common generating set installation, the
distance from the generator enclosure. Then the
engine coolant is cooled in a set-mounted radiator
enclosure must be designed to attenuate the noise
with air blown through the radiator core by an
generated inside the enclosure to produce the
engine driven fan. Some installations use a remotely
required level outside. Don't attempt to make this
mounted radiator, cooled by an electric motor-
noise level unnecessarily low, because the means of
driven fan. Where there is a continuously available
achieving it may be costly.
supply of clean, cool raw water, a heat exchanger
may be used instead of a radiator; the engine
Use of resilient mounts for the generating set plus
coolant circulates through the heat exchanger and
normal techniques for controlling exhaust, intake
is cooled by the raw water supply.
and radiator fan noise should reduce generating set
noise to an acceptable level for many installations.
An important advantage of a radiator cooling
If the remaining noise level is still too high, acoustic
system is that it is self-contained. If a storm or
treatment of either the room or the generating set is
accident disrupted the utility power source, it might
necessary. Sound barriers can be erected around
also disrupt the water supply and disable any
the generating set, or the walls of the generator
generating set whose supply of raw water
room can be sound insulated, or the generating set
depended upon a utility.
can be enclosed in a specially developed sound
insulated enclosure. See figure 8.1.
Whether the radiator is mounted on the generating
set or mounted remotely, accessibility for servicing
In most cases it is necessary that the air intake and
the cooling system is important. For proper
air discharge openings will have to be fitted with
maintenance, the radiator fill cap, the cooling
sound attenuators. If it is desired to protect
system drain cocks, the fan belt tension adjustment
operating personnel from direct exposure to
must all be accessible to the operator.
generating set noise, the instruments and control
station may be located in a separate sound-
insulated control room. 9.1 Set Mounted Radiator

9. ENGINE COOLING A set-mounted radiator is mounted on the

generating set base in front of the engine. See
Some diesel engines are air cooled but the majority figure 9.1. An engine-driven fan blows air through
are cooled by circulating a liquid coolant through the radiator core, cooling the liquid engine coolant
the oil cooler if one is fitted and through passages flowing through the radiator.
in the engine block and head. Hot coolant emerging
from the engine is cooled and recirculated through

FIG 8.1 TYPICAL SOUND ATTENUATED INSTALLATION

10
 FIG 9.1 SET MOUNTED RADIATOR DISCHARGING THROUGH OUTSIDE WALL

Set mounted radiators are of two types. One type is be relatively clean to avoid clogging the radiator
used with the cooling fan mounted on the engine. core. Adequate filtration of air flowing into the
The fan is belt-driven by the crankshaft pulley in a room should assure relatively clean air. However if
two-point drive. The fan support bracket, fan the air at the site normally contains a high
spindle and drive pulley are adjustable with respect concentration of dirt, lint, sawdust, or other matter,
to the crankshaft pulley in order to maintain proper the use of a remote radiator, located in a cleaner
belt tension. The fan blades project into the environment, may alleviate a core clogging problem.
radiator shroud, which has sufficient tip clearance
for belt tension adjustment. It is recommended that a set-mounted radiator's
discharge air should flow directly outdoors through
The other type of set mounted radiator consists of a duct that connects the radiator to an opening in
an assembly of radiator, fan, drive pulley and an outside wall. The engine should be located as
adjustable idler pulley to maintain belt tension. The close to the outside wall as possible to keep the
fan is mounted with its centre fixed in a venturi ducting short. If the ducting is too long, it may be
shroud with very close tip clearance for high- more economical to use a remote radiator. The air
efficiency performance. The fan drive pulley, idler flow restriction of the discharge and the inlets duct
pulley and engine crankshaft pulley are precisely should not exceed the allowable fan static pressure.
aligned and connected in a three-point drive by the
belts. This second type of set-mounted radiator When the set-mounted radiator is to be connected
usually uses an airfoil-bladed fan with the close- to a discharge duct, a duct adapter should be
fitting shroud. specified for the radiator. A length of flexible duct
material (rubber or suitable fabric) between the
The proper radiator and fan combinations will be radiator and the fixed discharge duct is required to
provided by FG Wilson and furnished with the isolate vibration and provide freedom of motion
generating set. Air requirements for cooling a between the generating set and the fixed duct.
particular FG Wilson generator are given in the
specification sheet. The radiator cooling air must

11
FIG 9.2 REMOTE RADIATOR CONNECTED DIRECTLY FIG 9.3 REMOTE RADIATOR ISOLATED FROM
TO ENGINE COOLING SYSTEM ENGINE COOLING SYSTEM BY HEAT
EXCHANGER

9.2 Remote Radiator A separate pump circulates radiator coolant

between the remote radiator and the heat exchanger
A remote radiator with electric motor-driven can be tank.
installed in any convenient location away from the
generating set. See figure 9.2. A well-designed Heat exchangers also are used for cooling the
remote radiator has many useful features and engine without a radiator, as described in the
advantages that provide greater flexibility of following section.
generating set installations in buildings.
9.4 Heat Exchanger Cooling
More efficient venturi shroud and fan provide a
substantial reduction in horsepower required for A heat exchanger may be used where there is a
engine cooling. The fan may be driven by a continuously available supply of clean, cool raw
thermostatically controlled motor, which will only water. Areas where excessive foreign material in the
draw power from the generating set when required air might cause constant radiator clogging - such as
to cool the engine. A remote radiator can be in saw mill installations - may be logical sites for
located outdoors where there is less air flow heat exchanger cooling. A heat exchanger cools the
restriction and air is usually cooler than engine engine by transferring engine coolant heat through
room air, resulting in higher efficiency and smaller passages in the elements to cool raw water. Engine
size radiator; and fan noise is removed from the coolant and raw cooling water flows are separated
building. completely in closed systems, each with its own
pump, and never intermix.
Remote radiators must be connected to the engine
cooling system by coolant piping, including flexible A heat exchanger totally replaces the radiator and
sections between engine and piping. fan. See figure 9.5. It usually is furnished as part of
the generating set assembly, mounted on the
9.3 Remote Radiator/Heat Exchanger engine, although it can be located remotely. Since
System the engine does not have to drive a radiator fan,
there is more reserve power available.
Another type of remote radiator system employs a
heat exchanger at the engine . See figure 9.3 and 9.4. The raw water side of the heat exchanger requires a
In this application, the heat exchanger functions as dependable and economical supply of cool water.
an intermediate heat exchanger to isolate the engine Soft water is desired to keep the heat exchanger in
coolant system from the high static head of the good operating condition. For standby service, a
remote radiator coolant. The engine pump well, lake or cooling tower is preferred over city
circulates engine coolant through the engine and water since the latter may fail at the same time that
the element of the heat exchanger. normal electric power fails, making the generator
useless.

12
 AUXILIARY PUMP

HEAT
EXCHANGER

FIG 9.4 TYPICAL HEAT EXCHANGER INSTALLATION FIG 9.5 HEAT EXCHANGER COOLING SYSTEM

9.5 Antifreeze Protection 10. FUEL SUPPLY

If the engine is to be exposed to low temperatures, A dependable fuel supply system must assure
the cooling water in the engine must be protected instant availability of fuel to facilitate starting and
from freezing. In radiator-cooled installations, to keep the engine operating. This requires, at a
antifreeze may be added to the water to prevent minimum, a small day tank (usually incorporated
freezing. Ethylene glycol permanent antifreeze is into the generating set baseframe - called a
recommended for diesel engines. It includes its basetank) located close to the set. With generally
own corrosion inhibitor, which eventually may have only a capacity of 8 hours operation, this day tank
to be replenished. Only a non-chromate inhibitor is often backed up by an auxiliary remote fuel
should be used with ethylene glycol. system including a bulk storage tank and the
associated pumps and plumbing. Extended
The proportion of ethylene glycol required is capacity basetanks are also generally available for
dictated primarily by the need for protection against longer operation prior to refuelling. Especially for
freezing in the lowest ambient air temperature that standby generating sets it not advisable to depend
will be encountered. The concentration of ethylene on regular delivery of fuel. The emergency that
glycol must be at least 30% to afford adequate requires use of the standby set may also interrupt
corrosion protection. The concentration must not the delivery of fuel.
exceed 67% to maintain adequate heat transfer
capability. 10.1 Fuel Tank Location
For heat exchanger cooling, antifreeze does only
The day tank should be located as close to the
half the job since it can only be used in the engine
generating set as possible. Normally it is safe to
water side of the heat exchanger. There must be
store diesel fuel in the same room with the
assurance that the raw water source will not freeze.
generating set because there is less danger of fire or
fumes with diesel than with petrol (gasoline). Thus,
9.6 Water Conditioning if building codes and fire regulations permit, the day
tank should be located in the base of the generating
Soft water should always be used in the engine set, along side the set, or in an adjacent room.
whether cooling is by radiator or by heat exchanger
Adding a commercial softener is the easiest and Where an remote fuel system is to be installed with
most economical method of water softening. Your a bulk storage tank, the bulk tank may be located
FG Wilson Distributor can recommend suitable outside the building where it will be convenient for
softeners. Manufacturers instructions should be refilling, cleaning and inspection. It should not,
carefully followed. however, be exposed to freezing weather because
fuel flow will be restricted as viscosity increases
with cold temperature. The tank may be located
either above or below ground level.

13
10.2 Remote Fuel Systems fuel level gauges on the basetank and no manual fill
facility All other connections on top of the tank
Three types of remote fuel systems are must be sealed to prevent leakage. Fuel System 1 is
recommended by the manufacturer: not compatible with the polyethylene fuel tanks
standard on smaller generator sets. The optional
Fuel System 1: Installations where the bulk fuel metal tank is required. A 2001 Series control system
tank is lower than the day tank. (or above) is required.
Fuel System 2: Installations where the bulk fuel
tank is higher than the day tank. The position of the bulk fuel tank should take into
Fuel System 4: Installations where fuel must be account that the maximum suction lift of the fuel
pumped from a free standing bulk fuel tank to transfer pump is approximately 3 metres and that the
the day tank. maximum restriction caused by the friction losses in
the return fuel line should not exceed 2 psi.
Fuel System 1: The bulk fuel tank is lower than the
day tank. With this system the fuel must be pumped Fuel System 2: The bulk tank is located higher
up from the bulk tank to the day tank which is than the basetank. With this system the fuel is
integrated into the baseframe. See figure 10.1. gravity fed from the bulk tank to the basetank. See
figure 10.2.

Figure 10.2:Typical Layout with Fuel System 2

Figure 10.1: Typical Layout with Fuel System1 The key components are the bulk fuel tank (item 1),
The key components are the bulk fuel tank (item 1), which is higher than the basetank, remote fuel
which is lower than the basetank, remote fuel system controls (item 2) located in the generator set
system controls (item 2) located in the generator set control panel, a DC motorised fuel valve (item 3),
control panel, an AC powered electric fuel pump fuel level switches in the basetank (item 4), an
(item 3), fuel level switches in the basetank (item 4), extended vent/return line (continuous rise) on the
an extended vent on the basetank (item 5), the fuel basetank (item 5), the fuel supply line (item 6), a
supply line (item 6), the fuel return line (item 7), and fuel strainer (item 7) and an isolating valve at the
a fuel strainer (item 8) on the inlet side of the pump. bulk tank (item 8).
When set to automatic, the system operates as When set to automatic, the system operates as
follows: low fuel level in the basetank is sensed by follows: low fuel level in the basetank is sensed by
the fuel level sensor. The pump begins to pump the fuel level sensor. The DC motorised valve is
fuel from the bulk tank to the basetank through the opened and fuel is allowed to flow from the high
fuel supply line. To help ensure that clean fuel level bulk tank to the basetank by the force of
reaches the engine, fuel from the bulk tank is gravity. To help ensure that clean fuel reaches the
strained just prior to the electric fuel pump. When engine, fuel from the bulk tank is strained just prior
the basetank is full, as sensed by the fuel level to the motorised valve. When the basetank is full,
sensor, the pump stops. If there should be any as sensed by the fuel level sensor, the motorised
overflow of fuel in the basetank, the excess will valve is closed.
drain back into the bulk tank via the return line. Any overflow into the basetank or overpressure in
the basetank will flow back to the bulk tank via the
With this system, the basetank must include the extended vent.
overflow (via the return line), a 1.4 metre extended
vent to prevent overflow through the vent, sealed

14
With this system, the basetank must include an top of the tank must be sealed to prevent leakage.
overflow via the return line, sealed fuel level gauges Fuel System 4 is not compatible with the
and no manual fill facility. All other connections on polyethylene fuel tanks standard on smalle
top of the tank must be sealed to prevent leakage. generator sets. The optional metal tank is required.
Fuel System 2 is not compatible with the A 2001 Series control system (or above) is required.
polyethylene fuel tanks standard on smaller
generator sets. The optional metal tank is required. Distance ‘A’ on Figure 10.4 is limited to 1400mm for
A 2001 Series control system (or above) is required. all generator sets with metal basetanks. Note that
the maximum restriction caused by friction losses
Distance ‘A’ in Figure 10.2 is limited to 1400mm for
and height of the return line should not exceed 2
all generator sets with metal basetanks.
psi.
Fuel System 4: Some installations may require a
system where fuel is pumped from a free standing 10.3 Tank Construction
bulk tank (see Figure 10.4). This pumped system Fuel tanks are usually made of welded sheet steel or
would only be used if gravity feed is not possible reinforced plastic. If an old fuel tank is used, be
from the bulk tank to the basetank. sure it is made of a proper material. It should be
cleaned thoroughly to remove all rust, scale and
foreign deposits.
Connections for fuel suction and return lines must
be separated as much as possible to prevent re-
circulation of hot fuel and to allow separation of
any gases entrained in the fuel. Fuel suction lines
should extend below the minimum fuel level in the
tank. Where practical, a low point in the tank
should be equipped with a drain valve or plug, in an
accessible location, to allow periodic removal of
Figure 10.4:Typical Layout with Fuel System 4 water condensation and sediment. Or a hose may
be inserted through the tank's filter neck when
The key components are the above ground bulk necessary to suck out water and sediment.
fuel tank (item 1), remote fuel system controls (item The filler neck of the bulk fuel tank should be
2) located in the generator set control panel, an AC located in a clean accessible location. A removable
Fuel Pump (item 3), a DC motorised fuel valve (item wire screen of approximately 1.6 mm (1/16 inch)
4), fuel level switches in the basetank (item 5), the mesh should be placed in the filler neck to prevent
fuel supply line (item 6), an extended vent/return foreign material from
line (continuous rise) on the basetank (item 7), a
fuel strainer (item 8) and an isolating valve at the entering the tank. The filler neck cap or the highest
bulk tank (item 9). point in the tank should be vented to maintain
atmospheric pressure on the fuel and to provide
When set to automatic, the system operates as pressure relief in case a temperature rise causes the
follows: low fuel level in the basetank is sensed by fuel to expand. It will also prevent a vacuum as fuel
the fuel level sensor. The DC motorised valve is is consumed. The tank may be equipped with a fuel
opened and the pump begins to pump fuel from the level gauge - either a sight gauge or a remote
bulk tank to the basetank through the supply line. electrical gauge.
To help ensure that clean fuel reaches the engine,
fuel from the bulk tank is strained just prior to the 10.4 Fuel Lines
motorised valve. When the basetank is full, as The fuel lines can be of any fuel compatible material
sensed by the fuel level sensor, the pump stops such as steel pipe or flexible hoses that will tolerate
and the motorised valve is closed. Any overflow environmental conditions.
into the basetank or overpressure in the basetank
will flow back to the bulk tank via the extended Fuel delivery and return lines should be at least as
vent. large as the fitting sizes on the engine, and overflow
With this system, the basetank must include an piping should be one size larger. For longer runs of
overflow via the return line, sealed fuel level gauges piping or low ambient temperatures the size of these
and no manual fill facility. All other connections on lines should be increased to ensure adequate flow.

15
Flexible piping should be used to connect to the
engine to avoid damage or leaks caused by engine
vibration.
The fuel delivery line should pick up fuel from a
point no lower than 50 mm (2”) from the bottom of
tank at the high end, away from the drain plug.

10.5 Day Tank Capacity

The capacity of the day tank is based on the fuel
consumption and the expected number of hours of
operation that is requested between refills.
Particularly with standby generators, the availability
of fuel delivery service will determine the number of
operating hours that must be provided for. Don't
depend on quick service the very day your set
starts to operate. A power outage may hamper your
supplier's operation also.

In addition, the size of the day tank should be large

enough to keep fuel temperatures down, since some
engines return hot fuel used to cool the injectors.

Model Extra Capacity

With Fuel Without Fuel
Coolers Coolers
P910-P1100E 1500 litres 3000 litres
P1250-P1650E 2250 litres 4500 litres
P1700-P2200E 3000 litres 6000 litres

16
11. SELECTING FUELS Reliable operation of diesel engines may vary from
one fuel to another, depending on many factors,
FOR STANDBY including fuel characteristics and engine operating
DEPENDABILITY conditions.

The types of fuels available for diesel engines, vary The fuels commonly known as high-grade fuels
from highly volatile jet fuels and kerosene to the seldom contribute to the formation of harmful
heavier fuel oils. Most diesel engines are capable engine deposits and corrosion. On the other hand,
of burning a wide range of fuels within these while refining improves the fuel, it also lowers the
extremes. The following information will assist you B.T.U. or heat value of the fuel. As a result, the
in selecting the type of fuel that will afford the best higher grade fuels develop slightly less power than
overall performance and reliability of your the same quantity of low grade fuel. This is
Generating Set. usually more than offset by the advantages of high
grade fuels such as quicker starts and less frequent
overhauls. Before using low-grade fuels, therefore,
11.1 Types Of Fuel Oil
some understanding of the problems and extra
costs that may be encountered is necessary.
The quality of fuel oil can be a dominant factor in
satisfactory engine life and performance. A large Fuels with high sulphur content cause corrosion,
variety of fuel oils are marketed for diesel engine wear and deposits in the engine. Fuels that are not
use. Their properties depend upon the refining volatile enough or don't ignite rapidly may leave
practices employed and the nature of the crude oils harmful deposits in the engine and may cause poor
from which they are produced. For example, fuel starting or running under adverse operating
oils may be produced within the boiling range of conditions. The use of low grade fuels may require
148 to 371°C (300 to 700°F), having many possible the use of high priced, higher detergent lubricating
combinations of other properties. oils and more frequent oil changes.

The additional contaminants present in low grade

fuels may result in darker exhaust and more 11.2 Fuel Selection Guide
pronounced odour. This may be objectionable in
hospitals, offices commercial and urban locations. Specify fuel properties according to the following
Thus, location, application and environmental chart.
conditions should be considered when selecting Final Cetane Sulphur
fuel. Boiling Number Number
Point (Min) (Max)
The Generating Set owner may elect to use a low Winter 290°C (550ºF) 45 0.5 %
grade fuel because high-grade fuels are not readily Summer 315°C (600ºF) 40 0.5 %
available in his area or because he can realise a net
saving with low grade fuels despite higher engine Selecting a fuel that keeps within these
maintenance costs. In that case, frequent specifications will tend to reduce the possibility of
examination of lubrication oil should be made to harmful deposits and corrosion in the engine, both
determine sludge formation and the extent of lube of which could result in more frequent overhauls
oil contamination. and greater maintenance expense. Specify exact
fuel properties to your local fuel supplier.
Aside from the various grades of fuel oil commonly
used in diesel engines, aircraft jet fuels also are 11.3 Maintaining Fresh Fuel
sometimes used, especially in circumstances where
the jet fuels are more readily available than Most fuels deteriorate if they stand unused for a
conventional fuels. Jet fuels are lower in B.T.U. period of many months. With standby generators it
content and lubrication quality than conventional is preferable to store only enough fuel to support a
fuels. As a result, some diesel fuel systems must few days or even only eight hours of continuous
undergo major modifications to accommodate this running of the Generating Set so that normal engine
type of fuel. For use of jet fuel please consult FG testing will turn over a tank full within a year and a
Wilson. half.

17
 Other solutions are to add inhibitors to the fuel or
to obtain greater turnover by using the fuel for
other purposes. A gum inhibitor added to diesel
fuel will keep it in good condition up to two years.

If the building furnace has an oil burner, it is

possible to burn diesel fuel in the furnace,
connecting both the engine and the furnace to the
same tank. In this way, a large supply of diesel fuel
is available for emergency use by the Generating
Set, and the fuel supply is continuously turned over
since it is being burned in the furnace. Thus, there
is no long term storage problem.

11.4 Self Contained Dependability

In some areas, where natural gas is cheap, natural

gas spark ignition engines are used in Generating
Sets that are intended for continuous service. For
standby service, however, this is not recommended.
The natural gas supply and regulation system adds
substantially to the complexity of the installation,
and there is little to be gained in terms of fuel cost
over a period of time. More important, it makes the
emergency power less dependable. Not only is
such an engine less dependable than a diesel, but
often the same storm or accident that disrupts the
normal electric power also cuts off gas service.
Thus, a natural gas engine would be disabled at the
very time it is needed. By contrast, a diesel engine,
with its fuel in a nearby tank, is a self contained
system that does not depend on outside services.
It is more dependable and affords greater standby
protection than systems which depend on a public
utility for fuel.

18

Downloaded from www.Manualslib.com manuals search engine

12. TABLES AND FORMULAS FOR ENGINEERING STANDBY GENERATING
SETS

Table 1. Length Equivalents

Unit Microns Meters Kilometres Inches Feet Yards Miles

1 Micron 1 0.000001 -- 0.00003937 -- -- --
1 Meter 1,000,000 1 -- 39.37 3.281 1.0936 --
1 Kilometre -- 1000 1 39,370 3281 1093.6 0.621
1 Inch 25,400 0.0254 -- 1 0.0833 0.0278 --
1 Foot -- 0.3048 -- 12 1 0.3333 --
1 Yard -- 0.9144 -- 36 3 1 --
1 Mile -- 1609 1.609 63,360 5280 1760 1

One unit in the left-hand column equals the value of units under the top heading.

Table 2. Area Equivalents

Unit In 2 Ft2 Acre Mile 2 M2 Hectare Km 2

1 In 2 1 0.006944 -- -- 0.00064516 -- --
1 Ft 2 144 1 -- -- 0.0929 -- --
1 Acre -- 43,560 1 0.0015625 4,047 0.4047 0.004047
1 Mile 2 -- 27,878,400 640 1 2,589,998 258.99 2.5899
1 M2 1550 10.764 -- -- 1 -- --
1 Hectare -- 107,639 2.471 0.003861 10,000 1 0.01
1 Km 2 -- 10,763,867 247.1 0.3861 1,000,000 100 1

One unit in the left-hand column equals the value of units under the top heading.

Table 3. Mass Equivalents

Tons
Unit Ounces Pounds Kilograms Short Long Metric
1 Ounce 1 0.0625 0.02835 -- -- --
1 Pound 16 1 0.4536 -- -- --
1 Kilogram 35.27 2.205 1 -- -- --
1 Short Ton 32000 2000 907.2 1 0.8929 0.9072
1 Long Ton 35840 2240 1016 1.12 1 1.016
1 Metric Ton 35274 2205 1000 1.102 0.9842 1

One unit in the left-hand column equals the value of units under the top heading.

19
 Table 4. Volume and Capacity Equivalents

Unit Inches 3 Feet3 Yards 3 Meters 3 US Liquid Imperial Litres

Gallons Gallons
1 Inch 3 1 0.000579 0.0000214 0.0000164 0.004329 0.00359 0.0164
1 Ft.3 1728 1 0.03704 0.0283 7.481 6.23 28.32
1 Yd.3 46656 27 1 0.765 202 168.35 764.6
1 M3 61023 35.31 1.308 1 264.2 220.2 1000
1 231 0.1337 0.00495 0.003785 1 0.833 3.785
U.S.Liq.Gal
1 Imp. Gal. 277.42 0.16 0.00594 0.004546 1.2 1 4.546
1 Litre 61.02 0.03531 0.001308 0.001 0.2642 0.22 1

One unit in the left-hand column equals the value of units under the top heading.

Table 5. Conversions for Units of Speed

Unit Feet/Secon Feet/Min Miles/Hr Meters/Sec Meters/Mi Km/Hr

d n
1 Foot/Sec 1 60.0 0.6818 0.3048 18.288 --
1 Foot/Min 0.0167 1 0.1136 0.00508 -- --
1 Mile/Hr 1.467 88 1 26.822 1.6093
1 Meter/Sec 3.281 196.848 -- 1 -- --
1 Meter/Min 0.05468 -- 0.03728 -- 1 --
1 Km/Hr -- -- 0.6214 0.2778 -- 1

One unit in the left-hand column equals the value of units under the top heading.

Table 6. Conversions For Units Of Power

Unit Horsepower Foot-lb/Minute Kilowatts Metric Btu/Minute

Horsepower
1 Horsepower 1 33,000 0.746 1.014 42.4
1 Foot- -- 1 -- -- 0.001285
lb/Minute
1 Kilowatt 1.341 44,260 1 1.360 56.88
1 Metric 0.986 32,544 0.736 1 41.8
Horsepower
1 Btu. /Minute 0.0236 777.6 0.0176 0.0239 1

One unit in the left-hand column equals the value of units under the top heading.
Mechanical power and ratings of motors and engines are expressed in horsepower.
Electrical power is expressed in watts or kilowatts.

20
 Table 7. Conversions for Measurements of Water

Unit Feet3 Pounds Gal Gal Litres Head lb/in² Ton/Ft² Head Ft³/Min Gal.(U.S)
(U.S (IMP) (Ft) (Meters /Hr
) )
Feet3 1 62.42 -- -- -- -- -- -- -- -- --
Pounds 0.01602 1 0.12 0.10 0.4536 -- -- -- -- -- --
Gal -- 8.34 1 -- -- -- -- -- --
(U.S)
Gal -- 10.0 -- 1 -- -- -- -- --
(IMP)
Litres -- 2.2046 -- -- 1 -- -- --
Head -- -- -- -- -- 1 4.335 --
(Ft)
lb/in² -- -- -- -- -- 2.3070 1 0.02784 0.7039
Ton/Ft² -- -- -- -- -- 35.92 -- 1 --
Head -- -- -- -- -- -- 1.4221 -- 1
(Meters)
Ft³/Min -- -- -- -- -- -- -- -- -- 1 448.92
Gal. -- -- -- -- -- -- -- -- -- 0.002227 1
(U.S)/Hr

One unit in the left-hand column equals the value of units under the top heading.

Table 8. Barometric Pressures and Boiling Points of Water at Various Altitudes

Barometric Pressure Water Boiling

Point
(Ft) Inches of lb/in 2 Feet Water ºF ºC
Mercury
Sea Level 29.92 14.69 33.95 212.0 100
1000 28.86 14.16 32.60 210.1 99
2000 27.82 13.66 31.42 208.3 98
3000 26.81 13.16 30.28 206.5 97
4000 25.84 12.68 29.20 204.6 95.9
5000 24.89 12.22 28.10 202.8 94.9
6000 23.98 11.77 27.08 201.0 94.1
7000 23.09 11.33 26.08 199.3 93
8000 22.22 10.91 25.10 197.4 91.9
9000 21.38 10.50 24.15 195.7 91
10,000 20.58 10.10 23.25 194.0 90
11,000 19.75 9.71 22.30 192.0 88.9
12,000 19.03 9.34 21.48 190.5 88
13,000 18.29 8.97 20.65 188.8 87.1
14,000 17.57 8.62 19.84 187.1 86.2
15,000 16.88 8.28 18.07 185.4 85.2

One unit in the left-hand column equals the value of units under the top heading.

21
 Table 9. Conversions of Units of Flow

Unit U.S Million U.S Feet3 /Second Meters 3 /Hour Litres/Second

Gallons/Minute Gallons/Day
1 U.S 1 0.001440 0.00223 0.2271 0.0630
Gallon/Minute
1 Million U.S 694.4 1 1.547 157.73 43.8
Gallons/Day
1 Foot3 /Second 448.86 0.646 1 101.9 28.32
1 Meter3 /Hour 4.403 0.00634 0.00981 1 0.2778
1 Litre/Second 15.85 0.0228 0.0353 3.60 1

One unit in the left-hand column equals the value of units under the top heading.

Table 10. Conversions of Units of Pressure and Head

Unit mm Hg in. Hg in H2 O ft H2 O lb/in² kg/cm² Atmos kPa

1mm 1 0.0394 0.5352 0.0447 0.01934 0.00136 0.0013 --

Hg
1 in. 25.4 1 13.5951 1.1330 0.49115 0.03453 0.0334 3.386
Hg
1 in 1.86827 0.0736 1 0.0833 0.03613 0.00254 0.0025 0.249
H2 O
1 ft 22.4192 0.8827 12 1 0.43352 0.030479 0.0295 2.989
H2 O
1 lb/ in² 51.7149 2.0360 27.6807 2.3067 1 0.07031 0.0681 6.895
1 735.559 28.959 393.7117 32.8093 14.2233 1 0.9678 98.07
kg/cm²
Atmos. 760.456 29.92 406.5 33.898 14.70 1.033 1 101.3
kPa 7.50064 0.2953 4.0146 0.3346 0.14504 0.0102 0.0099 1

One unit in the left-hand column equals the value of units under the top heading.

Table 11. Approximate Weights of Various Liquids

Pounds per U.S Specific Gravity

Gallon
Diesel Fuel 6.88 - 7.46 0.825 - 0.895
Ethylene Glycol 9.3 - 9.6 1.12 - 1.15
Furnace Oil 6.7 - 7.9 0.80 - 0.95
Gasoline 5.6 - 6.3 0.67 - 0.75
Kerosene 6.25 - 7.1 0.75 - 85
Lube. Oil (Medium) 7.5 - 7.7 0.90 - 0.92
Water 8.34 1.00

22
 Table 12. Electrical formulae

Desired Data Single Phase Three-Phase Direct Current

Kilowatts (kW)
I x V x PF 3 x I x V x PF IxV
1000 1000 1000
Kilovolt-Amperes
kVA IxV 3 xVxE
1000 1000
Electric Motor I x V x Eff . x PF 3 x I x V x Eff . x PF I x V x Eff .
Horsepower 746 746
746
Output (HP)

Amperes (I) HP x 746 HP x 746 HP x 746

When Horsepower V x Eff . x PF 3 x V x Eff . x PF V x Eff
is known

Amperes (I) kW x 1000 kW x 1000 kW x 1000

When Kilowatts V x PF 3 x V x PF V
are known

Amperes (I) kVA x 1000 kVA x 1000

When kVA is V 3 xV
known

Where:
V = Volts
I = Amperes
Eff = Percentage Efficiency
Watts
PF = Power Factor=
IxV

23
 TABLE 13. kVA/kW AMPERAGE AT VARIOUS VOLTAGES
(0.8 Power Factor)

kVA kW 208V 220V 240V 380V 400V 440V 460V 480V 600V 2400V 33000V 4160V
6.3 5 17.5 16.5 15.2 9.6 9.1 8.3 8.1 7.6 6.1
9.4 7.5 26.1 24.7 22.6 14.3 13.6 12.3 12 11.3 9.1
12.5 10 34.7 33 30.1 19.2 18.2 16.6 16.2 15.1 12
18.7 15 52 49.5 45 28.8 27.3 24.9 24.4 22.5 18
25 20 69.5 66 60.2 38.4 36.4 33.2 32.4 30.1 24 6 4.4 3.5
31.3 25 87 82.5 75.5 48 45.5 41.5 40.5 37.8 30 7.5 5.5 4.4
37.5 30 104 99 90.3 57.6 54.6 49.8 48.7 45.2 36 9.1 6.6 5.2
50 40 139 132 120 77 73 66.5 65 60 48 12.1 8.8 7
62.5 50 173 165 152 96 91 83 81 76 61 15.1 10.9 8.7
75 60 208 198 181 115 109 99.6 97.5 91 72 18.1 13.1 10.5
93.8 75 261 247 226 143 136 123 120 113 90 22.6 16.4 13
100 80 278 264 240 154 146 133 130 120 96 24.1 17.6 13.9
125 100 347 330 301 192 182 166 162 150 120 30 21.8 17.5
156 125 433 413 375 240 228 208 204 188 150 38 27.3 22
187 150 520 495 450 288 273 249 244 225 180 45 33 26
219 175 608 577 527 335 318 289 283 264 211 53 38 31
250 200 694 660 601 384 364 332 324 301 241 60 44 35
312 250 866 825 751 480 455 415 405 376 300 75 55 43
375 300 1040 990 903 576 546 498 487 451 361 90 66 52
438 350 1220 1155 1053 672 637 581 568 527 422 105 77 61
500 400 1390 1320 1203 770 730 665 650 602 481 120 88 69
625 500 1735 1650 1504 960 910 830 810 752 602 150 109 87
750 600 2080 1980 1803 1150 1090 996 975 902 721 180 131 104
875 700 2430 2310 2104 1344 1274 1162 1136 1052 842 210 153 121
100 800 2780 2640 2405 1540 1460 1330 1300 1203 962 241 176 139
0
112 900 3120 2970 2709 1730 1640 1495 1460 1354 1082 271 197 156
5
125 1000 3470 3300 3009 1920 1820 1660 1620 1504 1202 301 218 174
0
156 1250 4350 4130 3765 2400 2280 2080 2040 1885 1503 376 273 218
3
187 1500 5205 4950 4520 2880 2730 2490 2440 2260 1805 452 327 261
5
218 1750 5280 3350 3180 2890 2830 2640 2106 528 380 304
8
250 2000 6020 3840 3640 3320 3240 3015 2405 602 436 348
0
281 2250 6780 4320 4095 3735 3645 3400 2710 678 491 392
2
312 2500 7520 4800 4560 4160 4080 3765 3005 752 546 435
5
375 3000 9040 5760 5460 4980 4880 4525 3610 904 654 522
0
437 3500 10550 6700 6360 5780 5660 5285 4220 1055 760 610
5
500 4000 12040 7680 7280 6640 6480 6035 4810 1204 872 695
0

24
Conversions of Centigrade and Fahrenheit

Water freezes at 0 ºC (32ºF) Water boils at 100 ºC (212ºF)

ºF= ( 1.8 x ºC ) + 32 ºC = 0.5555 ( ºF - 32 )

Fuel Consumption Formulas

Fuel Consumption(lb / hr) = Specific FuelCons.( lb / BHP / hr) xBHP

Spec. Fuel Cons. (lb / BHP / hr) x BHP

Fuel Consumption(US gal / hr ) =
FuelSpecific Weight(lb / US gal )
FuelSpec.Weight( lb / US gal) = FuelSpecific Gravity x8.34 lb

FuelCons.( US gal / hr) x FuelSpec. Wt (lb / US gal)

Specific FuelConsumption(lb / BHP / hr ) =
BHP

Spec.Fuel Cons.(lb / BHP / hr)

Specific Fuel Consumption( kg / BHP / hr) =
BHP

Electrical Motor Horsepower

kW Input x Motor Efficiency

Electrical Motor Horsepower =
0.746 x Generator Efficiency

kW Output Required
Engine Horsepower Required =
0.746 x Generator Efficiency

Piston Travel
Feet Per Minute ( FPM) = 2 x L x N
Where L = Length of Stroke in Feet
N = Rotational Speed of Crankshaft in RPM

BREAK MEAN EFFECTIVE PRESSURE (BMEP) (4 Cycle)

792 , 000 x BHP

BMEP =
Total Displacement x RPM

25
13. GLOSSARY OF TERMS
ALTERNATING CURRENT (AC) - A current which periodically reverses in direction and changes its magnitude
as it flows through a conductor or electrical circuit. The magnitude of an alternating current rises from zero to
maximum value in one direction, returns to zero, and then follows the same variation in the opposite direction.
One complete alternation is one cycle or 360 electrical degrees. In the case of 50 cycle alternating current the
cycle is completed 50 times per second.

AMBIENT TEMPERATURE - The air temperature of the surroundings in which the generating system operates.
This may be expressed in degrees Celsius or Fahrenheit.

AMPERE (A) - The unit of measurement of electric flow. One ampere of current will flow when one volt is applied
across a resistance of one ohm.

APPARENT POWER (kVA, VA)- A term used when the current and voltage are not in phase i.e. voltage and
current do not reach corresponding values at the same instant. The resultant product of current and voltage is
the apparent power and is expressed in kVA.

AUTOMATIC SYNCHRONIZER - This device in its simplest form is a magnetic type control relay which will
automatically close the generator switch when the conditions for paralleling are satisfied.

BREAK MEAN EFFECTIVE PRESSURE (BMEP) - This is the theoretical average pressure on the piston of an
engine during the power stroke when the engine is producing a given number of horsepower. It is usually
expressed in pounds/inch2. The value is strictly a calculation as it cannot be measured, since the actual cylinder
pressure is constantly changing. The mean or average pressure is used to compare engines on assumption that
the lower the BMEP, the greater the expected engine life and reliability. In practice, it is not a reliable indicator of
engine performance for the following reasons.:
The formula favours older design engines with relatively low power output per cubic inch of displacement in
comparison with more modern designs. Modern engines do operate with higher average cylinder pressures, but
bearings and other engine parts are designed to withstand these higher pressures and to still provide equal or
greater life and reliability than the older designs. The formula also implies greater reliability when the same engine
produces the same power at a higher speed. Other things being equal, it is unlikely that a 60 Hz generating set
operating at 1800 RPM is more reliable than a comparable 50 Hz generating set operating at 1500 RPM. Also it is
doubtful that a generator operating at 3000 RPM will be more reliable than one operating at 1500 RPM even if the
latter engine has a significantly higher BMEP. The BMEP for any given generating set will vary with the rating
which changes depending on fuel, altitude and temperature. The BMEP is also affected by generator efficiency
which varies with voltage and load.

CAPACITANCE (C)- If a voltage is applied to two conductors separated by an insulator, the insulator will take
an electrical charge. Expressed in micro-farads (µf).

CIRCUIT BREAKER - A protective switching device capable of interrupting current flow at a pre-determined
value.

CONTINUOUS LOAD - Any load up to and including full rated load that the generating set is capable of
delivering for an indefinitely long period, except for shut down for normal preventive maintenance.

CONTINUOUS RATING - The load rating of an electric generating system which is capable of supplying
without exceeding its specified maximum temperature rise limits.

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CURRENT (I) - The rate of flow of electricity. DC flows from negative to positive. AC alternates in direction. The
current flow theory is used conventionally in power and the current direction is positive to negative.

CYCLE - One complete reversal of an alternating current or voltage from zero to a positive maximum to zero to a
negative maximum back to zero. The number of cycles per second is the frequency, expressed in Hertz (Hz).

DECIBEL (dB) - Unit used to define noise level.

DELTA CONNECTION - A three phase connection in which the start of each phase is connected to the end of
the next phase, forming the Greek letter Delta (D). The load lines are connected to the corners of the delta. In
some cases a centre tap is provided on each phase, but more often only on one leg, thus supplying a four wire
output.

DIRECT CURRENT - An electric current which flows in one direction only for a given voltage and electrical
resistance. A direct current is usually constant in magnitude for a given load.

EFFICIENCY - The efficiency of a generating set shall be defined as the ratio of its useful power output to its
total power input expressed as a percentage.

FREQUENCY - The number of complete cycles of an alternating voltage or current per unit of time, usually per
second. The unit for measurement is the Hertz (Hz) equivalent to 1 cycle per second (CPS).

FREQUENCY BAND - The permissible variation from a mean value under steady state conditions.

FREQUENCY DRIFT - Frequency drift is a gradual deviation of the mean governed frequency above or below
the desired frequency under constant load.

FREQUENCY DROOP - The change in frequency between steady state no load and
steady state full load which is a function of the engine and governing systems.

FULL LOAD CURRENT - The full load current of a machine or apparatus is the value of current in RMS or DC
amperes which it carries when delivering its rate output under its rated conditions. Normally, the full load current
is the "rated" current.

GENERATOR - A general name for a device for converting mechanical energy into electrical energy. The
electrical energy may be direct current (DC) or alternating current (AC). An AC generator may be called an
alternator.

HERTZ (Hz) - SEE FREQUENCY.

INDUCTANCE (L) - Any device with iron in the magnetic structure has what amounts to magnetic inertia. This
inertia opposes any change in current. The characteristic of a circuit which causes this magnetic inertia is know
as self inductance; it is measured in Henries and the symbol is "L".

INTERRUPTABLE SERVICE - A plan where by an electric utility, elects to interrupt service to a specific
customer at any time. Special rates are often available to customers under such agreements.

kVA - 1,000 Volt amperes (Apparent power). Equal to kW divided by the power factor.

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kW - 1,000 Watts (Real power). Equal to KVA multiplied by the power factor.

POWER - Rate of performing work, or energy per unit of time. Mechanical power is often measured in
horsepower, electrical power in kilowatts.

POWER FACTOR - In AC circuits, the inductances and capacitances may cause the point at which the voltage
wave passes through zero to differ from the point at which the current wave passes through zero. When the
current wave precedes the voltage wave, a leading power factor results, as in the case of a capacitive load or
over excited synchronous motors. When the voltage wave precedes the current wave, a lagging power factor
results. This is generally the case. The power factor expresses the extent to which voltage zero differs from the
current zero. Considering one full cycle to be 360 degrees, the difference between the zero point can then be
expressed as an angle q. Power factor is calculated as the cosine of the q between zero points and is expressed as
a decimal fraction (0.8) or as a percentage (80%). It can also be shown to be the ratio of kW, divided by kVA. In
other words, kW= kVA x P.F.

PRIME POWER - That source of supply of electrical energy utilised by the user which is normally available
continuously day and night, usually supplied by an electric utility company but sometimes by owner generation.

RATED CURRENT - The rated continuous current of a machine or apparatus is the

value of current in RMS or DC amperes which it can carry continuously in normal service without exceeding the
allowable temperature rises.

RATED POWER - The stated or guaranteed net electric output which is obtainable continuously from a
generating set when it is functioning at rated conditions. If the set is equipped with additional power producing
devices, then the stated or guaranteed net electric power must take into consideration that the auxiliaries are
delivering their respective stated or guaranteed net output simultaneously, unless otherwise agreed to.

RATED SPEED - Revolutions per minute at which the set is designed to operate.

RATED VOLTAGE - The rated voltage of an engine generating set is the voltage at which it is designed to
operate.

REACTANCE - The out of phase component of impedance that occurs in circuits containing inductance and/or
capacitance.

REAL POWER - A term used to describe the product of current , voltage and power factor, expressed in kW.

RECTIFIER - A device that converts AC to DC.

ROOT MEAN SQUARE (RMS) - The conventional measurement of alternating current and voltage and
represents a proportional value of the true sine wave.

SINGLE PHASE - An AC load or source of power normally having only two input terminals if a load, or two
output terminals if a source.

STANDBY POWER - An independent reserve source of electrical energy which upon failure or outage of the
normal source, provides electric power of acceptable quality and quantity so that the user's facilities may
continue in satisfactory operation.

STAR CONNECTION - A method of interconnecting the phases of a three phase system to form a
configuration resembling a star ( or the letter Y). A fourth or neutral wire can be connected to the centre point.

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TELEPHONE INFLUENCE FACTOR (TIF) - The telephone influence factor of a synchronous generator is a
measure of the possible effect of harmonics in the generator voltage wave on telephone circuits. TIF is measured
at the generator terminals on open circuit at rated voltage and frequency.

THREE PHASE - Three complete voltage/current sine waves, each of 360 electrical degrees in length, occurring
120 degrees apart. A three phase system may be either 3 wire or 4 wire ( 3 wires and a neutral).

UNINTERRUPTABLE POWER SUPPLY (UPS) - A system designed to provide power

without delay or transients, during any period when the normal power supply is incapable of performing
acceptably.

UNITY POWER FACTOR - A load whose power factor is 1.0 has no reactance's causing the voltage wave to lag
or lead the current wave.

WATT - Unit of electrical power. In DC, it equals the volts times amperes. In AC, it equals the effective volts
times the effective amps times power factor times a constant dependent on the number of phases.

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