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This article was published in ASHRAE Journal, April 2016. Copyright 2016 ASHRAE. Posted at www.ashrae.org. This article may not
be copied and/or distributed electronically or in paper form without permission of ASHRAE. For more information about ASHRAE
Journal, visit www.ashrae.org.
Stephen W. Duda
In my last column for the “Engineer’s Notebook” series,1 I pointed out that building
system design engineers who regularly design comfort heating and cooling systems
may be called upon only occasionally to design and specify mechanical systems
related to emergency power generation. There may be some facets of engine genera-
tor system design with which an experienced HVAC engineer will not necessarily
be familiar. That previous column dealt with the fuel oil systems; this column will
attempt to tackle engine cooling and generator room ventilation.
This column is intended to apply where an engine design required for the radiator is a source of intake
generator is installed indoors. Complete packaged or makeup air, and a duct enclosure from the radiator
engine generator systems are commercially available in discharge to the building exterior. The primary disad-
an assembled engine and generator, with factory pre- vantage of the unit-mounted radiator is that, on large
packaged exhaust system, radiator, louvers, and acces- units, the airflow rate of the radiator’s cooling fan can be
sories in a weather-proof housing ready to “plug and exceptionally high—a difficult hurdle to overcome if the
play.” This column is not intended to apply to that type of engine-generator package is to be located remote from a
product. ready path to outdoors.
packages with remote radiators, but their size and pres- working nearby,2 as exhaust temperatures can approach
sure capacity limits the distance to the radiator. Often, 1,000°F (540°C).
the engineer will need to specify separate external The muffler is most often sized and selected by the
pumps, with a separate power connection. Since we are engine generator manufacturer, and either critical-
discussing emergency power generation, these external grade or super-critical grade are most often chosen.
jacket water pumps and remote radiator fans will obvi- Physical styles include an inline cylindrical type, or
ously also require a source of emergency power. Remind space/layout considerations may indicate use of a
the electrical engineer to oversize the generation capac- “pancake” style that is wider but flatter, with bottom-
ity because of the power that will need to be diverted in and side-out arrangement. Just as with the pipe, it
from emergency use to power the jacket water pumps may require insulation for safety reasons, or factory-
and remote radiator fans. insulated models may be specified. Engine generator
Design Tip: Today’s engines often require two sepa- manufacturers also frequently offer a pipe expansion
rate piping circuits for jacket cooling water—one each fitting for use at the generator exhaust manifold connec-
for the engine and turbocharger—and the radiators tion, and a weather cap of some sort for the termination
typically are coiled with the two circuits intertwined. A point.
total of four pipe lines are required, two supply and two Some engineers add a spring-loaded pressure relief
return, and cannot be combined due to their differing device in the engine exhaust piping, because they
temperatures. Failure to recognize this may result in believe it is required by NFPA 37-20103 Paragraph 8.1.4
costly last-minute design changes and a lesson learned “Exhaust systems shall be designed and constructed to
the hard way. withstand forces caused by the ignition of unburned fuel
Design Tip: Selecting jacket water circulating pumps or shall have provisions to relieve those forces without
is not unlike selecting pumps for HVAC chilled or heat- damaging the exhaust system.” However, the explana-
ing water. However, the jacket water is typically a glycol tory appendix material at the end of NFPA 37 Item
solution (in locations where winter temperatures can A.8.1.4 reads “Normally, this provision is met by the
be expected to fall below freezing), and the operating built-in strength of the system.” Building operators find
temperatures are higher than most heating water selec- the pressure relief devices to be a tremendous nuisance
tions, so density, specific heat, and other fluid proper- and the component manufacturers this author spoke to
ties must be properly applied. Do not use the common agree that the system is designed with sufficient robust-
properties of water without appropriate adjustment. ness so as to avoid the pressure relief fittings.
Finally, radiator pressure ratings need to be reviewed. The length of the exhaust run may be just a few
A typical radiator may be designed for close coupling yards/meters if located near an exterior wall or roof;
with relatively low pressure ratings. If located far away but may be a great distance away if, for example,
from the engine, the pumping pressure requirements the exhaust must route vertically from a basement
can exceed the radiator pressure rating. This may through a tall building. If lengthy, the engineer must
require addition of a secondary loop with an isolation consider the maximum exhaust static pressure avail-
heat exchanger. able as published by the engine manufacturer – often
on the order of 27-in. w.c. (6.7 kPa). Long runs also
Engine Exhaust Mufflers, Piping and Accessories require consideration for additional expansion fit-
The engine exhaust must be ducted outdoors and tings as the piping will be subject to cycles between
discharged at an acceptable location. Common com- ambient temperature and the nearly 1,000°F (540°C)
ponents of the exhaust system are flexible connectors, exhaust temperature. Supports, anchors, and guides
mufflers, anchors and guides, an end-cap or other need to be selected to allow for expansion and
termination, and pressure relief. Particulate filters can contraction.
also be required in some pollution control districts. Design Tip: Do not manifold the exhaust piping
The piping itself can be standard-weight welded steel from multiple engine sets. Instead, route each engine’s
pipe. Insulation, typically Calcium Silicate, on that exhaust pipe to the outdoors separately. If manifolded,
pipe is often needed for safety of personnel who may be the online machine will backfeed exhaust to an offline
engine, causing portions such as the turbocharger to engineers use a modulating damper actuator for room
freewheel without the oiling system active. temperature control as explained in the subsequent
Design Tip: In lieu of steel piping with field-applied subsection.
insulation and applied expansion fittings, many engi- Design Tip: In locations where winter temperatures
neers find it more convenient and cost-effective to can be expected to fall below freezing, it is advantageous
specify a pre-engineered listed double-wall exhaust flue to install a separate smaller intake louver/damper sized
system offered by many of the same manufacturers that for the larger of (a) the room’s ventilation airflow rate
sell boiler exhaust flues. This type of product is already or (b) the engine manufacturer’s published combustion
insulated, and the manufacturer includes the expansion airflow demand. By keeping the ventilation and com-
fittings, guides and anchors, plus the technical expertise bustion air function separate from the large air require-
to properly select same. ment of the radiator, room heating during generator
Design Tip: Options for terminating the engine operation is facilitated. This feature can also be achieved
exhaust include the roof or sidewall. One trick features using one large louver/damper with a separate actuator
sidewall termination by poking through the same lou- controlling only a few of the damper blades of the larger
ver serving the radiator discharge. The radiator airflow assembly.
helps carry away the exhaust fumes so the adjacent Design Tip: To guard against risk of having the damp-
building walls don’t stain. ers fail to open when needed for emergency operation,
specify these dampers to be actuated by motors with a
Air-Side Components spring return feature, which fail-safe in the position
The next challenge is to design and specify the ventila- favorable to generator operation. If non-spring types are
tion, heating, combustion air, and radiator air cooling. used, the actuators must be powered from the emer-
Regardless of whether the radiator is unit-mounted or gency power system.
remote, the generator equipment room will need ventila- Design Tip: Using a remote radiator does not com-
tion, combustion air, and (depending on climate) heating; pletely remove the need for ventilation airflow across
but the radiator air cooling provisions described here are the engine/generator set during operation. If the
only applicable for unit-mounted radiators. radiator is remote from the engine/generator set, local
ventilation of the engine/generator room is necessary
Combustion Air & Radiator Makeup-Air Design for removal of heat from the engine itself, plus genera-
For the case of the factory-mounted radiator, the tor winding heat removal, which could be up to 5% of
airflow rate of the radiator’s cooling fan can be quite rated generator capacity. Manufacturer’s literature
high and its external pressure drop capability is quite provides the full-load rated heat losses to the room
low (e.g., 0.5 in.w.c [125 Pa]), requiring both a large for the engine and generator that must be removed by
discharge louver and a large intake louver. The intake ventilation.
louver should preferably be located on the wall directly
opposite the radiator discharge louver. If located on an Generator Room Heating & Ventilation
adjacent wall, the intake louver should be as remote It would be uncommon for an emergency generator
as practical from the radiator discharge louver, so that equipment room to be air-conditioned, but they cer-
outdoor air is drawn across the hot generator and engine tainly might be ventilated; and in many climates winter
during operation. heating will be necessary as well. Ventilation can be as
In locations where winter temperatures can be simple as an exhaust fan and makeup air intake louver,
expected to fall below freezing, automatic motorized controlled either thermostatically, or based on occu-
dampers should be used on both the intake and exhaust pancy, or both. Control the ventilation system to power
louvers so that they may be closed during long idle peri- on when room temperature in the summer exceeds
ods when the emergency generator is not in use. The a desired setpoint, and perhaps anytime the room is
dampers should be wired to open on the same signal occupied.
that starts the engine generator. While the actuators Winter heat is usually provided via a unit heater;
can be simple two-position open-closed models, many gas-fired, hot water, or steam are common sources;
louver discharge and/or the outdoor air intake lou- systems may find useful these tips and suggestions on
ver may be needed and even required by local codes, emergency generator auxiliaries such as exhaust muf-
depending on distance to the property line, orienta- flers and piping; local and remote radiators; combus-
tion, and type of neighborhood (residential, commer- tion air and radiator makeup-air. The December 2015
cial, institutional, or industrial). Mitigating strategies “Engineer’s Notebook” column included a related dis-
may include sound attenuators or an exterior barrier cussion of fuel oil storage tanks and tank accessories,
wall. Space does not allow a full treatment of sound fuel oil piping, valves, and accessories, leak detection
attenuation in this column, so see instead the topic in and monitoring systems, return oil coolers, and fuel oil
the ASHRAE Handbook.4 transfer pumps.
Design Tip: The engine-generator package manufac-
turer will publish allowable static resistance the radia- Acknowledgments
tor fan can overcome external to the radiator itself, and The author heartily thanks Jeffery M. Coffelt, P.E.,
is often 0.5-in. w.c. (125 Pa), so the engineer must be Member ASHRAE, for his technical contributions to this
mindful of this when selecting the louver, damper, and column.
any sound attenuator.
References
Conclusions 1. Duda, S. 2015. “Fuel oil systems.” ASHRAE Journal 57 (12).
2. Duda, S. 2014. “Overlooked code requirements.” ASHRAE
The intent of this column was to review some of the Journal 56 (12).
necessary non-electrical design considerations for die- 3. NFPA 37-2010, Standard for Installation and Use of Stationary Com-
bustion Engines and Generators. Quincy, Mass.: National Fire Protection
sel engine emergency generator systems. The engineer Association.
or designer who is infrequently asked to design these 4. 2015 ASHRAE Handbook—HVAC Applications, Chapter 48.