Finning Contacts:

Ben Mah – Project Development Manager

bmah@finning.com

Chris Schurmans – Project Development Manager

cschurmans@finning.com

Ryan Goertz – Business Development Manager

rgoertz@finning.com

Ian McMaster – Electric Power Generation Representative

Ian.McMaster@finning.com

Jim Boyd – Project Development Manager

Jim.Boyd@finning.com

Bryce Burgeson – Electric Power Generation Representative

bburgeson@finning.com

Moe Jabouri – Strategic Account Manager

Moe.Jabouri@finning.com

Jim Donnelly – Senior Specifications Specialist

Jim.Donnelly@finning.com

Sid Kuzmanovic – Project Development Manager

Sinisa.Kuzmanovic@finning.com

Mickey Randhawa – Technical Applications Representative

Malkiat.Randhawa@finning.com

Gavin Gunderson – Electric Power Generation Representative

Gavin.Gunderson@finning.com

Chris Koehler – Technical Applications Representative

Page 35 Chris.Koehler@finning.com
 Introduction to
Diesel Genset
Application and
Installation

Mag Wahban
Large Electric Power

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 Agenda
• Engine Room Design
• Air Intake Systems
• Cooling Systems
• Ambient Conditions
• Exhaust Systems
• Fuel Systems
• Engine Room Ventilation
• Foundations & Isolation

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 Engine Room Design Considerations

• Single or Multiple Use Facility

• Single or Multiple Generators
• Prime Power or Standby
• Ventilation Requirements
• Cooling Requirements
• Serviceability
• Clearances
• Access

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 Single or Multiple Use Facility
Single Use Facility
The room is primarily dedicated to generators.
Multiple Use Facility
The multi use facility would not only have generator sets,
but also auxiliary equipment such as boiler units,
compressors, etc.

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 Engine Room Location Considerations
Prime Power versus Standby Power

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 Serviceability

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 Engine Room Layout

• Emergency Wash Station

• Fire Suppression System
• Compressed Air
• Ventilation Air
• Water
• Shore Power
• Load Testing
• Cable Routing

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 Engine Room – Cable Routing & Control Panel

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 Serviceability - Clearances

• Generator set
– Overhead
– Side
– Front and Rear

• Electrical Equipment
– Breakers
– Connections
– Buss Bar

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 Air Intake
Systems

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 Air Cleanliness
• Dirt and debris ingested into the engine are a major
source of wear on moving engine parts.
• The air intake is a significant path for dirt and debris to
enter the engine.
• Sources of dirt and debris in the air intake include:
– Materials left from initial fabrication and assembly of
ducts
– Air Filter changes
– Air intake duct leaks
– Environment

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 Particles in Intake Air
• Particles under 0.001mm (1 micron) diameter have little
effect and will pass out through the exhaust

• Particles from 0.001 – 0.01mm (1-10 microns) diameter

have a measurable effect on the engine

• One teaspoon of 0.125mm (125 microns) diameter dust

per hour will create catastrophic failure of an engine in 24
hours

The average human hair is 0.08mm (80 microns) in diameter

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 Air Cleaner Configurations

• Engine mounted
• Remote mounted
• Multiple element
• Multi-stage

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 Combustion Air Flow Requirements
• Varies according to engine
model, rating and fuel
• Provided on technical data
sheet in both volumetric and
mass flow terms
• Establishes total flow
requirement for use in
design of the site air intake
system
• Used in restriction
calculations

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 Cooling Systems

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 Review of the Basics – Engine Heat Balance

Internal Heat
~ 25% - 35%

Mechanical Work
30%-40%

Exhaust Energy
~ 30%-35%
Radiation ~ 5%

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 Review of the Basics – Heat Removal

Internal heat is removed by:

– Jacket water
– Oil cooler
– Aftercooler

Oil cooler heat load is included in the jacket water heat

load on diesel engines and in the aftercooler heat load
on most engines manufacturers

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 Review of the Basics – System Types
Cooling system is defined by how the aftercooler
heat is handled:
– JWAC jacket water aftercooled
– SCAC separate circuit aftercooled
– ATAAC air to air aftercooled
– Two stage aftercooler (JWAC+SCAC)

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 Radiators – Installed and Remote

Installed/Engine mounted Remote

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 Radiator Air Flow

• Restriction
– Try to design room to ½”
H2O restriction
– Plan cooling at ¾” H2O
restriction
• Louvers typically require
an additional 25% larger
opening, heavy duty bird
screen material,
• Walls at the air exit
should be 2 fan
diameters or more
away from the radiator

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 Radiator Sizing

Required information for proper radiator sizing:

– Heat rejection to JW and AC
– Radiant heat added to room
– Room air restriction (if installed radiator)
– Line loss and pump flow rate
– Site altitude
– Max ambient temperature

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 Heat Rise

• Heat Rise - Potential temp rise

as intake air moves across gen-
set Air at Increasing
Radiator Temperature
• For Caterpillar Diesel Engines: Air in
– Tier 2 engine in a power room: Enclosure
5oC heat rise or Room
– Tier 4 engine with CEM in a Ambient Air
power room: 6oC heat rise Outside
– Tier 2 engine in an enclosure:
7oC heat rise
– THESE ARE MINIMUM VALUES
• When specifying, make sure to
clarify location of ambient
temp or specify cooling system
capability including heat rise. Airflow Direction

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 Ambient
Conditions

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 Altitude
• Operating generator sets at altitude can effect performance
– Cooling: lower air density reduces cooling capability, larger radiators/fans or
more airflow needed.
– Combustion: intake air is less dense, resulting in lower power or or higher
volume of air needed for the same amount of power.
• In general, generator sets operating over 1000M (3281 ft) may
require a derate. Information specific to each generator set is
available (example below)
Altitude
Derate

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 Ambient Temperature
• Where the temperature of the ventilating air to the generator
exceeds specific temprature, derating of the generator set may be
necessary
– This is the temperature of the air when it reaches the air intake, not the outside
ambient air temperature
– Temperature derate information is available for all products (example below).

Temp Derate

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 Specsizer – Ambient/Altitude Derate
Cat Specsizer will account for ambient and altitude derates

User inputs on Ambient

Site capability (based on user inputs)

Factory (STP) capability

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 Humidity

• Condensation from humidity can cause performance

and maintenance related issues for generator sets
– Engine: corrosion, air filter damage
– Generator End: Insulation damage
• Generator ends that have been exposed to moisture
and not properly dried can experience catastrophic
failures.
• For High humidity areas, space heaters should be used
to raise the temperature to 5 C above the ambient
temperature, to prevent condensation

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 Exhaust Systems

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 Exhaust System Considerations

• Minimize back pressure

• Reduce noise
• Provide adequate clearance
• Ensure proper mounting

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 Back Pressure

• Design target – half the

maximum allowable
system back pressure
• Common reasons for the
increase back pressure
– Exhaust pipe diameter
– Sharp bends
– Exhaust pipe length
– Silencer resistance

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 Noise Reduction

• Determine Attenuation Level

– Level 1: Residential (18-25 dB reduction)
– Level 2: Critical (18-30 dB reduction)
– Level 3: Supercritical (32-42 dB reduction)
• Selecting a Silencer
– Balance sound attenuation with back pressure
– Space, Cost, Appearance

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 Fuel Systems

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 Diesel Fuel Supply System

• Fuel Storage System

• Fuel Transfer System
• Fuel Filtration System

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 Fuel Storage System
• Main Tank
– Sizing Rule of Thumb: Fuel
Consumption Rate x Hours
Between Refills at 100% load
factor depending on
application
• Day Tank
– Required when main fuel
tank is:
• Same level, > 50 ft away
• > 12 ft below engine
• Required by code

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 Fuel Transfer System
• Fuel Pump Capability and
Design Considerations
– Vertical distance from tank to
pump
– Internal piping system losses
– Elevation
• Routing
– Avoid hot surfaces
– Low to the ground

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 Fuel Filtration System
• Engine fuel filters must never
be removed or bypassed.
– Duplex fuel filters can be used
to allow filter changes while the
unit is running
• Removal of water and
sediment
– Water separator

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 Diesel Fuel Quality CSA282-19

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 Engine Room
Ventilation

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 Ventilation
• Remove Radiant and
Convection Heat
– Genset and Switchgear
performance
– Adequate conditions for
personnel
• Engine Room Temperature
Rise
– 5oC to 12.5oC
– Never exceed 49oC
• Air Velocity
– 1.5 m/s in working areas

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 Ideal Ventilation - Direction
• Airflow Direction
– Generator end to Radiator
– Horizontal flow
– Low entry
• Air should be
– Cool
– Dry
– Clean

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 Ventilation Considerations - Routing
• Airflow Routing
– Entry as far and low as possible
– Discharge as high as possible
– Do not blow cool air toward hot engine components

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 Incorrect Flow Single Engine

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 Multiple Engine Arrangement

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 Incorrect Ventilation

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 Foundations &
Isolation

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 Functional Requirements for Foundations

• Support total weight (mass) & dynamic loading

of equipment, accessory equipment and fluids
(coolant, oil and fuel)
• Maintain alignment between engine, driven
equipment, and accessory equipment
• Isolate equipment vibration from surrounding
structures

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 Concrete Foundations

• Avoid excessively thick bases

• Mass no less than mass of
equipment

• For paralleled units foundation must

withstand twice the weight
• Minimum 12 inch edge clearance
• Depth to attain minimum weight
𝐹𝐹𝐹𝐹 = 𝑊𝑊 ÷ (𝐷𝐷 × 𝐵𝐵 × 𝐿𝐿)
FD = Foundation Depth B = Foundation Width
W = Total Weight of Equipment L = Foundation Length
D = Density of Concrete

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 Isolators

• Types of Isolators
– Bulk Isolation (<spring/rubber isolation)
– Rubber (<=90% isolation)
– Spring (>96% isolation)

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 Caterpillar Resources – EP Application Center
Single source for Caterpillar
Electric Power resources
– SpecSizer Access
– Technical Information Portal
– Product Information
– White Papers
– Customer Testimonials
– Training
– Cat EP News

https://www.cat.com/en_US/articles/solutions/electric-power-generation/electric-
power-app-center.html

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Finning Contacts:
Ben Mah – Project Development Manager
bmah@finning.com

Chris Schurmans – Project Development Manager

cschurmans@finning.com

Ryan Goertz – Business Development Manager

rgoertz@finning.com

Ian McMaster – Electric Power Generation Representative

Ian.McMaster@finning.com

Jim Boyd – Project Development Manager

Jim.Boyd@finning.com

Bryce Burgeson – Electric Power Generation Representative

bburgeson@finning.com

Moe Jabouri – Strategic Account Manager

Moe.Jabouri@finning.com

Jim Donnelly – Senior Specifications Specialist

Jim.Donnelly@finning.com

Sid Kuzmanovic – Project Development Manager

Sinisa.Kuzmanovic@finning.com

Mickey Randhawa – Technical Applications Representative

Malkiat.Randhawa@finning.com

Gavin Gunderson – Electric Power Generation Representative

Gavin.Gunderson@finning.com

Chris Koehler – Technical Applications Representative

Page 35 Chris.Koehler@finning.com