Generator engines give off deadly carbon monoxide gas through their exhaust
systems.
Carbon monoxide gas, if breathed in sufficient concentrations, can cause
unconsciousness or death. Exhaust gases must be piped safely away from any
room or enclosure that houses a generator and to a well ventilated area where
people will not be endangered.
Besides the possibility of carbon monoxide poisoning, exhaust piping becomes
extremely hot during operation and remains hot for a long time after shutdown.
For that reason, the following precautions are necessary:
7-2. General Rules
for Exhaust Systems
When installing an exhaust system for a generator, the following rules should
be considered:
7-3.
Routing
Exhaust Piping Through Combustible Walls
Figure 10. Wall Thimble
7-4.
Routing Exhaust
Piping Through Combustible Roofs
Exhaust piping that passes through any combustible roof must be separated
from the roof by a ventilated metal thimble that is at least 6 inches in
diameter larger than the piping. The thimble must extend at least 9 inches
(229mm)(10 inches (250mm) recommended) above and below roof construction.
Figure 11. Roof
Thimble
7-5. Rain Cap
A rain cap is recommended on the end of the exhaust pipe. The rain cap is
attached to the end of the pipe and opens due to the pressure from the exhaust
discharge force. The rain cap protects the exhaust system from the environment
when the system is not running.
7-6. Spark Arrestor
Use of a spark arrestor is required by the U.S. Department of Forestry if
located on lands under their jurisdiction. The spark arrestor is recommended
in areas where combustible materials may ignite such as dry grass, leaves,
or other combustible materials.
The exhaust back pressure of the generator when measured at full load must
not exceed the manufacturer's recommendations. The size of exhaust pipe,
number and type of ends and fittings together with the selection and location
of muffler determine exhaust back pressure.
A typical 90 degree bend in an exhaust system is equal to adding 8 feet (2.67
meters) of pipe.
SECTION 8 - Gaseous Fuel Systems
8-1. General (Gaseous Fuel
Systems)
Some generators are equipped with fuel systems that utilize Liquefied Petroleum
(LP) or Natural Gas as a fuel.
Local fuel gas codes may vary widely. For that reason, it is recommended
that a local gas distributor or installer be consulted when installing a
gaseous fuel supply system. In the absence of local fuel gas codes and
regulation, booklets published by the National Fire Protection Association
(NFPA) may be used as sources of information.
The installer must ensure that the correct fuel delivery system is installed,
and that applicable standards and codes are strictly complied with.
8-2. Advantages of Gaseous
Fuels
Use of Natural and LP gas as a fuel may result in a slight power loss. However,
that disadvantage is usually compensated for by the many advantages of gaseous
fuels. Some of the advantages of gaseous fuels are:
Low residue content, resulting in minimum carbon formation.
8-3. Gaseous Fuel System Variations
Any one of four different types of gaseous fuel systems may typically be
installed by the factory on your generator system, dependent upon the model.
These are:
8-4. Properties of Gaseous
Fuels
Natural Gas: Is lighter than air and tends to settle in high places.
Natural gas is found in the gaseous state only at normal ambient conditions.
Natural gas is highly explosive and accumulations of the gas can be ignited
at the slightest spark. For that reason, adequate ventilation is absolutely
essential and fuel lines must be free of leaks. Local fuel/gas codes usually
dictate the maximum pressure at which natural gas can enter a structure.
A primary regulator is required, to reduce the pressure of the delivered
gas to the reduced pressure required by code.
LP Gas: Is heavier than air, tends to settle in low places. The gas
is highly explosive and the slightest spark can cause an explosion. LP gas
is usually supplied in pressure tanks as a liquid, but is found in gaseous
form at normal atmospheric temperature and pressure. It may consist of (1)
butane, or (2) propane, or (3) a mixture of these two gases. Fuel suppliers
may fill the supply tank with a mixture made up primarily of butane in warm
weather. Butane may not provide sufficient vapor pressure in colder weather
and more propane may have to be added to the mixture. The ratio of butane
to propane is especially important when a large outdoor supply tank is used.
LP gas must be converted to its vapor state before it enters the engine
carburetor.
The maximum pressure at which natural gas can enter the building is established
by code and may vary from area to area. The gas distribution company will
usually provide piping from the main distribution line to the standby generator
site. A primary regulator is needed to reduce gas supply pressures to the
required safe level before the gas enters a building. Such a regulator may
or may not be provided by the gas supplier. It is the responsibility of the
gas supplier to ensure that sufficient gas pressure is available to operate
the primary regulator.
Gas outlet pressure from the primary regulator to the standby generator's
shutoff valve should typically not exceed approximately 0.50 pounds per square
inch (psi), or 14 inches of water column. Optimum supply pressure to most
small generator's shutoff valve is 11 inches of water column. Depending on
the characteristics of the specific shutoff valve in use, the valve may or
may not open at supply pressures greater than 0.50 psi (14 inches water
column).
Install a flexible length of fuel line between rigid piping and the Generator
engine's natural gas connection point.
Natural gas is delivered to the primary regulator. From the primary regulator,
in most installations, the gas flows through a solenoid operated fuel shutoff
valve, a pressure reducing valve and the engine's natural gas carburetor.
The shutoff valve is electrically energized open during startup and running,
is de-energized closed on shutdown. The carburetor measures engine air flow
and meters gas to the engine based on throttle setting and load. The carburetor
also provides a positive gas shutoff.
8-6. LP Gas Vapor Withdrawal
System
This type of system utilizes the vapors formed above the liquid fuel in the
supply tank. Approximately 10-20 percent of the tank capacity is needed for
fuel expansion from the liquid to the vapor state.
Ambient temperatures around the supply tank must be high enough to sustain
adequate vaporization or the system will not function properly. In addition
to the cooling effects of ambient air, the vaporization process itself provides
an additional cooling effect. Vapor withdrawal systems are generally more
suited for smaller engines that need less fuel.
When ambient temperatures are low and fuel consumption is high, the vapor
withdrawal system may not function efficiently. This is particularly true
with larger engine machines.
Many LP gas and Natural Gas vaporous fuel systems are identical as a demand
regulator is used to provide fuel to the engine.
8-7. LP Liquid Withdrawal
System
This type of system delivers gas in liquid form to a generator. The liquid
fuel must then be vaporized before it is delivered to the engine
carburetor.
Liquid withdrawal (LP) gas systems usually employ a "vaporizer-regulator"
to convert the liquid to its vapor state. A "vaporizer-regulator" is mounted
in the air flow of the engine to provide heat to the regulator for fuel
vaporization.
LP liquid withdrawal is typically used for equipment used in remote locations
where size and availability of refilling the tank is limited. Liquid withdrawal
is also used for trailered and construction site equipment.
8-8. Dual Natural/LP Gas Fuel
System
In some areas, the cost of Natural gas may be reduced considerably by procuring
the gas on "interrupted service" rates. Such "interrupted service" can be
obtained by using LP gas as an emergency fuel whenever Natural gas is not
available.. Automatic changeover is accomplished by using two regulators
- a line pressure regulator for natural gas and a vacuum operated regulator
for LP gas. The differences in pressures compensates for the greater BTU
value of LP gas.
During operation on Natural gas, a 5 inch (water column) (typical) pressure
exists in the common line to the carburetor. This pressure closes the LP
gas regulator. Loss of Natural gas pressure causes loss of pressure in the
line; the LP gas regulator then opens to admit LP gas into the system. A
separate power mixture adjustment in the LP gas line provides precise setting
of air/fuel ratios for each of the two fuels. Changeover is automatic with
the engine operating.
8-9. Gaseous Fuel System Piping
The following general rules apply to piping used in gaseous fuel systems:
NOTE: In the absence of local purging and leak test standards, NFPA
No. 54 may be used as a guide.
8-10. Gaseous Fuel Pipe Sizes
A "Gas Flow Pipe Sizing Chart" (Table 8-1) is provided
below. Use the chart to determine the correct piping diameter in gaseous
fuel systems (such as Natural gas and LP gas vapor withdrawal type).
To find the proper pipe diameter, the installer must know (a) the length
of the gas piping run, and (b) the cubic feet of gas needed by the generator
when under full load.
First, find the length of the piping run on the chart.
From the pipe length figure on the chart, move horizontally across the chart
until you reach a number that is just higher than the cubic feet of gas needed
under full load. From the cubic feet of gas figure, move straight up vertically
in the chart to the pipe diameter given in that vertical column. This is
the pipe size required.
LP Gaseous Fuel Example: A small 16 horse power generator when operating
at full load requires a supply of 51 cubic feet per hour of LP gas. Length
of the piping run from the supply tank is 60 feet. Propane gas having a specific
gravity of 1.5 and with a multiplier of 0.633 is used
(Table 8-2). From the pipe length in the chart,
trace horizontally across to "86" (the first number larger than 51 cubic
feet). Moving vertically upward in the chart, a 3/4 inch pipe is needed.
Applying the chart conversion factor (86 x 0.633=54.44) and the 3/4 inch
pipe is still adequate.
Natural Gas Example: A small 16 horse power generator operating at full load requires 115 cubic feet per hour of Natural gas. Length of the piping run from the supply tank is 75 feet. Natural gas having a specific gravity of 0.65 and with a multiplier of 0.962 (Table 8-2) is to be used. From the pipe length in the chart, trace horizontally across to "155" (the first number larger than 115 cubic feet). Moving vertically upward in the chart, a 1 inch pipe is required. Apply the conversion factor (155 x 0.962=149.1) and the 1 inch pipe is still adequate.
Table 8-1. Gas Flow Pipe Sizing Chart |
|||||||||||
Length of |
1/2 In. |
3/4 In. |
1 In. |
1-1/4 In. |
1-1/2 In. |
2 In. |
2-1/2 In. |
3 In. |
4 In. |
6 In. |
8 In. |
15/4.57 |
76 |
172 |
345 |
750 |
1220 |
2480 |
3850 |
6500 |
13880 |
28700 |
79000 |
30/9.14 |
52 |
120 |
241 |
535 |
850 |
1780 |
2750 |
4700 |
9700 |
27370 |
55850 |
45/13.72 |
43 |
99 |
199 |
435 |
700 |
1475 |
2300 |
3900 |
7900 |
23350 |
45600 |
60/18.29 |
38 |
86 |
173 |
380 |
610 |
1290 |
2000 |
3450 |
6800 |
19330 |
39500 |
75/22.86 |
|
70 |
155 |
345 |
545 |
1120 |
1750 |
3000 |
6000 |
17310 |
35300 |
90/27.43 |
|
77 |
141 |
310 |
490 |
1000 |
1560 |
2700 |
5500 |
15800 |
32250 |
105/32.00 |
|
65 |
131 |
280 |
450 |
920 |
1430 |
2450 |
5100 |
14620 |
29850 |
120/36.58 |
|
|
120 |
270 |
420 |
860 |
1340 |
2300 |
4800 |
13680 |
27980 |
150/45.72 |
|
|
109 |
242 |
380 |
780 |
1220 |
2090 |
4350 |
12240 |
25000 |
180/54.86 |
|
|
100 |
225 |
350 |
720 |
1120 |
1950 |
4000 |
11160 |
22800 |
210/64.01 |
|
|
92 |
205 |
320 |
660 |
1030 |
1780 |
3700 |
10330 |
21100 |
240/73.15 |
|
|
|
190 |
300 |
620 |
970 |
1680 |
3490 |
9600 |
19740 |
270/82.30 |
|
|
|
178 |
285 |
580 |
910 |
1580 |
3250 |
9000 |
18610 |
300/91.44 |
|
|
|
170 |
270 |
545 |
860 |
1490 |
3000 |
8500 |
17660 |
450/137.16 |
|
|
|
140 |
226 |
450 |
710 |
1230 |
2500 |
7000 |
14420 |
600/182.88 |
|
|
|
119 |
192 |
390 |
900 |
1030 |
2130 |
6000 |
12480 |
Table 8-2. Chart Conversion Factors |
|||||
Specific |
Multiplier |
Specific |
Multiplier |
Specific |
Multiplier |
0.50 |
1.100 |
0.700 |
0.926 |
1.200 |
0.707 |
0.55 |
1.040 |
0.800 |
0.867 |
1.400 |
0.655 |
0.60 |
1.000 |
0.900 |
0.817 |
1.500 |
0.633 |
0.65 |
0.962 |
1.000 |
0.775 |
1.700 |
0.594 |
Note 1: Use of elbows increases pressure drop on fuel lines.
A 90 degree elbow adds 3 to 8 feet of equivalent length to your
pipe estimate. |
Go to APPENDIX A - Applicable Codes
Tips on Hooking up a Generator (genset) to a Uninterruptible Power System (UPS)
|
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Copyright © Dexter A. Hansen