GENERATOR

MAINTENANCE
COURSE
Workshop Session
28 – 29 August 2023
Johannesburg
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 INTRODUCTION

ü Who we are?

ü What we do?

ü Why you should listen?

Thursday, September 14, 23 Page 3

 PAIN + SOLUTION

ü What’s the pain?

ü What are the current solutions?

ü How can we eliminate the pain?

Thursday, September 14, 23 Page 4

 MY STORY

Thursday, September 14, 23 Page 5

 @ulizwe Lizwe Engineers Benjamin Mqenebe

Lizwe Engineers Ntozelizwe Benjamin Mqenebe

9/14/23
9/14/23 [Link]
2015
6 Proprietary & Confidential ©
Proprietary & Confidential © 2015 66
 [Link]/speaking
9/14/23
9/14/23 [Link]
2015
7 Proprietary & Confidential ©
Proprietary & Confidential © 2015 77
9/14/23
9/14/23 [Link]
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 EQUIPMENT LIFE CYCLE
1. Design

Equipment Life 2. Purchase

4. Disposal Cycle

Thursday, September 14, 23 3. Operation & Maintenance Page 9

 1. DESIGN

ü How to design generators?

ü Who is involved in the design

process?

ü What design precautions are

taken with safety?
Thursday, September 14, 23 Page 10
 1. DESIGN

ü What design precautions are

taken with maintenance?

Thursday, September 14, 23 Page 11

 PERMITTING THRESHOLD FOR
GENERATORS
• Generators requiring permits:
–Emergency generators rated greater
than 450 kW
–Distributed generators of any size
Designing for Generator Maintenance
- Access around generator
ü Space around generator for safe working
whilst undertaking maintenance

ü Ideally a 1m free working area around

the engine, alternator &control panel.

ü Isolation taps on the jacket/sump heater

to allow for quick replacement.
Thursday, September 14, 23 Page 13
Designing for Generator Maintenance

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Designing for Generator Maintenance
- Access to generator
ü Access to the generator – rooftop or
basement

ü Oil replacement – up to 500L for large

generators – lifts etc.

ü Fuel replacement – ground floor fuel fill

points
Thursday, September 14, 23 Page 15
Designing for Generator Maintenance

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Designing for Generator Maintenance
- Removal
ü Access to larger serviceable items for
repair – radiators, alternators, etc.

ü Removal of generator in and out of plant

rooms – ensure louvre apertures are
larger than the generator

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Designing for Generator Maintenance
- Removal
ü Removal of generator containers from
rooftop locations – containers to rated
for full lifting weight of generator

Thursday, September 14, Page 18

23
Designing for Generator Maintenance

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Designing for Generator Maintenance
- Temporary generator/load bank
ü Economically more viable to include at
design/installation stage

ü Makes load bank testing easier as part of

maintenance regime

ü Easy connection of temporary generation

in the event of a failure
Thursday, September 14, 23 Page 20
Designing for Generator Maintenance

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 2. PURCHASING

ü How purchasing is done?

ü Who is involved in the purchasing

process?

ü What influence purchase decision

is it Quality or Price?
Thursday, September 14, 23 Page 22
 3. OPERATIONS & MAINTENANCE

ü Where to start with involvement of

Operations & Maintenance?

ü Who design O&M Manual Plans?

Thursday, September 14, 23 Page 23

 3. OPERATIONS & MAINTENANCE

ü What is looked at in the setting of

O&M Manual Plans?

ü When does a Maintenance Plan

Optimized?

Thursday, September 14, 23 Page 24

 4. Disposal

ü Who is the custodian of an asset

finance/maintenance/operations?

ü Is disposal policy amended and if

so how often?

ü How will a Generator be disposed?

Thursday, September 14, Page 25
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 OVERVIEW OF GENERATORS

ü INBOUND MARKETERS ARE

RESPONSIBLE FOR FINDING LIFE
ON MARS

Thursday, September Page 26

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 SHORT TERM OPERATING RESERVES
(STOR)
- Current Climate
ü Government committed to
expansion of renewable
technology
ü Decommission of coal fired and
nuclear power stations – less
capacity
Thursday, September 14, 23 Page 27
 OVERVIEW OF GENERATORS

ü INBOUND MARKETERS ARE

RESPONSIBLE FOR FINDING LIFE
ON MARS

Thursday, September Page 28

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 OVERVIEW OF GENERATORS

ü INBOUND MARKETERS ARE

RESPONSIBLE FOR FINDING LIFE
ON MARS

Thursday, September Page 29

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 USE STANDBY GENERATION FOR
STOR, TRIAD AVOIDANCE
- Standby generator capacity
ü High cost of ownership

ü Maintenance Costs

Thursday, September 14, 23 Page 30

 USE STANDBY GENERATION FOR
STOR, TRIAD AVOIDANCE
- Standby generator capacity
ü Fundamentals need for reliability

ü Utilization improves reliability

Thursday, September 14, Page 31

23
 STAGES EXPLAINED
- Stage 1 – 1000 MW

- Stage 2 – 2000 MW

- Stage 3 – 4000 MW – 3000MW

1Thursday,
Billion granted for Generator
September 14,
Oil
Page 32
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 OVERVIEW

Thursday, September Page 33

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 OVERVIEW
ü When would we need an Emergency
Generator?

ü How does an emergency generator

work?

Thursday, September 14, Page 34

23
 OVERVIEW
ü What planning needs to be done?

ü How do I properly size the

generator?

Thursday, September 14, 23 Page 35

 Emergency Backup Components
- Automatic Transfer Switch
- Generator
- Engine
- Lubrication System
- Cooling System
- Fluid Systems
- DC Electrical System
- Exhaust System
Thursday, September 14, 23 Page 36
 Transfer Switch Components
Transfer Switch:

A transfer switch is an electrical

device for switching loads
between alternate power
sources. An automatic transfer
switch monitors the condition of
the sources and connects the
load to the alternate source if
the preferred source fails.

Thursday, September 14, 23 Page 37

 Sequence of Operations
- Utility Fails
- Generator Starts – Load Transfers
- Utility Returns – Transfers Back
- Engine Cools Down
- Generator Shuts Off

Thursday, September 14, 23 Page 38

 Time Delays
• Time Delay Engine Start (TDES)
ü 0-6 SECONDS
•Time Delay Normal to Emergency (TDNE)
ü 0.0 TO 60 seconds
• Time Delay Emergency to Normal (TDEN)
ü 1 TO 60 MINUTES – “My generator is
still Running!”
Thursday, September 14, 23 Page 39
 Maintenance of ATS
• Automatic Transfer Switch (ATS)
ü Physical Inspection
ü Performance Test
ü (Engine Start Test/Minimum Option)
ü Utility Failure Simulation
ü (Full System Test/Best Option)

Thursday, September 14, 23 Page 40

 Note: Arc Flash/Blast Hazard
ü Arc Flash is the result
of a rapid release of
energy due to an arcing
fault between a phase
bus bar and another
phase bus bar, neutral
or a ground. During an
arc fault the air is the
conductor.
Thursday, September 14, 23 Page 41
 Arc Flash/Blast Hazard and OHS Act
ü Compliance with OSHA involves adherence
to a six-point plan:
- A facility must provide, and be able to
demonstrate, a safety program with defined
responsibilities.
- Calculations for the degree of arc flash
hazard.
- Correct personal protective equipment (PPE)
for workers.
Thursday, September 14, 23 Page 42
Training for workers on the hazards of arc flash.
 Arc Flash/Blast Hazard and OHS Act
ü Compliance with OSHA involves adherence
to a six-point plan:
- Training for workers on the hazards of arc
flash.
- Appropriate tools for safe working.
- Warning labels on equipment. Note that the
labels are provided by the equipment
owners, not the manufacturers.
Thursday, September 14, 23 Page 43
 Arc Flash Risk Factor
ü Property Damage

ü Injury to Personnel

ü Loss of Life

Thursday, September 14, 23 Page 44

 When would we need an Emergency
Generator?
- Causes of Outages (Normal)
ü Weather: Lightning, wind, rain, snow,
heat, cold and ice

ü Utility Equipment Problems and Grid

Overload

Thursday, September 14, 23 Page 45

 When would we need an Emergency
Generator?
- Causes of Outages (Normal)
ü Fallen Trees or Tree Growth

ü Animal Contact

Thursday, September 14, 23 Page 46

 When would we need an Emergency
Generator?
- Causes of Outages (Normal)
ü Human Error: Underground digging,
cranes, traffic, vandalism, etc.

ü Miscallenous: Mechanical damage,

construction error, fire, etc.

Thursday, September 14, 23 Page 47

 When would we need an Emergency
Generator?
- Risks involved during a loss of power
ü Loss of Communications

ü Loss of Security

ü Lost or Corrupted Data

Thursday, September 14, 23 Page 48

 When would we need an Emergency
Generator?
- Risks involved during a loss of power
ü Lost Productivity

ü Lost Confidence

ü Continuation of Emergency Services

Thursday, September 14, 23 Page 49

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Thursday, September Page 57
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 When would we need an Emergency
Generator?
ü We need it in South Africa Currently!

ü When we spend 10billion on Fuel?

ü Load Shedding is a National Alert!

Thursday, September 14, 23 Page 58

 How does an emergency generator
work?
ü Generator and Automatic Transfer
Switch
ü Permanent or Rental Generator
(SLA)

Thursday, September 14, 23 Page 59

How does an emergency generator
work?

Thursday, September 14, 23 Page 60

 How does an emergency generator
work?
- Emergency Generator are complex
ü System Design, Installation, On-going
Maintenance and impact reliability

Thursday, September 14, 23 Page 61

 How does an emergency generator
work?
- Emergency Generator are complex
ü Single Generator designs have single
points of failure
o Rental Power backup strategy
o Consider Integrated Paralleling
Solution with multiple generators

Thursday, September 14, 23 Page 62

 How does an emergency generator
work?
- Emergency Generator are complex
ü Fuel Reliability
o Natural Gas, Propane, Diesel, Bi-
fuel
o How much fuel is enough? Is fuel
maintained?

Thursday, September 14, 23 Page 63

 How does an emergency generator
work?
- Emergency Generator are complex
ü Costs
o Fuel type, paralleled solution,
enclosures, connectivity features
o What is the best solution for
critical power? (Is it using Gas and
not Fuel?)
Thursday, September 14, 23 Page 64
 SEQUENCE OF OPERATION
Status: Normal Critical
Transfer Switch

Utility
Generator Distribution Panel
Distribution Panel Equipment
Transfer Switch

Generator

65
 SEQUENCE OF OPERATION
Status: Utility failure Critical
Transfer Switch

Utility
Generator Distribution Panel
Distribution Panel Equipment
Transfer Switch

Generator

66
 SEQUENCE OF OPERATION
Critical
Status: Line interrupt delay Transfer Switch

Utility
Generator Distribution Panel
Distribution Panel Equipment
Transfer Switch

Generator

67
 SEQUENCE OF OPERATION
Critical
Status: Transfer switches signal generator to start Transfer Switch

Utility
Generator Distribution Panel
Distribution Panel Equipment
Transfer Switch

Generator
68
 SEQUENCE OF OPERATION
Critical
Status: Transfer switches verify rated output Transfer Switch

Utility
Generator Distribution Panel
Distribution Panel Equipment
Transfer Switch

Generator
69
 SEQUENCE OF OPERATION
Status: Transfer switches transfer to generator Critical
Transfer Switch

Utility
Generator Distribution Panel
Distribution Panel Equipment
Transfer Switch

Generator

70
 SEQUENCE OF OPERATION
Status: Utility is re-energized
Critical
Transfer Switch

Utility
Generator Distribution Panel
Distribution Panel Equipment
Transfer Switch

Generator

71
 SEQUENCE OF OPERATION
Critical
Status: Return-to-utility timer Transfer Switch

Utility
Generator Distribution Panel
Distribution Panel Equipment
Transfer Switch

Generator
72
 SEQUENCE OF OPERATION
Status: The load is transferred back to utility, Critical
generator cool-down begins Transfer Switch

Utility
Generator Distribution Panel
Distribution Panel Equipment
Transfer Switch

Generator
73
 SEQUENCE OF OPERATION
Critical
Status: Generator shuts down Transfer Switch

Utility
Generator Distribution Panel
Distribution Panel Equipment
Transfer Switch

Generator
74
 What planning needs to be done?
- Full or Limited Operation?
ü Standby Generator picks us selected
loads automatically

Thursday, September 14, 23 Page 75

 What planning needs to be done?
- Orderly Shutdown?
ü UPS backs up selected loads until they
can be shutdown

Thursday, September 14, 23 Page 76

 What planning needs to be done?
- No Backup?
ü No power until the utility returns
ü No services provided

Thursday, September 14, 23 Page 77

 What planning needs to be done?
ü Who will be in charge?

ü Determine the loads to be backed up

ü What is the Voltage and Amperage?

ü Where will the generator be located?

Thursday, September 14, Page 78
23
 What planning needs to be done?
ü How will it be hooked up to the
building? Who will hook it up?

ü Have we scheduled a practice outage?

Thursday, September 14, 23 Page 79

 What loads are powered by a
ü Lighting generator?

ü Computers

ü Security System and Phone Systems

ü Air Conditioning/Heat
Thursday, September 14, 23 Page 80
 What loads are powered by a
ü UPS/Data generator?

ü Pumps (fuel, water, etc.)

ü Other electrical equipment

Thursday, September 14, 23 Page 81

How do I properly size the generator?
- After selecting loads (Whole or Limited)
ü What is the Voltage (single or three
phase)

ü What is the amperage needed

Thursday, September 14, 23 Page 82

How do I properly size the generator?
- After selecting loads (Whole or Limited)
ü Oversize the generator by 25% to
handle motor starting and unexpected
loads

ü Work with Engineer, Electrician or

Generator Dealer
Thursday, September 14, 23 Page 83
How do I properly size the generator?
- After selecting loads (Whole or Limited)
ü Make a written plan for this if you are
relying on rental power

ü kW = Volts * Amps * 1.732 * 0.8

1000

Thursday, September 14, 23 Page 84

 Where do we get one in an
Emergency?
ü Generator dealer so I properly size
the generator?

Thursday, September 14, 23 Page 85

 EMISSIONS STANDARDS

Generator Type Existing New

Emergency No Emission Standards EPA Nonroad Standards

Standards Based Upon Standards Based Upon

Distributed Achievable Levels Achievable Levels
 EMISSIONS STANDARDS
üEmergency generators:
- Existing – no actual emissions
limits; just follow manufacturers
maintenance and operating
requirements/instructions.
- New – generator must meet the
emissions standards set by the
US EPA for Nonroad engines.
 EMISSIONS STANDARDS
üEmergency generators:
- New – generator must meet the
emissions standards set by the
South African EPA for Non-road
engines.
 EMISSIONS STANDARDS
üEmergency generators:

***An “old” generator being

installed as a new generator
must comply with the currently
applicable Non-road standards.
 EMISSIONS STANDARDS
üExisting, distributed generators must
meet the following standards:
Emission Standards
Pollutant
In lbs/MWh
Nitrogen Oxides 4.0
Nonmethane Hydrocarbons 1.9

Particulate Matter
0.7
(liquid-fueled reciprocating engines only)

Carbon Monoxide 10.0

Carbon Dioxide 1,900
 EMISSIONS STANDARDS
• New Distributed generators must
meet the following standards:
Emission Standards in lbs/MWh
Pollutant Installed Installed Installed
On or After On or After On or After
Jan. 11, 2006 Jan. 1, 2008 Jan. 1, 2012
Nitrogen Oxides 2.2 1.0 0.6
Nonmethane Hydrocarbons 0.5 0.5 0.3
Particulate Matter
(liquid-fueled reciprocating 0.7 0.7 0.07
engines only)
Carbon Monoxide 10.0 10.0 2.0
Carbon Dioxide 1,900 1,900 1,650
 EMISSIONS STANDARDS
üFor distributed generators,
remember:
- The standards for existing,
distributed generators equate to an
approximate 90% reduction in
emissions, for a typical diesel
generator.
 Emissions Standards
üFor distributed generators, remember:
- The standards for new, distributed
generators can be met by the latest
gaseous-fueled generators and by
well-controlled diesel generators.
 Emissions Standards
üFor distributed generators, remember:
- Emissions standards for
distributed generators are fuel-
neutral.*
*New, distributed generators using
landfill or waste gases
do not have multiple “tiers” of emission
standards.
 Operating Requirements
• An emergency generator has no limits
on the number of hours it can
operate…but it can only operate
during emergencies, testing, or
maintenance.
¡ Ground Level Ozone
¡ “Code Red” or
Pollution Forecast or = ¡ “Code Orange”
¡ Particle Pollution Forecast

*National Fire Protection Association ** Joint Commission on Accreditation of Healthcare Organizations

 Operating Requirements
• A distributed generator has no limit on
the number of hours it can operate…
and it can operate at any time.

¡ Ground Level Ozone

¡ “Code Red” or
Pollution Forecast or = ¡ “Code Orange”
¡ Particle Pollution Forecast

*National Fire Protection Association ** Joint Commission on Accreditation of Healthcare Organizations

 Operating Requirements
However…
• No generator can be operated for
testing or maintenance before 5pm
(except those required to meet NFPA*
or JCAHO** standards) on a day
when:
¡ Ground Level Ozone
¡ “Code Red” or
Pollution Forecast or = ¡ “Code Orange”
¡ Particle Pollution Forecast

*National Fire Protection Association ** Joint Commission on Accreditation of Healthcare Organizations

 Other Requirements
• Sulfur content limits for all fuels:

Diesel Fuel Gaseous Fuels Alternative Fuels

Sulfur 10 grains Total S 10 grains Total S

0.05% S
Content Per Per
Limit (500 ppm) 100 dscf 100 dscf
 Other Requirements
• Records to be kept:
–monthly and yearly fuel usage,
–monthly and yearly operating hours
(a non-resettable hour meter is
required),
–monthly and yearly testing and
maintenance.
 Other Requirements
• For each shipment of liquid fuel
received, a receipt must be obtained
from the distributor which identifies:
–the type of fuel;
–the sulfur content of the fuel; and
–the test method used to determine
the sulfur content.
 Other Requirements
• For each shipment of liquid fuel
received, a receipt must be obtained
from the distributor which identifies:

(As an alternative, a laboratory may

analyze the fuel after each
shipment, in order to certify the
above information.)
 Other Requirements
• Records must be kept at least 5 years.

• Records can be hard copies (papers) or

electronic copies (CDs, floppy disks, etc.)

• No requirement to report records…but an

owner must provide the records to the
Department upon request.
 Credit for Emissions Reductions
üA generator can receive “credit” to
use toward achieving its applicable
emission rates by:
 Credit for Emissions Reductions

- Operating on a fuel that would

otherwise be flared (landfill gas,
process gas);
 Credit for Emissions Reductions

- Operating as a “combined heat and

power” system; or
Credit for Emissions Reductions

– Simultaneously generating
electricity from a non-emitting
resource (wind, solar, etc.).
 Air Permits for Generators
• Permit Application Forms Caterpillar- 470 kW emergency generator

• Permitting Process
• Permitting Requirements
• Full Compliance Evaluation

Caterpillar -100 kW emergency generator

 Permitting Threshold for Generators
• Generators requiring permits:
–Emergency generators rated greater
than 450 kW
–Distributed generators of any size
 Permitting Threshold for Generators

• Generators requiring permits:

–Emergency generators rated greater
than 450 kW
–Distributed generators of any size
 Permitting Threshold for Generators

• Generators which do not require

permits:
–Emergency generators equal to or
less than 450 kW provided that
Regulation No. 1125 does not apply
–Any generator for residential use
only
 How Do I Apply for a Generator Air
Permit?
• Submit:
–AQM-1: Administrative Information
Form
–AQM-3.3: Generator/Engine
Application
–AQM-5: Emissions Information
 How Do I Apply for a Generator Air
Permit?
• Submit:
–Stationary Generator Initial
Notification
–Permit fees per generator:
R___ for construction permit
R___ for legal advertising
Design
 FABRICATION
• Base frame and tank
• Structural frame work
• Inlet ventilation system
• Outlet ventilation system
 FABRICATION
• Base frame and tank
• Structural frame work
• Inlet ventilation system
• Outlet ventilation system
 FABRICATION

Structural Framework Inlet / Outlet Ventilation System

 FABRICATION - SUBCONTRACTORS
• Stainless steel panels
• Stainless steel doors
• Flashing
• Muffler
• Weather louvre
• Surface treatment
FABRICATION - SUBCONTRACTORS

Insulation Fit Out

Complete Panels Door Trial Assembly

FABRICATION - SUBCONTRACTORS

Muffler Elbow & Weather Cowl

Weather Louvre
PROJECT PICTURES – COMPLETE
ASSEMBLY

Outlet End Inlet End

Fuel Connections Exhaust Duct & Blankets

PROJECT PICTURES – COMPLETE
ASSEMBLY

Fuel Interface Genset Installation

Genset Removable Roof

PROJECT PICTURES – COMPLETE
ASSEMBLY

CSBP Generator Package

PROJECT SUMMARY SCHEDULE
PROJECT SUMMARY BUDGET &
MARGIN
 OVERVIEW
ü When would we need an Emergency
Generator?
ü How does an emergency generator
work?
ü What planning needs to be done?
ü How do I properly size the
generator?
Thursday, September Page 126
14, 23
 OVERVIEW
ü When would we need an Emergency
Generator?
ü How does an emergency generator
work?
ü What planning needs to be done?
ü How do I properly size the
generator?
Thursday, September Page 127
14, 23
GENERATOR AND ENGINE CONTROLS

ü Diesel generators are the workhorse of the

power generator industry. Most diesel
generators are designed for a more
permanent installation. They are longer
lasting and more robust in construction but
more expensive to repair.

Thursday, September Page 128

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 MAINTENANCE POINTS
ü AC Generator
- Physical Condition
- Instrumentation
- Performance Test
- Building Load
- No Load

Thursday, September Page 129

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 MAINTENANCE POINTS
ü Engine
- Lube System
- Cooling System
- Air System
- Electrical System
- Instrumentation
- Protection System
- Exhaust Systems
Thursday, September Page 130
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 Fuel Management

- If its for higher services fuel

management service is
completely managed and includes
monitoring and supply:
ü Fuel tankers
ü Fuel Pump Facilities
ü Spill kits
Thursday, September 14, 23 Page 131
 Lubrication
Systems

Thursday, September 14, 23 Page 132

 Fuel Systems

Thursday, September Page 133

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 Fuel Issues
& Polishing

Thursday, September Page 134

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 Fuel Issues
&
Polishing

Thursday, September Page 135

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 Fuel Issues
&
Polishing

Thursday, September 14, 23 Page 136

 Lubrication System
What does my engine oil actually do?
Primarily it stops all the metal surfaces in
your engine from grinding together and
tearing themselves apart from friction

Change oil and filters every 200-250 hours

or annually. Oil breaks down over time due
to high temperatures and infrequent
maintenance.
Thursday, September 14, Page 137
23
 Lubrication System
ü External Oil leaks
ü Oil level on dipstick
- Low Importance, larger engines can
consume up to 12 quarts in a 10 hour period.
- High Importance,
- Coolant in oil
- Fuel in oil

Thursday, September 14, Page 138

23
 Lubrication System
ü External Oil leaks
ü Oil level on dipstick
- Low Importance, larger engines can
consume up to 12 quarts in a 10 hour period.
- High Importance,
- Coolant in oil
- Fuel in oil

Thursday, September 14, Page 139

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 Cooling Systems
ü Major Components
- Engine Block
- Water Pump
- Radiator
- Thermostat
- Block heater
- Belts
-Thursday,
Hoses & Fan
September 14, Page 140
23
 Cooling Systems
ü External coolant leaks
ü Belt condition-cracked or loose
ü Block heater – on constantly or leaking
ü Hoses – leaking, soft, brittle, bulging
ü Radiator – Leaking, plugged, broken fan
shroud

Thursday, September 14, Page 141

23
Exhaust Systems – Areas of Concern

ü Silencer – rust, leaks, broken

brackets
ü Rain cap – opens and closes properly
ü Piping, tailpipe – leaks, broken
brackets
ü Turbo- leaking exhaust or oil
ü Crank Case Breathers-oil over
generator
Thursday, September 14, 23 Page 142
 Wet Stacking
What is it?
Wet stacking is a condition in diesel engines in which not
all the fuel is burned and passes on into the exhaust side
of the turbocharger and on into the exhaust system..
What it causes?
Wet stacking not only reduces the operating performance
of the gensets, it also creates a significant fire hazard.
What causes it?
the diesel engine is running at only a small percentage of
its capacity 40-70%
Thursday, September 14, 23 Page 143
 Wet Stacking

Thursday, September 14, 23 Page 144

 Vibration Attenuation

Thursday, September 14, 23 Page 145

 Sound Attenuation

Thursday, September 14, 23 Page 146

 Sound Attenuation
ü Attenuators are tailored to the volume of
air passing through them and the desired
noise level to be achieved from any plan
room installation.

Thursday, September 14, Page 147

23
 Sound Attenuation

Thursday, September Page 148

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 Sound Attenuation
ü The attenuation modules are configured
to suit the client's specific noise
requirement, giving full consideration to
the size of the plant room, the size of
apertures available or generator housing
whether it is a new build or a conversion
of an existing building.

Thursday, September 14, 23 Page 149

 Bespoke
Enclosures

Thursday, September 14, 23 Page 150

 Bespoke Enclosures
ü Each enclosure is uniquely engineered
and manufactured to suit the generator,
noise levels, available space and cooling
requirements. UPS and Switchgear
Packages can either be incorporated or
accommodated separately.

Thursday, September Page 151

14, 23
 Bespoke Enclosures
ü Using the latest 2D and 3D CAD Software
all items required within the container can
be drawn in situ, allowing for all appropriate
access and maintenance clearances
around each item to be detailed. This
approach not only highlights any issues
prior to the manufacture of the unit but also
enables us to give the client a full visual
impression of the end product.
Thursday, September 14, 23 Page 152
 Custom ISO
Containers

Thursday, September 14, 23 Page 153

 Custom ISO Containers
ü Generator Supplier must be able to offer a
full range of customised ISO containers:
from bunded secure containagen products
to a 13.5m fully sound attenuated system,
all of which are housed within an ISO style
container. As with our bespoke container,
the custom ISO containers can offer both
UPS and Switchgear Packages within the
design.
Thursday, September 14, 23 Page 154
 Custom ISO Containers

ü All ISO container conversions start out as

a new container brought in 10, 20, 30 or
40ft configurations. The standard
containers are then modified to
accommodate doors and attenuators at
either end or roof mounted. The internal
walls are acoustically treated to match
the noise level requirements of the client.
Thursday, September 14, 23 Page 155
 Sound Attenuation
ü Attenuators can be manufactured to be
vertically or horizontally mounted. All
element of a plant room installation can
be accommodated, including ductwork,
louvers' silencers and acoustic doors.

Thursday, September 14, 23 Page 156

 Drop Over Enclosures
ü Manufacturing of drop over acoustic
enclosures. The drop over style has the
advantage of providing a more cost
effective solution with low installation time,
integral weatherproofing and quick access
to the generator set for maintenance. These
canopies are particularly suited to situations
where space at the site is limited and a slab
tank is used as a bulk tank.
Thursday, September 14, Page 157
23
 Drop Over Enclosures
ü Drop over enclosures can also be
manufactured to be in a demountable
format so that they can be shipped to site
in kit form. This makes them ideal for use
within basements, car parks or where an
enclosure is required but access is very
limited. The drop over can be engineered
to suit any generator set from 5kVA to
2.5mVA.
Thursday, September 14, 23 Page 158
 Engine Starting Systems

ü To be provided in class

Thursday, September Page 159

14, 23
 Load Banks
ü What is a Load Bank?
- Simulates utility failure without taking building
off grid
ü Why are they needed? (benefits)
- Satisfy requirements of NFPA 110
- Remove carbon build-up
- Reseats the piston rings reducing crankcase
vapours and pressure
- Tests adequate room ventilation and cooling
system
Thursday, efficiency.
September 14, 23 Page 160
 Load Banks

ü Tests the power system without interruption to

the critical loads.
ü Assures performance at full load capacity.
ü Determines engine and generator problems
before expensive failures.

Thursday, September 14, 23 Page 161

 Load Bank Testing

ü Tests the power system without interruption to

the critical loads.
ü Assures performance at full load capacity.
ü Determines engine and generator problems
before expensive failures.
Thursday, September 14, 23 Page 162
NFPA 110 Generator Classifications

ü National Fire Protection

Association

Thursday, September 14, 23 Page 163

 NFPA 110 Generator Classifications
Level 1
ü Failure of the equipment to perform could result
in the loss of human life or serious injuries.
Level 2
ü Failure of the equipment to perform is less critical
to human life and safety and where the authority
having jurisdiction shall permit a higher degree of
flexibility than that provided by a Level 1 system.
Thursday, September 14, 23 Page 164
 NFPA 110 Recommendations

ALL LEVEL 1 AND LEVEL 2 GENERATORS NEED TO BE

LOAD BANKED FOR 4 HOURS EVERY 3RD YEAR
80% OF NAME PLATE RATING FOR 4 HOURS

Thursday, September 14, 23 Page 165

 NFPA 110 Recommendations
ü Exercise monthly for 30 minutes
- Loading that maintains a minimum exhaust gas
temperature as recommended by manufacturer.
- Under operating conditions and not less than 30%
of nameplate rating.
- If above can not be achieved then run until oil
pressure and water temperature have stabilized
but less than 30 minutes.
Thursday, September 14, 23 Page 166
 NFPA Compliance Inspectors

State Health Inspectors – Level 1

State Fire Marshal – Level 1 and 2

Thursday, September 14, 23 Page 167

 Generator Applications

ü To be provided in class

Thursday, September 14, 23 Page 168

 Cogeneration

ü To be provided in class

Thursday, September 14, Page 169

23
 Emergency Power Systems

ü To be provided in class

Thursday, September 14, Page 170

23
 Legally Required Standby Systems
ü To be provided in class

Thursday, September 14, Page 171

23
 Optional Standby Systems

ü To be provided in class

Thursday, September 14, Page 172

23
 Applicable Codes and Standards

ü To be provided in class

Thursday, September 14, Page 173

23
 Troubleshooting & Maintenance of
Onsite Power Generator
ü To be provided in class

Thursday, September 14, 23 Page 174

Developing a Local System Approach
to Troubleshooting
ü To be provided in class

Thursday, September 14, 23 Page 175

 Common Generator Problems

ü To be provided in class

Thursday, September Page 176

14, 23
Recommended Generator Maintenance
ü To be provided in class

Thursday, September Page 177

14, 23
 ELECTRICAL TESTING OF
GENERATORS
ü To be provided in class

Thursday, September Page 178

14, 23
 EMERGENCY POWER SYSTEMS

ü To be provided in class

Thursday, September Page 179

14, 23
 EMERGENCY POWER SYSTEMS

ü To be provided in class

Thursday, September Page 180

14, 23
 EMERGENCY POWER SYSTEMS

ü To be provided in class

Thursday, September Page 181

14, 23
 EMERGENCY POWER SYSTEMS

ü To be provided in class

Thursday, September Page 182

14, 23
 EMERGENCY POWER SYSTEMS

ü To be provided in class

Thursday, September Page 183

14, 23
 Emergency Power Systems

ü To be provided in class

Thursday, September Page 184

14, 23
 Emergency Power Systems

ü To be provided in class

Thursday, September 14, 23 Page 185

 Emergency Power Systems

ü To be provided in class

Thursday, September 14, 23 Page 186

 Beyond Basics
ü Laboratory-Fluid Analysis
ü Change coolant every 3-5 years
ü Change air filters every 5-7 years
ü Change batteries every 3 years (NFPA
110)
ü Thermographic Predictive
Maintenance (recommended by
NFPA)
Thursday, September 14, 23 Page 187
 Fluid Analysis Programs
ü Types
- Oil
- Coolant
- Fuel
ü Benefits
- Determine engine and generator
problems before expensive failures.
Thursday, September 14, 23 Page 188
 Analysis Program Benefits
ü Oil Analysis
- Tracks history
- Indicates wear metals and contents
in PPM
- Indicates fuel dilution
- Indicates glycol dilution
- Recommends corrective measures to
be taken
Thursday, September 14, 23 Page 189
 Analysis Program Benefits
ü Coolant Analysis
- Tracks history
- Indicates freezing point of coolant
- Indicates wear metals and contents in
PPM
- Indicates conductivity ability of coolant
- Indicates Nitrite levels
- Recommends corrective measures to be
taken
Thursday, September 14, 23 Page 190
 Analysis Program Benefits
ü Fuel Analysis
- Tracks history
- Indicates stability
- Indicates bacteria count - #1 cause of
engine break down
- Indicates Cetane content
- Recommends corrective measures to be
taken
Thursday, September 14, 23 Page 191
 Bacteria In the Diesel
Diesel is an organic fuel.
Bacteria infect systems and form bio-films on steel surfaces.
Accelerated corrosion occurs wherever the bio-film settles
Microscopic in size, they can develop into a mat easily
visible to the naked eye very quickly. A single cell, weighing
only one millionth of a gram can grow to a biomass of 10
kilograms in just 12 hours, resulting in a biomass several
centimeters thick across the fuel/water interface.
Once contaminated diesel enters the fuel system, it is very
difficult to eradicate.
Thursday, September 14, 23 Page 192
 Thermographic PM
ü Before an electrical component burns up, it heats
up.
ü Infrared Thermographs finds the problems early
in the failure cycle. Early detection allows
maintenance personnel to take corrective action
before a component fails, minimizing damage to
the component, reducing repair costs, eliminating
production losses, preventing safety hazards and
saving energy.
Thursday, September 14, 23 Page 193
 Benefits of Thermal Imaging
ü Determines if the components and system have
been properly installed and are not damaged
ü Reduces downtime
ü Reduces risk of equipment failure
ü Increases safety
ü Improves insurability
ü Improves system performance
ü Determines whether components and systems
operate properly and meet the design intent
ü Saves money
Thursday, September 14, 23 Page 194
 Detecting the Unseen

Thursday, September 14, 23 Page 195

 Detecting the Unseen

Thursday, September 14, 23 Page 196

 Data Centre Thermal Mapping

Thursday, September 14, 23 Page 197

 Basic Maintenance

ü Regular maintenance and testing is essential

- Standby generator maintenance regimes
- Major/Minor service per annum
- Monthly checks & running
- Weekly checks & running
- Load Bank testing
- System Black Starts

Thursday, September 14, 23 Page 198

 Basic Maintenance

ü Tests should include

• Full mains failure test is most effective (ideally
monthly)
• Checking starting system and batteries (monthly)
• Annual full load test
ü Avoid long periods of low load running

Thursday, September 14, 23 Page 199

 Basic Maintenance

ü Annual Service – Major Service

• Change Oil & Filters (except Air Filter)
• Check Lubricating System, Fuel System, Cooling
System, Air Intake System, Control Panel &
Instruments, Exhaust System, Engine Electrical
System, Alternator and General Engine
Maintenance

Thursday, September 14, 23 Page 200

 Basic Maintenance

ü Six Monthly Service – B Minor Service

• Check Lubricating System, Fuel System, Cooling
System, Air Intake System, Control Panel &
Instruments, Exhaust System, Engine Electrical
System, Alternator and General Engine
Maintenance

Thursday, September 14, 23 Page 201

 Basic Maintenance

ü Six Monthly Service – B Minor Service

• Check Lubricating System, Fuel System, Cooling
System, Air Intake System, Control Panel &
Instruments, Exhaust System, Engine Electrical
System, Alternator and General Engine
Maintenance

Thursday, September 14, 23 Page 202

 Basic Maintenance

ü Six Monthly Service – B Minor Service

• Check Lubricating System, Fuel System, Cooling
System, Air Intake System, Control Panel &
Instruments, Exhaust System, Engine Electrical
System, Alternator and General Engine
Maintenance

Thursday, September 14, 23 Page 203

 Basic Maintenance
Basic Maintenance
–Inspection of output circuit breaker
•Set mounted, Floor standing or Link box/Isolator
•HV or LV
–Inspection of mains/generator changeover system
•Break before make
•Make before break
•Synchronising (G59/3) switchgear
–Inspection of generating set auxiliary power
–Sometimes the responsibility for maintenance is with
others
Thursday, September 14, 23 Page 204
 Basic Maintenance
Planned Preventative Maintenance
–Fluid Sample Testing
•Engine Oil
•Engine Coolant
•Fuel
–Battery Testing & Replacement Programme
•Monthly or at least 6 monthly testing of the charge
capacity for starting batteries
•Lead acid batteries have a 2 to 5 year life in a non
temperature controlled environment – change within
Thursday, September 14, 23 Page 205
this period
 Basic Maintenance
Remote Condition Monitoring
•Monitoring of essential parameters of the generator:
–Temperatures, Pressures, Voltage, Current etc…..
–Thermal Imaging of Switchgear

Thursday, September 14, 23 Page 206

 Generator and Engine Controls
ü Grounding and Bonding of Generator Systems
ü Governors
ü Voltage Regulators
ü Engine Protection
ü Onsite Generator Controls including PLC and
SCADA Systems

Thursday, September 14, 23 Page 207

 Generator and Engine Controls
ü Diesel Power Generator set have been developed
with the user in mind.
ü Control System are easy to use and deliver
unrivalled functionality.
ü Simple manual start control module or complex
controller with an advanced PLC Functionality
ü Key start – for basic and off prime power
requirements
ü Auto/remote start for standby and emergency
power aplications
Thursday, September 14, 23 Page 208
 Generator and Engine Controls
ü Generator synchronization capabilities – for load
sharing with generators
ü Mains synchronization – used for precise load
requirements and/or export of the national grid
mains supply
ü Fuel transfer systems – for managing the critical
fuel supply to generators
ü Remore monitoring – for monitoring all alarms,
fault signals, fuel system, generator running
models all from numerous PC or mobile devices
Thursday, September 14, 23 Page 209
 Bespoke Control Systems
ü It is the heart of your diesel generator as it
manages how and when your generator
operates in every possible perceivable scenario.
ü As is it is important to management your control
system correctly to make the most out of your
generator.
ü Diesel generators around the world operate
with different makes and designs of control
systems and are managed with different
hardware and software.
Thursday, September 14, 23 Page 210
 Bespoke Control Systems
ü It is the heart of your diesel generator as it
manages how and when your generator
operates in every possible perceivable scenario.
ü As is it is important to management your control
system correctly to make the most out of your
generator.
ü Diesel generators around the world operate
with different makes and designs of control
systems and are managed with different
hardware and software.
Thursday, September 14, 23 Page 211
 Bespoke Control Systems
ü It is the heart of your diesel generator as it
manages how and when your generator
operates in every possible perceivable scenario.
ü As is it is important to management your control
system correctly to make the most out of your
generator.
ü Diesel generators around the world operate
with different makes and designs of control
systems and are managed with different
hardware and software.
Thursday, September 14, 23 Page 212
Troubleshooting and Maintenance of Onsite Power
Generation Systems
ü Developing a Logical Systematic Approach to
Troubleshooting
ü Common Generator Problems
ü Recommended Generator Maintenance Practices
ü Electrical Testing of Generators
Electrical Equation for Power Consumption
TO DETERMINE: SINGLE-PHASE THREE-PHASE DIRECT
CURRENT
KVA IxE I x E x 1.73 ——–
1000 1000
Kilowatts I x E x PF I x E x 1.73 x PF IxE
1000 1000 1000
Horsepower I x E x %EFF x PF I x E x 1.732 x %EFF x PF I x E x %EFF
746 746 746
Amperes (when HP is known) HP x 746 HP x 746 HP x 746
E x %EFF x PF 1.73 x E x %EFF x PF E x %EFF
Amperes (when kW is known) KW x 1000 KW x 1000 KW x 1000
E x PF 1.73 x E x PF E
Amperes (when KVA is known) KVA x 1000 KVA x 1000 ——–
E 1.73 x E
The Functions of Grounding

The work of grounding systems is probably one of the best kept set of secrets
in the electrical industry. At first glance, the deceptively simple passive
elements of grounding systems obviously could not do very much, or could
they? The answer is that grounding systems come in many shapes, forms, and
sizes and do many duties, many of which are absolutely essential. If they are
designed and constructed well, then the systems they support have a good
chance of working well. However, if the grounding system is flawed in design
or installation, or if it is damaged by impact or chemical attack, the related
systems are negatively affected.

Consider the case of a static grounding grid with its variety of grounding
electrode shapes in an industrial plant that is energized through a high-voltage
utility substation. This almost completely hidden grounding system performs
all these tasks:
The Functions of Grounding

It minimizes the ground potential rise and coincident step and touch potentials
that occur from high-voltage system zero sequence current flowing through
the earth during utility system ground faults, such as insulator string arc-over.
It equalizes the direct-current (dc) potentials within the plant that build up
from process flows.
It limits the system-to-frame voltage for human safety and prevents overstress
in phase-to-ground voltage.
For all practical purposes, it provides an equipotential plane on which humans
can stand and not be harmed during times of ground fault within the plant.
That is, it equalizes the potential of, say, a motor stator that a...
Grounding

Proper grounding for electrical systems is very important for the safety of the
linemen, cablemen, groundmen, and the public. Correct operation of
protective devices is dependent on the grounding installation. The National
Electrical Safety Code (ANSI-C2 Standard) specifies the grounding methods for
electrical supply and communications facilities. The National Electrical
Code (NFPA-70 Standard) specifies the grounding methods for all facilities that
are within or on public or private buildings or other structures.
Grounding

The substation grounding system governs the proper functioning of the whole
grounding installation and provides the means by which grounding currents
are conducted to remote earth. It is very important that the substation ground
have a low-ground resistance, adequate current-carrying capacity, and safety
features for personnel. The substation grounding system normally consists of
buried conductors and driven ground rods interconnected to form a
continuous-grid network. The surface of the substation is usually covered with
crushed rock or concrete to control the potential gradient when large currents
are discharged to ground and to increase the contact resistance to the feet of
personnel in the substation. Substation equipment should be connected to the
ground grid with large conductors to minimize the grounding resistance and
limit the potential between the equipment and the ground surface to a...
 Parts

Thursday, September 14, 23 Page 220

Critical Power: NFPA 110: Standard for
Emergency and Standby Power
Tom Divine, PE,
Smith Seckman Reid Inc.,
Houston, Tex.

Kenneth Kutsmeda, PE, LEED AP,

Jacobs Engineering,
Philadelphia, Penn.
 Applicable NFPA codes and standards
associated with EPSS
• NFPA 70: National Electrical Code (NEC)

• NFPA 110: Standard for Emergency and Standby Power

Systems

• NFPA 99: Standard for Health Care Facilities.

Emergency power supply system (EPSS) is the total
system for distributing electrical power within a facility
when the normal power source is interrupted.

• Emergency Power Source (EPS)

• Transfer Switching Device

• Overcurrent Protection

• Control Systems
 NFPA 70: National Electrical Code
(NEC)
Standard for the safe installation of electrical wiring
and equipment in the U.S.

• Article 700: Emergency Systems

• Article 701: Legally Required Standby Systems

• Article 702: Optional Standby Systems

• Article 708: Critical Operations Power Systems

NEC Article 700: Emergency Systems
Systems intended to supply illumination and
power to equipment essential for safety to
human life.

Examples:
• Egress lighting
• Life support systems
• Elevators
• Fire detection and fire alarm
• Fire pumps.
NEC Article 700: Emergency Systems
Requirements:

• Start and transfer automatically

• Dedicated transfer equipment
• Available for load in 10 sec
• Point of distribution must have physical
separation
• Emergency system wiring shall be
independent of all other wiring
• Selective coordination
• AHJ must witness testing.
NEC Article 700: Emergency Systems
Alternate source of power must be a storage
battery, generator set, UPS, separate
service, or fuel cell system:
• 2 hr on site fuel storage
• 90 min battery capacity

Additional requirements for assembly

occupancies over 1,000 persons or
buildings higher than 75 ft:
• Fire Protection for Feeder Circuit Wiring
• Fire Protection for Feeder Equipment
NEC Article 701: Legally Required
Standby
Systems intended to supply power to aid
firefighting, rescue operation, and control of
health hazards.

Examples:
• Smoke removal systems
• Communications systems
• Ventilation systems
• Sewage disposal systems
• Industrial processes that when stopped could
create hazards.
=

NEC Article 701: Legally Required

Standby
Requirements:
• Start automatically
• Available for load in 60 sec
• 2 hr on-site fuel storage
• AHJ must witness testing.

NEC indicates that generators used for

emergency and legally required systems
shall not be solely dependent on public source
(gas line) for fuel supply unless where
acceptable to the AHJ.
 NEC Article 702:
Optional standby systems
Systems intended to supply power to prevent physical
discomfort, interruption of an industrial process,
damage to equipment, or disruption of business.
Examples:
• Refrigerators/freezers
• Data processing
• Farms
• Commercial buildings
• Carnivals.
 NEC Article 702:
Optional standby systems
Requirements:
• Manual or automatic start
• No available for load time requirements
• No on-site fuel storage requirements

Portable generators are acceptable to be connected to

an optional standby power system.
Emergency/legally required:
Designed to safely evacuate people and
prevent hazards by keeping portions of the
system operating for a certain period of
time.

Critical operations/mission critical:

Designed to keep the entire facility or
critical components operating for the
complete extent of the outage.
“A mission critical system is a system that is essential to
the survival of a business or organization. When a mission
critical system fails or is interrupted, operations are
significantly impacted.”

• Availability: System must function when required (24x7)

• Reliability: System must not fail. If a failure occurs, the

system must respond and recover quickly.

• Security: System must provide protection against an attack,

either human or naturally caused.
Types of mission critical facilities
Private: business continuity
Attributes defined by the business based on its
business case
• Business enterprise data centers
• Financial data centers and trading

Public safety
Attributes defined by code and governed by the
agency having jurisdiction (AHJ)
• Emergency call centers
• Police and fire stations
• National security.
Private business continuity

Facilities where the levels of

availability and reliability are dictated
by the business case.

• Acceptable level of risk

• Downtime for maintenance

• Required degree of redundancy

• Protection against failures.

Private business continuity
• Low tolerance for risk
• No downtime
• High level of reliability.

Redundant components/generators
(N+1, N+2, or 2N)
Allows for one of the components or
generators to be taken offline for
maintenance or failure of one
generator without affecting the
operation of the facility.
 Public safety facilities

Facilities where the levels of availability and

reliability are required to protect the public
safety, public health, and national security.
 NEC Article 708: Critical Operations
Power Systems (COPS)
• Addresses homeland security issues for mission critical
facilities.
• Provides requirements for the installation, operation,
control, and maintenance of electrical equipment serving
critical operation areas that must remain operational
during a natural or human caused disaster.
• Critical operations power systems are installed in vital
facilities that if incapacitated would disrupt national
security, public health, and public safety.
 NEC Article 708: Requirements for
standby power
• Provide an alternate power supply
• Alternate power shall have on-site fuel capacity to
operate for 72 hr
• Generator can’t be dependent on public utility gas for
fuel
• Redundant equipment is required, or at minimum, the
means, to connect roll up equipment
• Equipment must be located above the 100 yr flood plain.
 NEC Article 708: Requirements for
standby power
• COPS system wiring shall be independent of all
other wiring
• Fire protection for feeders
• Selective coordination
• Documented commissioning
• Documented maintenance plan.
Examples of facilities that would
use COPS:
• Police and fire stations
• Emergency management centers
• Emergency call centers
• Government facilities involved with
national security
• Financial facilities involved with
national economic security
• Hospitals.
 NEC Article 517: Scope
• Scope: Health care facilities for humans
• Special requirements
– Wiring, protection, grounding, x-ray, operating rooms
• “Essential electrical system”
• Amends requirements of other articles, particularly
Article 700.
 NEC Article 517: Key definitions
• Essential electrical system:
– Alternate source, usually standby generator
– Plus distribution and ancillary equipment
• Structure under NEC 2010
– Emergency system
Life safety branch
Critical branch
– Equipment system
 NEC Article 517: Structure
• Life safety branch: 517.32
– Getting out of the building
– Plus a couple of other things
– Prescriptive and proscriptive
• Critical branch: 517.33
– Patient care
– Effective hospital operations
– Less restrictive that life safety branch
 NEC Article 517: Structure
• Equipment system: 517.34
– Delayed connection
– Some equipment required, some optional
– In practice, mostly HVAC.
 NEC Article 517: Special rule
• Generators are sized for demand load – 517.30(D)
• 700.4 and 701.4 require sizing for connected load
• Potential for generator damage from light loading: wet
stacking.
NEC Article 517: Wet Stacking
NFPA 110: Standard for Emergency and Standby
Power Systems
• Describes requirements for performance
• Doesn’t drive requirement for system: 1.2.1
– Building codes
– NFPA 70: NEC
– NFPA 99: Health Care Facilities Code
– Operational requirements
 NFPA 110: Scope
• Installation: location, equipment, accessories
• Maintenance: inspections, frequency, records
• Testing: installation and maintenance
• System characteristics: transfer switches, fuel system
• Scope ends at load terminals of transfer switches.
 NFPA 110: Key abbreviations
• Emergency power supply: EPS
– Source, usually generator
• Emergency power supply system: EPSS
– Everything between the generator and the load terminals of the
transfer switches.
 NFPA 110: Inspection and testing
• Installation testing: EPSS
• Weekly inspection: EPSS
• Monthly load testing: EPSS
• Transfer switches operated monthly
• More extensive requirements for level 1 EPSS
 Code changes: NFPA 110 - 2013
• 6.1.6: Permits electrically interlocked circuit breakers as
transfer switch for medium-voltage mechanical equipment
• 8.1.2: Requires consideration of portable generator when
type criteria can’t be met
• 8.4.8: Requires that only “qualified persons” perform
maintenance, changed from “a properly instructed
individual.”
 Code changes: NFPA 110 - 2013
Annex: Not exactly code
• A.[Link]: Added description of fuel testing
• A.[Link]: Added description of standby and prime
generator ratings
• A.8.4.2: Requires a permanent record of the generator rating
to be readily available.
 Code changes: NEC 517 - 2014
• Definition of “emergency system” deleted
– Essential system composed of three branches: life safety, critical,
equipment
– In practice, has little effect
• Defines selective coordination requirement at 0.1 sec
• Purpose: Harmonization with NFPA 99, which
no longer uses the term.
NFPA 110: Standard for Emergency and
Standby Power Systems
Defines how emergency and standby power systems are to be
installed and tested. It contains requirements for energy
sources, transfer equipment, and installation and
environmental considerations.

NFPA 110 divides emergency power systems into three

categories:
• Type
• Class
• Level
NFPA 110: Standard for Emergency and
Standby Power Systems
The type refers to the maximum time that an emergency power
system can remain unpowered after a failure of the normal source.
NFPA 110: Standard for Emergency and
Standby Power Systems
The class of an emergency power system refers to the
minimum time, in hours, for which the system is designed to
operate at its rated load without being refueled or recharged.
NFPA 110: Standard for Emergency and
Standby Power Systems
The Level of an emergency power system refers to the level
of equipment installation, performance, and maintenance
requirements.
 NFPA 110: Testing requirements
Installation testing
• Start system and record performance
• Full-load test: 2 hr
– 30% of nameplate kW for ½ hr
– 50% for ½ hr
– 100% for 1 hr
• Engine crank and battery tests
• Detailed records.
 NFPA 110: Testing requirements
Monthly load testing
• Requirement covers entire EPSS
• Run generator under load
– Special requirements for diesel units
• Exercise transfer switches
– Round trip to emergency position and back.
 NFPA 110: Testing requirements
• Monthly load testing – diesel generators
– 30 min minimum
– Recommended exhaust temperature, or 30% of nameplate kW rating
• Otherwise, annual test with supplemental load, for ½ hr at
50%, 1 hr at 75%
• Level 1: 100% test for lesser of Class duration or 4 hr, every 3
yr, at 30% and at recommended exhaust temperature.
 NFPA 110: Testing requirements
Monthly load testing – diesel generators
• 30 min minimum
• Recommended exhaust temperature, or 30% of nameplate
kW rating
• Otherwise, annual test with supplemental load, for ½ hr at
50%, 1 hr at 75%
• Level 1: Annual 100% test for lesser of Class duration or 4 hr.
 NFPA 110: Testing strategies
• Transfer less sensitive load, if adequate
• Manage mechanical systems to increase load for test
– Let chilled water temperature drift upward before load testing
• Complete normal power system shutdown
• Load bank: start with facility load, supplement with load bank.
Because of the dependency on the generator to keep the
facility operating, all generator systems for mission critical
facilities are fully tested and commissioned before they are put
into service.

Factory witness testing

Site acceptance testing
• Load steps
• Transients response
• Heat run
Integrated system testing
• Test all system together
• Pull the plug.
Maintenance recommendations
• Implement a facility preventive
maintenance program
• Follow NETA recommendations,
perform maintenance and testing of
generators every 12 mo
• Exercise the generator regularly
• Load test generator
• Keep an inventory of spare parts
• Properly train all operators
• Periodic analysis of lube oil and fuel
oil.
During Hurricane Sandy there were many facilities in the
Northeast that relied on their standby power systems for
multiple days to keep the facility operating.
Lessons learned:

• Locate above the flood plain

• Adequate on-site fuel supply
• Means to change filters while
operating.
Locate generators and other standby power system
distribution equipment above the flood plain.

• Generators, transfer switches, and electrical equipment

can’t operate if under water
• During Hurricane Sandy, areas did see flooding above 100
yr flood plain.
• Recommend locating standby equipment above the 100 yr
flood plain or above the 500 yr flood plain, if possible.
 Have adequate supply of
on-site fuel storage
• Water subsided in about a day but the debris
and damage made it difficult to deliver fuel
(even for those facilities with emergency
contracts)
• On average, it was about 3 days before
facilities could get fuel delivered
• Recommend minimum of 72 hr fuel storage.
Provide means to change filters
out while operating

• Fuel that was delivered was

contaminated with water and debris
• Facilities operators were changing
filters every couple of hours to keep
the systems from clogging
• Recommend installing dual-header
filter systems with transfer valve that
allows for filter replacement while
engine is operating
• Consider fuel polishing system.
Classification summary

Emergency and Level 1 are systems

essential to the safety of human life.

Legally required and Level 2 are

systems less critical to human life, but
if stopped could create hazards or
hamper rescue and fire fighting
operations.

Critical systems have a requirement to

remain operational under all conditions
and demand a higher level of reliability
and availability.
Overall goal of emergency and
standby power systems is to
provide power when there is a
loss of utility.

• NFPA 70: National Electrical

Code (NEC)

• NFPA 110: Standard for

Emergency and Standby Power
Systems

• NFPA 99: Standard for Health

Care Facilities
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Go

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Go

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Go

ONSITE GENERATOR
CONTROLS

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Onsite Generator Controls
The online retailers, auction sites, search engines, social
media, banks and software companies that form the
backbone of the Internet economy need to be
operational 24/7/365. That’s why one of the major
goals of any online business is continuous uptime.

// Who: Data Centers

// What: Standby Power Systems to provide critical
power in the event of a utility
// Where: All over the world

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 VIBRATION ATTENUATION

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Vibration Attenuation

An elastomeric isolator between the generator foot and base

minimizes the transfer of energy to the base.

Several elastomeric isolator mount types have steel shells to

enhance lateral stiffness and prevent oil or solar degradation
of the elastomeric compound.

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Vibration Attenuation

Aligning bolts on the alternator foot are used when a coupler

connects the engine to a two-bearing alternator.

California-approved seismic spring isolators dissipate

generator set vibrations while preventing lateral and vertical
movement associated with earthquakes.

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 SOUND ATTENUATION

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Sound Attenuation
NEW QUITE EMERGENCY POWERR SYSTEM – SOUND- – Internal mounted exhaust silencer and
ATTENUATED ENCLOSURE KEEPS SYSTEM FROM lockable doors for security.
DISTURBING THE PEACE!
– The corrosion resistant enclosure can
Sound-attenuating enclosure eliminates noise: withstand winds up to 125 mph.

– To control sound, the enclosure specified for – Frequency of the generator is checked so
the project will be designed at a Level that it does not skip a beat.
specified

– This generator set and its sound-attenuating

– Will be designed for all-weather protection enclosure have really worked out well.
along with maximum sound attenuation.

– In addition to 14-gsuge-steel construction,

the enclosure features 1.5 inches of
polyether polyurethane sound-attenuating
foam that meets Underwriters Laboratories
specifications for flame and heat resistance.

– When generator set is running, measurable

sound is 77dBA.

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 Sound Science: Understanding and
Implementing Generator Set Noise
Control
The principles of generator set noise control are well understood, leaving economics as the primary
limiting factor in implementing noise reduction strategies for specific applications.

With the expanding use of diesel generator sets for emergency standby power, peak shaving and demand
response, there has come an increased focus on controlling the noise these generators create. Whether
generator sets are located in enclosures outside a facility, inside or on the roof, design engineers are
making more efforts to control generator set noise and vibration in order to reduce the effects on
neighbours and building occupants alike. And whether generator sets run continuously in prime-power
applications, intermittently in demand response applications, or occasionally in emergency standby
situations or testing, their operating sound levels may require remediation.

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Sound Attenuation

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What is Noise
Vibrating objects induce pressure waves that travel through the air and reach our ears as sound.
Noise, by definition, is merely unwanted sound. When the amplitude of the pressure waves
becomes too high, the amount of sound becomes uncomfortable. In addition to being annoying,
excessive sound can cause permanent hearing damage. This is why the Occupational Safety and
Health Administration (OSHA) established safety standards for workers exposed to loud noises.

Local ordinances and zoning laws also establish rules regarding the amplitude of unwanted
sound, but the standards are geared toward reducing public annoyance rather than promoting
safety.

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What is Noise
The human ear has such a wide dynamic range that the logarithmic decibel scale (dB) was
devised to express sound levels in a convenient way. The ratio between the softest sound the ear
can hear and the loudest sound it can experience without damage is approximately a million to
one or 1:1x106. By using a base-10 logarithmic scale, the whole range of human hearing can be
described by a more convenient number that ranges from 0 dB (threshold of normal hearing) to
140 dB (the threshold of pain).

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What is Noise
There are two dB scales used to describe sound: A and L.

• // The dB(L) scale is linear and treats all audible frequencies as having equal value. However,
the human ear does not experience all frequencies the same way. Our ears are particularly
sensitive to frequencies in the range of 1,000 to 4,000 Hz, and they are less sensitive to
sounds in lower or higher frequencies.

• // To adjust the sound pressure levels to more accurately reflect what the human ear
perceives, engineers use an “A-weighting filter.” This results in the frequency-weighted dB(A)
scale, which was adopted by OSHA in 1972 as the official regulated sound level unit.

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Sources of Generator Set Noise
There are two major frequency bands that not only emanate from different moving components
on the generator set but also require different methods to control. Frequencies below 300 Hz are
generally considered low frequency; frequencies above 300 Hz are considered high frequency.
Furthermore, there are no universal standards for the amount of permissible generator set noise.
Rather, each application is different, and each locale sets its own standards for noise emanating
from a property.

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Sources of Generator Set Noise

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Sound Produced by Generator Sets:

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Sound Produced by Generator Sets:

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Sound Produced by Generator Sets:

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Sound Produced by Generator Sets:

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Sound Produced by Generator Sets:

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Sound Produced by Generator Sets:

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 APPLICABLE CODES &
STANDARDS

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Codes and Standards for Onsite Power Systems
Criteria apply to generator sets and their manufacturers

Generator sets and the companies that make them can be

judged by how they measure up
to codes and standards established by private industry
and governmental groups. This ensures
that all compliant generator set manufacturers measure
performance the same way.

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Applicable Codes & Standards
• Generator sets and the companies that • Some of these guidelines define how to
make them can be judged by how they measure horsepower, electrical output or
measure up to codes and standards hundreds of other parameters. In addition,
established by private industry and a number of these codes set minimum
governmental groups. This ensures that all levels of equipment performance and
compliant generator set manufacturers establish criteria meant to increase safety
measure performance the same way. for manufacturing workers, power-system
operators and the general public.

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Applicable Codes & Standards
• Codes and standards also helps ensure
uniformity, Codes and standards also help
ensure uniformity and quality of onsite
power systems, although manufacturers
such as MTU Onsite Energy often exceed
minimum requirements.

• Some codes and standards apply to all

onsite power generation systems, while
others apply only when required by a
particular application or customer.

• Here is a closer look at the standards for

both design and manufacturing standards
and for safety and performance, plus code-
compliance information specific to
generator sets from MTU Onsite Energy:

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Applicable Codes & Standards
Design and manufacturing standards

• Standards that apply to all generator sets

are those established by the International
Organization for Standardization. ISO
defines how to measure and rate many
quality and performance parameters.

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Applicable Codes & Standards
ISO standards that are relevant to onsite power
generation systems are:

• // ISO 8528 — describes how to establish

ratings, measure performance and evaluate
engines, alternators, controls and
switchgear. This standard also defines test
methods for measuring vibration and
sound.

• // ISO 3046 — deals with important engine

related matters such as power ratings, fuel
consumption, vibration and test methods.
Compliance with ISO 3046 is usually noted
on a generator set’s specification sheet.

• // ISO 9001 — describes processes

manufacturers must use to manage quality
in their facilities. All of MTU Onsite Energy’s
manufacturing facilities are ISO 9001
certified.
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management
Applicable Codes & Standards
ISO standards that are relevant to onsite power
generation systems are:

• // ISO 14001 — defines environmental

management practices in manufacturing
facilities. All MTU facilities are ISO 14001
certified.

• // ISO 17025 — deals with testing and

calibration of instruments used to measure
performance and quality. All MTU test
instruments are calibrated in accordance
with this standard.

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 Applicable Codes & Standards
ISO 8528: The 85% load-factor advantage from Safety and performance standards
MTU Onsite Energy

One of the provisions of ISO 8528 sets a minimum Many codes and standards are applicable only in
24-hour average load factor of 70% for both certain applications, geographic locations or as
standby- and prime-rated generator sets. This requested by the customer. Well-known
means that a 1,000 kW generator set meeting this standards of this type are those from
standard must be able to provide an average of 700 Underwriters Laboratories (UL), the National
kW per hour over a 24-hour period. In emergency Fire Protection Association (NFPA), the
standby applications, this means that the average International Building Code (IBC), the Canadian
load factor that can be sustained by most generator Standards Association (CSA) and those found in
sets over an extended outage of 24 hours is only the National Electrical Code. These
70% of the nameplate rating, a factor that affects organizations have established safety and
generator set sizing considerations. However, performance-based criteria for onsite power
emergency standby generator sets from MTU. generation systems throughout North America.
Onsite Energy are certified at a load factor of 85%,
so a 1,000 kW generator can provide an average of
850 kW per hour over a 24-hour period. All other
generator set manufacturers meet the 70% load-
factor minimum, but only MTU Onsite Energy
exceeds it.

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Applicable Codes & Standards
Underwriters Laboratories (UL)

When a product complies with a specific UL • // UL 2200 — Addresses the entire

standard and the manufacturer pays the generator set and is primarily concerned
required fee to UL, that product can be labelled with reducing the risk of shock, fire and
as “UL listed.” Some manufacturers put phrases machinery-related injuries. This standard
such as “meets UL 2200” on their products also addresses matters such as the routing
when they haven’t gone through the proper UL of fuel lines and safety measures for
listing process — and, therefore, can’t use the rotating parts. UL 2200 also requires
“UL listed” label. MTU generator sets, however, manufacturers to load-test their generator
comply with relevant UL standards and MTU has sets to verify that they can produce
paid the appropriate fees to earn the “UL listed” nameplate-rated power levels.
designation. Popular UL listings available from
MTU include: • // UL 142 — Covers steel fuel tanks
intended for aboveground storage of diesel
fuel. Tanks covered by these requirements
are fabricated, inspected and tested for
leakage by MTU Onsite Energy before
shipment from the factory as completely
assembled vessels.

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Applicable Codes & Standards
• // UL 891 — Provides safety criteria for electrical
switchboards up to 600 volts.

• // UL 1008 — Sets standards for safety and

performance of automatic and manual transfer
switches as required by the National Electrical
Code.

• // UL 1558 — Addresses metal-enclosed low-

voltage power circuit breaker switchgear
assemblies containing such devices as low-
voltage power circuit breakers, other interrupting
devices, switches, control, instrumentation and
metering, protective and regulating equipment.

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Applicable Codes & Standards
National Fire Protection Association (NFPA) Component Tests Location to be checked

Visual 100% after removal of insulation

Thickness Measurement Random
• This national industry organization sets fire Main Cylindrical WFMPI/UT
Weld joints, Side holes, mud
holes and blow down outlet
prevention standards. In addition, NFPA Shell

establishes safety and performance Replica & Hardness

Replica & hardness shall be on
weld/HAZ & parent
standards for transfer switches and
100% thru the hot gases side
addresses the performance of emergency Visual
with weld joints
Furnace tubes
standby generator sets in critical with
Thickness Measurement
WFMPI & UT
Random
Weld Joints
applications such as those in healthcare bowling hoops
Replica & hardness shall be on
Replica & Hardness
facilities. Equipment from MTU Onsite weld/HAZ & parent
Visual 100%
Energy meets a number of NFPA standards, WFMPI Tube to Tube Plate weld joints
the most critical being NFPA 110: Smoke Tubes
and Thickness Measurement Random
Stay Tubes
Replica & hardness shall be on
Replica & Hardness
weld/HAZ & parent
Visual External Side
WFMPI/UT Circumferential Weld seam
Front & rear tube
plates and end Thickness Measurement Random
plates of wet back Replica & hardness shall be on
Replica & Hardness
weld/HAZ & parent
Visual
WFMPI Weld Joints
Reversal
Chamber Replica & hardness shall be on
Replica & Hardness
weld/HAZ & parent

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Applicable Codes & Standards
National Fire Protection Association (NFPA) • // NFPA 110 — Specifies how long it should
take a generator set to start and assume
• This national industry organization sets fire full-rated load in emergency standby power
applications. The regulation can be met at
prevention standards. In addition, NFPA
several levels depending on how quickly the
establishes safety and performance
standards for transfer switches and generator set can assume full-rated load.
addresses the performance of emergency The top rating, Type 10, goes to systems
that can start and assume full-rated load in
standby generator sets in critical
10 seconds or less. All MTU Onsite Energy
applications such as those in healthcare
diesel generator sets are capable of meeting
facilities. Equipment from MTU Onsite
this critical top rating.
Energy meets a number of NFPA standards,
the most critical being NFPA 110:
• // NFPA 70 — Details comprehensive
requirements for electrical design,
installation and inspection in a set of
standards known as the National Electrical
Code®. The NEC is not a legally binding
standard, but it has been adopted by all 50
states in order to codify the requirements
for safe electrical installations into a single
standard.

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Applicable Codes & Standards
Other standards

Additional sources of standards for onsite power generation equipment include the Canadian
Electrical Code, the Canadian Standards Association and CE mark. MTU products meet the relevant
requirements from all of these sources.

Conclusion

• The performance, quality and safety of onsite power generation systems are covered by a
number of recognized industry codes and standards. Generator sets from MTU Onsite Energy
not only meet these nationally recognized standards, but in several cases exceed them. Work
with your MTU distributor to determine standards apply to your onsite power application.

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Understanding Joint Commission
Standards
For Health Care Emergency Power Systems

Hospitals, nursing homes, clinics and other healthcare facilities

are required by state, local and national electrical codes to have
adequate emergency standby power systems that can be online
within seconds of a utility outage to supply critical loads.

The Joint Commission’s Environment of Care standard

associated with emergency power systems was among the top
ten standards cited for noncompliance during critical access
hospital surveys in the first half of 2011.i In order to enhance
the performance, capacity and reliability of emergency standby
power systems, new recommendations encourage healthcare
organizations to go beyond basic code-driven requirements.

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Summary

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 Questions?

Contact:
Ntozelizwe Benjamin Mqenebe, E&P Director
Lizwe-engineers@[Link]

Lizwe Engineers Group

120 Tulip Gardens, Shamrock Road, Vorna Valley,
Midrand, Johannesburg, 1685
Republic of South Africa
Mobile:+27 71 440 5741 / Fax:+27 86 663 1644
Tel: +27 56 515 1024
Website: [Link]

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