Application and Installation Guide for Generator Sets

A Comprehensive Resource from Cummins Power Generation

Designing and installing a reliable generator set installation requires careful consideration of standards, regulations, room layouts, fuel systems, exhaust, cooling, and electrical connections. Cummins Power Generation’s Application and Installation Guide for Generator Sets is a comprehensive reference document that provides essential technical information for engineers, installers, and project managers. This article summarizes the key content from this valuable guide.

Why This Guide Matters

Generator sets are critical for providing backup and prime power in a wide range of applications, from data centers and hospitals to industrial facilities and remote locations. A successful installation requires meticulous planning to ensure reliability, safety, and compliance with local regulations. This guide serves as a foundation for designing and executing generator installations, covering everything from standards and regulations to detailed layout considerations.

Section A: Standards, Regulations, and General Data

Navigating Standards and Directives

The guide provides a clear explanation of the hierarchy and application of standards, which is crucial for compliance.

• BS EN Standards: A standard prefixed BS EN is a European standard that has been transposed into a national (British) standard. The number of the standard is retained throughout Europe.
• ISO Standards: An ISO standard is an International Standard, which may be adopted as a national standard (e.g., BS 7698 is identical to ISO 8528).
• European Directives: These are laws enacted in EU law that instruct member states to incorporate them into their own national laws (via Statutory Instruments). Examples include the Machinery Directive (98/37/EC) and the Noise Emission Directive (2000/14/EC).

World Electricity Supplies

A key reference in this section is the comprehensive table of World Electricity Supplies. It details the frequency (Hz) and common supply voltage levels (V) for single-phase and three-phase systems for virtually every country. This is essential for configuring generator sets for international applications.

• United Kingdom: 50 Hz. Common supply voltages: 400/230 (three-phase), 240/230 (single-phase).
• United States: 60 Hz. Common supply voltages: 480/277, 208/120, 240/120.
• Australia: 50 Hz. Common supply voltages: 415/240.
• UAE (Abu Dhabi, Dubai): 50 Hz. Common supply voltages: 415/250, 380/220.
• India: 50 Hz. Common supply voltages: 400/230.

Essential Formulae and Conversion Tables

This section provides vital calculation tools, including:

• Equivalents: Conversion factors for horsepower, kilowatts, BTU, torque, and more.
• Formulae: Calculations for Brake Mean Effective Pressure (BMEP), Brake Horsepower (BHP), Torque, Temperature, and Power Factor (PF).
• Full Load Current Tables: Tabulated data showing the full load current (in Amps) for single-phase and three-phase generator sets at various voltages and kVA ratings.
• Installation Questionnaire: A detailed checklist to gather all necessary information before contacting a supplier or designing an installation. This covers site conditions, equipment details, exhaust, cabling, fuel, water, and commissioning requirements.

Section B: Foundations, Room Design, and Layout

Room Size and Layout Considerations

The guide provides essential guidance on the civil works required for a generator installation:

• Foundations: A level, sufficiently strong concrete floor is generally adequate. The guide includes calculations for soil bearing load and explains the need for a concrete pad or plinths.
• Recommended Room Sizes: Tables are provided with key dimensions to allow for good maintenance and escape access around the generator.
• Vibration Isolation: Cummins generator sets are built as a single module with resilient anti-vibration mountings, which absorb the majority of engine vibration and eliminate the need for heavy concrete foundations.
• Modular/Drop-Over Installations: The guide distinguishes between containerized systems and drop-over enclosures, noting the importance of a flat, level plinth for the latter.

Room Design Guidance Notes

This section offers practical guidance for designing generator rooms, particularly for installations requiring acoustic treatment:

• Inlet and Outlet Attenuators: Details on sizing attenuators (e.g., based on 100mm airways and 200mm acoustic modules) and weather louvres with a minimum 50% free area.
• Exhaust Systems: Practical advice on supporting exhaust pipes, using stainless steel bellows at the manifold, and ensuring termination at least 2.3m above ground level. Lagging the exhaust system within the room is recommended to reduce heat radiation.
• Cable Systems: Guidance on using flexible cables (e.g., EPR/CSP) to prevent vibration damage, with a note that cables can be terminated to a local terminal box for extensive cable runs.

Section C: Critical Sub-Systems

Fuel Systems

The guide provides an overview of fuel system components, including bulk tanks, service tanks, and transfer systems. It references important regulations like the Control of Pollution (Oil Storage) regulations (UK) and highlights the need for a fire valve and alarms.

Exhaust Systems

Beyond the basics of routing, this section covers the types of silencers (residential, acoustic), pipe materials (steel, stainless steel), and the importance of thermal lagging to reduce heat and protect personnel.

Cooling Systems

The guide addresses radiator types (40°C/50°C), remote radiator positioning, and pipe routing, emphasizing the need for flexible connections to prevent vibration transmission.

Starting Systems

The guide notes the need for high-quality batteries and appropriate charging systems to ensure reliable engine starts.

Section D: Control, Switchgear, and Electrical Systems

Control Systems and Paralleling

This section covers the control systems for generator set operation, starting with advanced systems like the Cummins PowerCommand™ series, which integrates controls, monitoring, and protection functions. It explains paralleling concepts for multi-generator and utility-paralleled systems.

Switchgear, Cabling, and Earthing

The guide provides guidance on:

• Switchgear: Low voltage (LV) and medium voltage (MV) switchgear application.
• Cabling: Requirements for load and control cabling, including cable types (PVC SWA PVC, CSP/EPR) and routing (trunking, tray, underfloor).
• Earthing: Essential for safety, with reference to relevant standards like BS 7671 (IEE Regulations).
• Circuit Breakers and ATS: The role of circuit breakers for protection and Automatic Transfer Systems (ATS) for failover from utility to generator power.

Conclusion: The Value of the Guide

Cummins’ Application and Installation Guide is an indispensable resource for anyone involved in the specification, design, or installation of generator sets. By integrating practical advice with references to a wide range of international standards and regulations, the guide provides a complete framework for a successful installation. Its content ensures the reliability, safety, and compliance of generator systems for their entire operational life.

Download the Full Guide

This overview is based on Cummins Power Generation’s guide. The full document provides a much deeper dive into each topic, including detailed case histories, extensive technical data on specific generator set models (air flows, exhaust flows, fuel consumption, and dimensions), and information on modular power stations up to 40 MW.

The guide is available to download for free from the provided link:

Download the Application and Installation Guide for Generator Sets (PDF)

Disclaimer: This article provides a summary of a third-party technical publication. While efforts have been made to accurately represent the content, please refer to the official Cummins document for complete technical details. Final design and installation decisions should be made by qualified professionals.