Monitoring Diesel Generators Set

Purpose

This article provides information about options available for monitoring industrial generator sets.

Monitoring alarms and operating parameters is an important part of any facilities management program. Many options are available for monitoring emergency or primary power. Main topics covered are:

• Monitoring Engine and Generator set
• Control Panel Options
• Options for Remote Monitoring

Monitoring Engine and Generator SetMany options are available to allow facilities manager or owner to monitor and interface with the standby or primary power generator set. Monitoring engine parameters allows for early diagnosis of developing problems. Repairing issues before they advance to shut-down failures will result in raising the reliability of both emergency and primary power systems. Basic configurations outlined below:

• Generator sets with engines that are not controlled by an ECM (Electronic Control Module). Older Generator sets are older (1990’s and prior). Monitoring capabilities limited to analog converted to digital signal via an A to D converter. Basic generator set parameters can be monitored, referred to as “Historic Generator Sets”.  
• ECM controlled generator sets. Common manufacturer practice is to incorporate a generator control module (monitors generator parameters) and engine control module (monitors engine parameters) into one operating system. This configuration allows for advanced parameter monitoring and control referred to as “Advanced Generator Sets”.
• New generator sets with advanced control panels.

Historic Generator Sets

The basic theory of operation for a diesel engine remains unchanged. Historic generator sets often have low hours and are completely reliable. Often these generator sets were replaced because of the inability to supply advanced information to facilities managers. If facility requirements do not require an advanced alarm and monitoring system Historic Generators Sets are a viable solution. Utilization of an aftermarket monitoring and control system can be employed to monitor and control:

The basic engine and generator functions can be easily monitored with this configuration are:

• Engine oil pressure.
• Engine coolant temperature (providing radiator has port for aftermarket sensor installation).
• Engine RPM (Revolutions per Minute).
• Generator voltage.
• Generator amperage.
• Compartment louver position and control (depending on hardware manufacturer).
• Compartment temperature (depending on hardware manufacturer).

To accomplish the monitoring and control functions, often aftermarket suppliers are used. Single or Multiple Generator applications can be monitored utilizing an aftermarket supplier. Reputable vendors supply product that comply with SAE (Society of Automotive Engineers) and other state and government agencies.

If a single generator configuration is needed to maintain power requirements for a facility or home the below listed configuration can be utilized. Gen-Tracker generator monitoring system is an option for monitoring the generator (Figure 1). In the below configuration the panel has the ability to perform the following time stamped functions:

• Monitor three voltage sensor inputs (Normal, Emergency and Load). Generator (switch panel) to Gen-Tracker communication.
• Four digital sensor inputs (such as oil pressure, coolant level, low fuel pressure and high coolant temperature). Engine to Gen-Tracker Communication.
• Engine starter contact status. Engine to Gen-Tracker communication.
• Fail to exercise. Software within Gen-Tracker unit (programmable) allow alarms when predetermined events do not occur according to plan. Can send event to land line, cellular, WIFI and Ethernet.
• Two fuel level inputs 5-20 V and 4-20 ma. Select one depending on fuel level style.
• Battery condition monitoring (float and cranking voltage).
• Remote starts and generator status.

Panel ConsiderationsSome considerations should be made when selecting the generator monitoring system for an application. Below are some items to consider:

• Capability of monitoring system – Will the selected system meet all monitoring and communication needs, and allow for future growth?
• Points to monitor on generator engine – These are digital inputs. Digital inputs or in the ON or OFF state. Some styles of these switches are high or low level switch, high or low pressure switches and high or low pressure switches.
• Selection of fuel tank level monitor. Two choices available 5 to 20 V and 4 to 20 ma. The 4 to 20 ma level monitors are widely used and considered more accurate.

A sample of a circuit card (Figure 2) is provided to illustrate the capability of monitoring unit circuit cards. At a glance a technician can see if the system is operating correctly or aid in problem isolation.

• DS1 COM – Solid lamp indicates unit is communicating with device (phone, network etc.).
• DS2 SIGNAL – Solid lamp indicates unit is waiting to transmit signal.
• DS3 FAULT – Solid lamp indicates generator faulted.
• DS4 HEARTBEAT – Blinking one second intervals, unit is OK.
• DS5 SPEED – Network speed on solid with 100Mbit and off if 10 Mbit connection.
• DS6 LINK – Solid lamp indicates linked to network.
• DS7 START CONTACT – Solid lamp indicates starter contacts open, off indicates closed.
• DS8 RELAY STATUS -

ECM Controlled Engines without Advanced Control Panels

A large advancement in diesel technology was the advent of the ECM. Called engine control module or electronic control module depending on the manufacturer. The ECM controls all engine functions via software and hardware. Hardware is classified into two main types:

• Input – Any device that provides an input signal to the ECM. Some signals considered input are temperature, pressure, speed, and position.
• Output – Any device that action is controlled by the ECM. Some of these devices are engine starter, light emitting diodes and digital signals to gauges, turbocharger control valve signals and injector fire signals.

The software in the ECM allows advanced monitoring functions. It can be accessed using a laptop and the proper adapter connected to a 9-pin data link connector. The connector is generally at the operator panel for the engine. Once connected engine parameters, some set points (excluding calibration), alarms and history can be accessed.

Each ECM has interface software. Most commonly a SAE J1939 datalink with a SAE J1587 as a backup. The datalink circuit is the digital communication link between engine ECM and Remote Monitoring System.

To accomplish remote monitoring of both engine and generator functions of a generator set, an additional control panel must be used. When selecting the control panel consider the following.

• To monitor all engine functions, panel must have J1939 connections and software.
• Does panel have OEM harness available for different manufacturers.
• Mounting hardware and connecting cables included.
• Software package is installed in the panel.
• Panel wiring connection options.

A connection example using a Panelsource P10 CAN BUS is used as the example controller (Figure 3). The configuration is as follows:

• Generator is connected to an automatic transfer switch.
• Generator start function connected to automatic transfer switch panel.
• P10 control panel connected to Automatic Transfer switch for generator monitoring and engine start functions.
• P10 control panel connected to engine ECM via J1939 Datalink for alarm monitoring and ECM access via manufacturer software. ECM software interface with P10 software.
• Ethernet option is used to connect to computer or network.
• Phone option used to allow communication with VOIP (Voice Over Internet Protocol).

The Panelsource P10 offers advanced ECM monitoring and control functions. Facilities managers can decide what parameters they would like to remotely monitor and notifications received. All engine and generator parameters can be monitored from the Ethernet connected computer or display screen of the P10. Some common notifications outside operator space can be:
• Low output for generator voltage and amperage.
• Generator start command.
• Un-commanded generator shutdown (cause could be loss of fuel supply).
• Any fault code deemed as “Critical” by generator set manufacturer. If these fault codes are not solved, they can progress to ECM commanded limp mode or complete engine shutdown.
• Any fault code that results in reduced engine performance.
• Any fault code that results in engine shutdown.

Planning for an Industrial Generator Installation

Purpose

This article explores different options available for various types of emergency generator applications. The applications discussed include generators exposed to weather and generators located inside of a facility.

• Permanent enclosed generator – Complete generator system housed in an enclosure that is located on gravel or concrete pad.

• Portable enclosed generator – Generator system housed in an enclosure that is mounted on a trailer frame. Commonly used in construction sites. Easiest to complete initial setup on because unit is self-sufficient.

• Generators located inside of a facility – Often can have redundant backup. Facility generators can be fueled by natural gas or diesel fuel. Day tanks are common in diesel fuel applications.

Permanent Enclosed Generator

Site Planning

When setting up the site always use the generator manufacturer, state and federal guidelines. It is helpful to design a basic drawing of the generator and supporting systems (Figure 1). Some considerations to be made are:

• Generator located with enough clearance between building and fuel supply to allow major maintenance.
• Fuel supply located accessible to fuel truck.
• Security fence installation for safety purposes.
• Buried or above ground fuel and electrical services.

The generator area can be designed to be large enough to fit the fuel tank and allow for major maintenance to be completed with ease (Figure 2). A Caterpillar 1000 kW generator set was used in the creation of the generator area. The following statistics were used in calculations:

• Physical size of generator (21 ½’ x 11 ½’).
• Weight of generator with fuel tanks full (44,000 lbs.).
• Fuel consumption of generator (71 gal per hour full load).
• Back up fuel supply tank (600 gallon).

Always consult local, state and federal regulations when designing the generator area. Spill containment should be considered. Fuel stored between back up fuel tank and generator fuel tank is 1200 gallon. This allows for 16 hours of continuous operation at full load.

Concrete Pad Design

It is not advised and against many building codes to place a generator set on gravel. The generator must be kept level and vibrates during operation and must be secured to a permanent structure. Concrete is the industry standard for normal soil applications.

The thickness and size of the pad is controlled by soil composition among many other geographical considerations. Consult all federal, state, and local authorities when determining the following:

• Ambient temperature for concrete pour (quick setting or normal). Fresh pours must be utilize vibration to insure all air bubbles are dissipated.
• Weight concrete can withstand (heavy loads require reinforcement).
• Amount of pad protrusion past generator set (overall size plus ½”). Accurate measurements must be acquired when calculating.

Concrete Anchors

Securing the generator set and backup fuel supply tank is usually completed using concrete anchors (Figure 3). There are many options for anchoring equipment to concrete:

• Heavy Duty Anchor – Installed prior to concrete pour. Taking good mounting measurements imperative.
• Adhesive Bond – Concrete cured, hole drilled, epoxy and stud installed. Stud must be square and level.
• Mechanical Bond – Concrete cured, hole drilled, stud set and tightened. Minimum requirements.

Portable Enclosed Generator

Portable generators require less site preparation than any other style of generator. They are offered in a variety of sizes from the Caterpillar 320 kW to the Baldor 2000 kW. Often portable generators are used in construction site applications supplying main power.

Site Preparation

One advantage of using a portable generator is that it can be moved to different locations at the same job site for power requirements as the job progress. A Baldor 2000 kW generator is required to satisfy power requirements on a construction site. Preparing the site for the arrival of the generator can include the following:

• Road established to location(s) of generator.
• If generator moves locations on site, area prepped prior to move.
• Generator dimensions are 46’ x 9’ with a height of 13’. Appropriate clearance to get to lot and size of lot able to support generator.
• Generator weight is 67,000 lbs. If soil conditions are moist, dunnage (Figure 4) can be used under rear wheels for support.
• Fuel usage for engine under full load is 142 gallons per hour, with a 2800 gallon fuel tank allowing for 19.72 hours of operation.
• Support lifting gear with dunnage (Figure 4) prior to engaging to remove from truck.

Generators Located Inside Facility

Generators that are purchased to be located inside a facility are most commonly a self-contained system (Figure 5). The engine, generator and engine cooling system are placed on a skid and factory aligned for operation. When moving the generator into the facility consider the following:

• Clearance – Enough for generator to be moved and placed onto concrete pad.
• Facility lifting device – Construction fork truck, installed overhead crane system or portable gantry system.
• Unload from truck – Construction fork truck or crane. Place in prep area to ready to be located in facility.

Site Preparation

Preparing a facility for a generator set installation (Figure 6) has a few additional steps. Setting up generator set mounting and auxiliary systems prior to installation can save system down time. Always consult federal, state and local authorities for regulations prior to beginning site preparation. The below items can be performed prior to setting the generator set:

• Concrete pad – Located appropriate distance to allow for generator maintenance. Concrete to regulations.
• Generator skid mounts – Number and location of mounts depends on size and style. Attach mounts to pads (must be aligned and square) to concrete pad.
• Intake air – Engine intake air is supplied from air in the room. Must have positive air supply when engine(s) are operating.
• Fuel supply – Some regulations require fuel supply piping to be located under floor level and protected by grating.
• Electrical drops – Have drops ready to run after installation.
• Cooling air – Ductwork with louvers can be installed so the generator set can be attached to them prior to removal of lifting device.
• Exhaust – Building must have exhaust system installed for the generator. The building exhaust can be installed prior to installing generator set. 

Before Selecting a Generator to Rent. What Should Be Important Point in Mind

Before renting a generator, make sure that you know your power requirements. You should know the proper voltage and maximum amperage needed, whether you need one or three-phase power and how long you will need to run the generator. Provide this information, along with a description of how you plan to use your rented generator, to your local, ARA-affiliated rental store professionals to enable them to help you rent the best generator for your purposes. Here are some factors that may affect which generator you decide to rent.

• Type. Rental generators come in a variety of types. See Generators and Related Products for Rent for more information on types of generators available for rent.
• Size. Generator rental options range from small, portable generators to large, trailer- or skid-mounted units. Larger units produce greater outputs — measured in watts or kilowatts (kw) — than smaller generators produce. It is important to rent the proper size generator for your application. To determine the size of generator that you should rent, add up the number of watts required for everything that you need to connect to the generator. To calculate wattage, multiply amps by volts. Keep in mind also that a motor may take three times more watts to start than to operate. In general, you should rent a generator that produces slightly more power than you require to prevent generator shut downs or the tripping of a circuit breaker. On the other hand, if your application requires a lot less power than the rated capacity that a diesel generator can provide, then the generator may fail to run at peak performance.
• Power source. Sources of power for most rental generators include either gas or diesel. Some generators for standby power do run on propane or natural gas, though. Many of the small, portable generators run on gas, whereas diesel often powers larger units. Diesel generators generate good power output, but may cost more to run than a gas generator.
• Environmental concerns. For some applications, reduced sound and emissions may be important. For example, a special event may require a quiet generator to prevent it from interrupting the festivities. Overall, most manufacturers of rental generators now design quieter and more efficient models than in previous years.
• Safety features. Rented generators come equipped with many features to keep both individuals and the equipment safe. For example, ground fault circuit interrupter (GFCI) protection systems on generators help protect people from electric shock or electrocution by shutting the equipment down when it detects electrical current leakage. In addition, to prevent damage to the equipment, many generators shut down when oil levels get too low. Some generators also include circuit breakers to protect the generators and the tools they run against problems from overloading.
Contact your local, ARA-affiliated, rental store for information on available rental products and services to meet your generator needs. To locate the rental store nearest you, use the Rental Store Quick Locator above.