MECHANICAL INSTALLATION — FUEL SYSTEM (DIESEL)
MECHANICAL CONNECTIONS
Introduction
After considering all applicable codes and laws and finding a suitable location site for the generator set, the installer should consider the mechanical connections that will be necessary to make during installation. The four (4) systems that could require mechanical connections are the following:
zFuel system
zExhaust system
zVentilation system
zCooling system
Fuel System Installation
Proper installation of the fuel system is essential in obtaining proper genset performance, safe working conditions, and preventing property and environmental damage.
When planning an installation, check state and local codes regarding fuel storage and handling. Piping and fuel system components must conform to these regulations. Most applications in the United States require that storage tanks, day tanks, and subbase fuel tanks be UL listed. The UL listing indicates that the tank has conformed to a series of construction and testing standards. In addition, most tanks must conform to National Fire Protection Association (NFPA) construction and installation requirements. The three NFPA codes that apply to day tanks and subbase fuel tanks are NFPA 30, Flammable and Combustible Liquids Code; NFPA 37, Standard for Installation and Use of Stationary Combustible Engine and Gas Turbines; and NFPA 110, Standard for Emergency and Standby Power Systems.
Use only compatible metal fuel lines to avoid electrolysis. This practice is particulary important when fuel lines must be buried. Buried fuel lines must be protected from any kind of corrosion. Use a flexible section of tubing between the engine and fuel supply line to prevent vibration damage. Refer to the generator set manual for outline drawings and detailed information.
NEVER use galvanized or copper fuel lines and fittings for fuel tank connection. Condensation in the tank and fuel lines combines with the sulfur in diesel fuel to produce sulfuric acid. The molecular structure of the copper or galvanized lines reacts with the acid and contaminates the fuel, which can clog filters and damage the engine fuel injection pump.
Diesel Fuel
MQ Power Industrial generator sets use ASTM No. 2 Diesel fuel. If an alternate diesel fuel is required, consult the appropriate engine manual.
The main components of a typical diesel fuel system are the fuel storage tank, fuel lines, transfer fuel tanks or day tanks, and auxiliary fuel pumps or lift pumps. Fuel storage tanks may be located indoors or outdoors, providing they meet local code requirements. The fuel supply tank should be located near the diesel engine to enable the engine mounted fuel transfer pump to operate within its capability. Fuel filters and fuel/water or sediment separators must be easily accessible for regular and scheduled maintenance. It is important to have a clean installation, making every effort to prevent entrance of moisture, dirt or contaminants of any kind. Clean all fuel system components before installing.
Supply Tank
Locate the supply fuel tank as close as possible to the generator set and within the five (5') foot (1.5 m) lift capacity of the engine fuel pump. Any fuel tank transfer pump capacity and supply piping should be sized on the basis of the maximum fuel flow rating. Refer to the generator set data sheet for detailed fuel consumption data.
If the main fuel tank is installed below the lift capabilities of the standard engine fuel pump, a transfer tank (referred to as a day tank) and auxiliary pump also will be required. If an overhead main fuel tank is installed, a transfer tank and float valve will be required to prevent fuel head pressures from being placed on the fuel system components.
Fuel leaks create fire and explosion hazards which can result in severe personal injury or death! Always use flexible tubing between the engine and fuel supply to avoid line failure and leaks due to vibration. The fuel system must meet applicable codes.
INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 37