COLUMN  ENGINEER’S NOTEBOOK

This article was published in ASHRAE Journal, April 2016. Copyright 2016 ASHRAE. Posted at www.ashrae.org. This article may not
be copied and/or distributed electronically or in paper form without permission of ASHRAE. For more information about ASHRAE
Journal, visit www.ashrae.org.
Stephen W. Duda

Engine Cooling for Emergency

Power Generation Systems
BY STEPHEN W. DUDA, P.E., BEAP, HBDP, HFDP, FELLOW ASHRAE

In my last column for the “Engineer’s Notebook” series,1 I pointed out that building
system design engineers who regularly design comfort heating and cooling systems
may be called upon only occasionally to design and specify mechanical systems
related to emergency power generation. There may be some facets of engine genera-
tor system design with which an experienced HVAC engineer will not necessarily
be familiar. That previous column dealt with the fuel oil systems; this column will
attempt to tackle engine cooling and generator room ventilation.
This column is intended to apply where an engine design required for the radiator is a source of intake
generator is installed indoors. Complete packaged or makeup air, and a duct enclosure from the radiator
engine generator systems are commercially available in discharge to the building exterior. The primary disad-
an assembled engine and generator, with factory pre- vantage of the unit-mounted radiator is that, on large
packaged exhaust system, radiator, louvers, and acces- units, the airflow rate of the radiator’s cooling fan can be
sories in a weather-proof housing ready to “plug and exceptionally high—a difficult hurdle to overcome if the
play.” This column is not intended to apply to that type of engine-generator package is to be located remote from a
product. ready path to outdoors.

Local Radiators Remote Radiators

The typical diesel engine applied in emergency power
generation is liquid-cooled, just like a diesel engine in
an over-the-road truck. And just like the big rig, the
engine’s jacket water is cooled in a water-to-air heat
exchanger called a radiator. The radiator for an engine
generator can either be unit-mounted, or remotely
installed.
The simplest radiator option in most cases is a local
factory-mounted radiator. The radiator’s cooling fan
is typically mechanically connected to the drive shaft,
so no external power source is needed, and the jacket
water is usually pre-piped to and from the engine and
radiator. Controls are extremely simple—if the engine
is cranking, the radiator fan is rotating. The only field
For very large radiators, or for engine-generator pack-
ages located where ample access to outdoor air is not
available, remote radiators may be needed. Remote
radiators can provide flexibility in terms of location,
with the most common choices being on the building
roof or on grade in a secure enclosure. Locating the
radiator remotely has the disadvantage of requiring field
jacket-water piping and often one or more jacket-water
circulating pumps.
Engine generator packages with a unit-mounted
radiator include factory-installed jacket water circulat-
ing pumps. Those pumps can still be provided even on
Stephen W. Duda, P.E., is senior mechanical engineer at Ross & Baruzzini, Inc. in
St. Louis.

54 A S H R A E J O U R N A L   ashrae.org  APRI L 2016


packages with remote radiators, but their size and pres-
sure capacity limits the distance to the radiator. Often,
the engineer will need to specify separate external
pumps, with a separate power connection. Since we are
discussing emergency power generation, these external
jacket water pumps and remote radiator fans will obvi-
ously also require a source of emergency power. Remind
the electrical engineer to oversize the generation capac-
ity because of the power that will need to be diverted
from emergency use to power the jacket water pumps
and remote radiator fans.
Design Tip: Today’s engines often require two sepa-
rate piping circuits for jacket cooling water—one each
for the engine and turbocharger—and the radiators
typically are coiled with the two circuits intertwined. A
total of four pipe lines are required, two supply and two
return, and cannot be combined due to their differing
temperatures. Failure to recognize this may result in
costly last-minute design changes and a lesson learned
the hard way.
Design Tip: Selecting jacket water circulating pumps
is not unlike selecting pumps for HVAC chilled or heat-
ing water. However, the jacket water is typically a glycol
solution (in locations where winter temperatures can
be expected to fall below freezing), and the operating
temperatures are higher than most heating water selec-
tions, so density, specific heat, and other fluid proper-
ties must be properly applied. Do not use the common
properties of water without appropriate adjustment.
Finally, radiator pressure ratings need to be reviewed.
A typical radiator may be designed for close coupling
with relatively low pressure ratings. If located far away
from the engine, the pumping pressure requirements
can exceed the radiator pressure rating. This may
require addition of a secondary loop with an isolation
heat exchanger.
Engine Exhaust Mufflers, Piping and Accessories
The engine exhaust must be ducted outdoors and
discharged at an acceptable location. Common com-
ponents of the exhaust system are flexible connectors,
mufflers, anchors and guides, an end-cap or other
termination, and pressure relief. Particulate filters can
also be required in some pollution control districts.
The piping itself can be standard-weight welded steel
pipe. Insulation, typically Calcium Silicate, on that
pipe is often needed for safety of personnel who may be
COLUMN  ENGINEER’S NOTEBOOK
working nearby,2 as exhaust temperatures can approach
1,000°F (540°C).
The muffler is most often sized and selected by the
engine generator manufacturer, and either critical-
grade or super-critical grade are most often chosen.
Physical styles include an inline cylindrical type, or
space/layout considerations may indicate use of a
“pancake” style that is wider but flatter, with bottom-
in and side-out arrangement. Just as with the pipe, it
may require insulation for safety reasons, or factory-
insulated models may be specified. Engine generator
manufacturers also frequently offer a pipe expansion
fitting for use at the generator exhaust manifold connec-
tion, and a weather cap of some sort for the termination
point.
Some engineers add a spring-loaded pressure relief
device in the engine exhaust piping, because they
believe it is required by NFPA 37-20103 Paragraph 8.1.4
“Exhaust systems shall be designed and constructed to
withstand forces caused by the ignition of unburned fuel
or shall have provisions to relieve those forces without
damaging the exhaust system.” However, the explana-
tory appendix material at the end of NFPA 37 Item
A.8.1.4 reads “Normally, this provision is met by the
built-in strength of the system.” Building operators find
the pressure relief devices to be a tremendous nuisance
and the component manufacturers this author spoke to
agree that the system is designed with sufficient robust-
ness so as to avoid the pressure relief fittings.
The length of the exhaust run may be just a few
yards/meters if located near an exterior wall or roof;
but may be a great distance away if, for example,
the exhaust must route vertically from a basement
through a tall building. If lengthy, the engineer must
consider the maximum exhaust static pressure avail-
able as published by the engine manufacturer – often
on the order of 27-in. w.c. (6.7 kPa). Long runs also
require consideration for additional expansion fit-
tings as the piping will be subject to cycles between
ambient temperature and the nearly 1,000°F (540°C)
exhaust temperature. Supports, anchors, and guides
need to be selected to allow for expansion and
contraction.
Design Tip: Do not manifold the exhaust piping
from multiple engine sets. Instead, route each engine’s
exhaust pipe to the outdoors separately. If manifolded,
the online machine will backfeed exhaust to an offline
APRI L 2016  ashrae.org  A S H R A E J O U R N A L 55
COLUMN  ENGINEER’S NOTEBOOK
engine, causing portions such as the turbocharger to
freewheel without the oiling system active.
Design Tip: In lieu of steel piping with field-applied
insulation and applied expansion fittings, many engi-
neers find it more convenient and cost-effective to
specify a pre-engineered listed double-wall exhaust flue
system offered by many of the same manufacturers that
sell boiler exhaust flues. This type of product is already
insulated, and the manufacturer includes the expansion
fittings, guides and anchors, plus the technical expertise
to properly select same.
Design Tip: Options for terminating the engine
exhaust include the roof or sidewall. One trick features
sidewall termination by poking through the same lou-
ver serving the radiator discharge. The radiator airflow
helps carry away the exhaust fumes so the adjacent
building walls don’t stain.
Air-Side Components
The next challenge is to design and specify the ventila-
tion, heating, combustion air, and radiator air cooling.
Regardless of whether the radiator is unit-mounted or
remote, the generator equipment room will need ventila-
tion, combustion air, and (depending on climate) heating;
but the radiator air cooling provisions described here are
only applicable for unit-mounted radiators.
Combustion Air & Radiator Makeup-Air Design
For the case of the factory-mounted radiator, the
airflow rate of the radiator’s cooling fan can be quite
high and its external pressure drop capability is quite
low (e.g., 0.5 in.w.c [125 Pa]), requiring both a large
discharge louver and a large intake louver. The intake
louver should preferably be located on the wall directly
opposite the radiator discharge louver. If located on an
adjacent wall, the intake louver should be as remote
as practical from the radiator discharge louver, so that
outdoor air is drawn across the hot generator and engine
during operation.
In locations where winter temperatures can be
expected to fall below freezing, automatic motorized
dampers should be used on both the intake and exhaust
louvers so that they may be closed during long idle peri-
ods when the emergency generator is not in use. The
dampers should be wired to open on the same signal
that starts the engine generator. While the actuators
can be simple two-position open-closed models, many
56 A S H R A E J O U R N A L   ashrae.org  APRI L 2016
engineers use a modulating damper actuator for room
temperature control as explained in the subsequent
subsection.
Design Tip: In locations where winter temperatures
can be expected to fall below freezing, it is advantageous
to install a separate smaller intake louver/damper sized
for the larger of (a) the room’s ventilation airflow rate
or (b) the engine manufacturer’s published combustion
airflow demand. By keeping the ventilation and com-
bustion air function separate from the large air require-
ment of the radiator, room heating during generator
operation is facilitated. This feature can also be achieved
using one large louver/damper with a separate actuator
controlling only a few of the damper blades of the larger
assembly.
Design Tip: To guard against risk of having the damp-
ers fail to open when needed for emergency operation,
specify these dampers to be actuated by motors with a
spring return feature, which fail-safe in the position
favorable to generator operation. If non-spring types are
used, the actuators must be powered from the emer-
gency power system.
Design Tip: Using a remote radiator does not com-
pletely remove the need for ventilation airflow across
the engine/generator set during operation. If the
radiator is remote from the engine/generator set, local
ventilation of the engine/generator room is necessary
for removal of heat from the engine itself, plus genera-
tor winding heat removal, which could be up to 5% of
rated generator capacity. Manufacturer’s literature
provides the full-load rated heat losses to the room
for the engine and generator that must be removed by
ventilation.
Generator Room Heating & Ventilation
It would be uncommon for an emergency generator
equipment room to be air-conditioned, but they cer-
tainly might be ventilated; and in many climates winter
heating will be necessary as well. Ventilation can be as
simple as an exhaust fan and makeup air intake louver,
controlled either thermostatically, or based on occu-
pancy, or both. Control the ventilation system to power
on when room temperature in the summer exceeds
a desired setpoint, and perhaps anytime the room is
occupied.
Winter heat is usually provided via a unit heater;
gas-fired, hot water, or steam are common sources;
Advertisement formerly in this space.
COLUMN  ENGINEER’S NOTEBOOK

electric-resistance heat can also FIGURE 1  

Radiator with recirculating damper.
be used. While unit heaters or
Flapper Cap
similar local heating units can
be applied for heating the gen- Double-Wall Breeching
erator equipment room during
long winter idle periods, don’t
attempt to heat the generator
Muffler 24 in. (Min.)
equipment room that way dur-
ing actual engine operation if MD
MD 5
using a unit-mounted radia- 1 Exhaust Piping (MD-4 Similar on
tor. The amount of outdoor air Opposite Side)
induced during operation by Flexible Connector
a unit-mounted radiator fan AP
is usually far too high to be
MD MD
heated in any practical way. To 2 3
illustrate, a 200 kW engine gen- FC
Floor Generator
erator package may require a
15,000 cfm (7500 L/s) radiator, Sheet Metal Ductwork from Generator to Louvers as Required
and a 750 kW package may need
40,000 cfm (20 000 L/s). Even if you could heat this air- damper in tandem but opposite to maintain acceptable
flow, the energy penalty to do so is unacceptable. room temperature.
But in many climates the room certainly will require
heat to protect sprinkler or any other water-based pip- Other Design Considerations
ing systems from freezing during a long period of gener- Since emergency generators are, by definition,
ator operation in cold weather. Therefore, use the waste intended for use in emergencies, we must keep in
heat from the radiator to your advantage. mind that all of the components discussed here need
Design Tip: Size the room’s heating unit(s) for the to be available in those same emergencies. Tornado,
winter heat loss through walls and roof, plus the heat hurricane, or other extreme weather event can be
needed to offset the day-to-day ventilation load. For responsible for loss of normal utility power, as can
room heating during generator operation, use an earthquakes or fires. So the design engineer must
auxiliary damper on the discharge side of the radia- consider design features intended to minimize risk
tor to recirculate warm radiator air back into the room to any of the engine-generator system components
(dampers MD-4 and MD-5 in Figure 1). A sheet metal in those scenarios. For that reason, indoor unit-
duct of some practical length (often 3 to 6 ft [1 to 2 m]) mounted radiators are sometimes preferred over
is connected from the radiator to the exterior wall remote outdoor radiators, for example. If remote
louver. The radiator discharge damper is placed near radiators are necessary, consider placing them in a
the louver, and a recirculation damper is placed on the secure courtyard protected as much as practical from
side of the duct between the radiator and the discharge damaging storms. If in a zone of higher seismicity,
damper. all components require seismic bracing and anchor-
Upon winter startup of the engine-generator pack- age. If located in a flood-risk zone, locating acces-
age, the intake louver (MD-2) and radiator discharge sories in safe dry areas away from potential flooding
louver (MD-3) remain closed, while the recirculation is necessary. And all components require access for
damper (MD-4 & 5) and combustion air damper (MD- maintenance.
1) are both open. This allows the radiator waste heat to Be kind to your neighbors! Diesel engines can be
keep the room warm. As the room temperature becomes very loud when operating, and that noise often has a
too warm, the control system via a temperature sensor straight line of escape directly through the radiator,
modulates the intake damper and radiator discharge damper and louver. Sound attenuation for the radiator

58 A S H R A E J O U R N A L   ashrae.org  APRI L 2016

Advertisement formerly in this space.
COLUMN  ENGINEER’S NOTEBOOK
louver discharge and/or the outdoor air intake lou-
ver may be needed and even required by local codes,
depending on distance to the property line, orienta-
tion, and type of neighborhood (residential, commer-
cial, institutional, or industrial). Mitigating strategies
may include sound attenuators or an exterior barrier
wall. Space does not allow a full treatment of sound
attenuation in this column, so see instead the topic in
the ASHRAE Handbook.4
Design Tip: The engine-generator package manufac-
turer will publish allowable static resistance the radia-
tor fan can overcome external to the radiator itself, and
is often 0.5-in. w.c. (125 Pa), so the engineer must be
mindful of this when selecting the louver, damper, and
any sound attenuator.
Conclusions
The intent of this column was to review some of the
necessary non-electrical design considerations for die-
sel engine emergency generator systems. The engineer
or designer who is infrequently asked to design these
Advertisement formerly in this space.
60 A S H R A E J O U R N A L   ashrae.org  APRI L 2016
systems may find useful these tips and suggestions on
emergency generator auxiliaries such as exhaust muf-
flers and piping; local and remote radiators; combus-
tion air and radiator makeup-air. The December 2015
“Engineer’s Notebook” column included a related dis-
cussion of fuel oil storage tanks and tank accessories,
fuel oil piping, valves, and accessories, leak detection
and monitoring systems, return oil coolers, and fuel oil
transfer pumps.
Acknowledgments
The author heartily thanks Jeffery M. Coffelt, P.E.,
Member ASHRAE, for his technical contributions to this
column.
References
1. Duda, S. 2015. “Fuel oil systems.” ASHRAE Journal 57 (12).
2. Duda, S. 2014. “Overlooked code requirements.” ASHRAE
Journal 56 (12).
3. NFPA 37-2010, Standard for Installation and Use of Stationary Com-
bustion Engines and Generators. Quincy, Mass.: National Fire Protection
Association.
4.  2015 ASHRAE Handbook—HVAC Applications, Chapter 48.