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Information Sheet # 16
Guide to Generator Set Exhaust Systems
Your Reliable Guide for Power Solutions

1.0 Introduction
A system designer must consider environmental and performance criteria when sizing and positioning the exhaust system of a generator
set. Correct installation of the exhaust is also crucial to ensuring full performance of the engine.
This info sheet is a guide and discusses the issues to be addressed when installing a generator set’s exhaust system.
2.0 Key purpose of the exhaust system:
All engine systems have exhaust systems to facilitate:
Safe evacuations of gases - Exhaust gases for safety and environmental concerns should be safely vented to atmosphere for both
inside and external locations.
Sound attenuation - Various muffler grades are available to meet different acoustic requirements.
Engine performance - Incorrect exhaust sizing can result in degraded engine performance.
3.0 Safe evacuation of exhaust gases:
When designing a system the following should be noted:
• To prevent re-circulation of gases into other areas outlets should be located upwind and away from any building and equipment
air intakes. Engine exhaust can also be a fire hazard and must never be exhausted adjacent to any combustible material.
• Pipe sleeve or fire proof materials are used when exhaust pipes pass through building material.
• Local codes should be consulted by the designer. (See diagram one for details)
4.0 Sound attenuation:
When designing a system the following should be noted:
• Consult local codes for sound level limitations. Generator set manufacturers offer four types of silencers, industrial, residential,
critical and hospital for very noise sensitive locations.
• Consult the attenuation curves given for a silencer to ensure it is within code. (Continued over)

Air inlet away from exhaust

5
See inset Flexible sections (Bellows)

1 2

3
1. Exhaust thimble (see diagram 1) 4
2. Muffler - Available in 4 grades
3. Water trap with drain
4. Flexible bellows Exhaust layout
details
Inside 5. Brackets to support weight
generator set of exhaust system
installation 6. Black iron exhaust pipe

Diagram three - Typical Exhaust System Layout

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 Diagram one - Exhaust Pipe Thimble Installation Diagram two - Exhaust System Calculations
3
Q (cfm or ft³/min) D (in)
Drip cap 10000
9000 P( in Hg per ft)
Rain cap 8000 1.0
7000 4
Corporate Office 6000
0.5
P.O. Box 581807 Flashing
5000
Tulsa, OK 74158-1807
5000
800.324.0066 Roof 4500 1.0 5
Holes in end of 4000 0.5
3500
inner sleeve 3000
6

Tulsa 9” Minimum 0.01

2500
9310 East 46th Street North 0.005 7
Tulsa, OK 74117 Exhaust Pipe Diameter 2000
918.836.0068 plus 12” 8
0.001
9” Minimum 1500 9
Exhausting through roof installation 0.0005
10
Oklahoma City
1000 0.0001
7300 Melrose Lane
Oklahoma City, OK 73127
Exhaust thimble is 900 0.00005
800
405.949.2332 required when exhaust 13
pipe passes through P(psi) =
L x SL x Q²
5
0.00001
5,184 x D
combustible material
Where: 39.6
Little Rock S (lb/ft³) =
P = Backpressure in psi
6800 Intersate 30 Exhaust Temperature + 460°F
psi = 0.4912 x in Hg
Little Rock, AR 72209 For each 90˚ bend calculate as:
501.907.5884 Outside or dividing wall L = Length of pipe in ft
Q = Exhaust gas flow ft³/min L (ft) = 15 x D
D = Inside diameter of pipe inches L (in) + 15 x D
S = Specific weight of gas lb/ft³
Horizontal vertical wall installation 12
Kansas City
211 E Marley Rd
Kansas City, KS 66115
913.312.2031

5.0 Engine performance:

St. Louis
53 Millwell Court The manufacturer can detail the maximum allowable back pressure or restriction with the system. It is specified as
Maryland Heights, MO 63043
314.739.8700 “inches hg”. When the back pressure is exceeded, the air-fuel ratio is reduced which results in a drop in fuel economy
and power output. The following should be undertaken:
• The designer, having the manufacture’s data for gas flow (ft³/min) and maximum back pressure, uses a chart (see
Austin diagram two for details) to determine the inside diameter of the pipe.
4918 Burleson Road
Austin, TX 78744 • The exhaust system should be designed as short as possible with a minimum of bends. A 90° pipe bend increases
512.477.6937 the length of the system and back pressure. (see diagram two)

6.0 Exhaust system criteria:

Dallas/Ft. Worth
2916 National Drive
Garland, TX 75041
972.265.0768
101 Industrial Boulevard
Mansfield, TX 76063
817.640.5544
Longview
1913 East US Hwy 80
White Oak, TX 75693
903.291.8305
San Antonio
5803 Rocky Point
San Antonio, TX 78249
210.333.0377
The designer of the system should also consider the exhaust factors in the design:
Water in the system - Water can be a by-product of exhaust and enter the system as rain. To prevent water from draining
back into the system, slant the horizontal pipe away from the engine and install a water trap at the lowest point. (see
diagram three for details) A rain cap should be fitted on exhaust pipes ending in the vertical position.
Flexible exhaust sections - To prevent damage due to vibration and thermal expansion, flexible bellow type sections
should be installed. Do not use bellows for required bends and alignment adjustment.
Soot deposits - For environmental and aesthetic reasons consider placement of the exhaust outlet to avoid exhaust gas
deposits accumulating on adjacent structures/buildings.
Exhaust structure - The exhaust system weight should be adequately supported and utilize robust material such as
Schedule 40 black iron. The systems can be supported by various means but must remain flexible and the weight should
never be carried by the engine manifold and/or turbo-charger. Galvanized piping should never be used in an exhaust
system. (see diagram three for details)
Wind effect - Consider the prevailing wind at the required locations and position the exhaust outlet to avoid exhaust
gases being returned into the generator set installation or entering other structures.

7.0 CODES:
National Protection Association Code Numbers 99 and 100 are important codes that cover generator exhaust systems.
The designer should also consult all applicable local codes.

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