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Guide to Generator Set Exhaust Systems

Information Sheet # 16
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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technology impacting the Power Generation Industry.
The installation information provided in this information sheet is informational in nature only, and should not be considered the advice of a properly licensed and qualified electrician or used in place of a detailed review of the applicable National
Electric Codes and local codes. Specific questions about how this information may affect any particular situation should be addressed to a licensed and qualified electrician.
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
0.5
6000
Flashing
5000
5000
Roof 4500 1.0 5
Holes in end of 4000 0.5
3500
inner sleeve 3000
6
9” Minimum 0.01
2500 7
0.005
Exhaust Pipe Diameter 2000
plus 12” 8
0.001
9” Minimum 1500 9
Exhausting through roof installation 0.0005
10
1000 0.0001
Exhaust thimble is 900 0.00005
800
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
P = Backpressure in psi S (lb/ft³) =
Exhaust Temperature + 460°F
psi = 0.4912 x in Hg
Outside or dividing wall L = Length of pipe in ft For each 90˚ bend calculate as:
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

5.0 Engine performance:

The manufacturer can detail the maximum allowable back pressure or restriction with the system. It is specified as “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 diagram two
for details) to determine the inside diameter of the pipe.
• The exhaust system should be designed as short as possible with a minimum of bends. A 90° pipe bend increases the length of
the system and back pressure. (see diagram two)
6.0 Exhaust system criteria:
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.
Oklahoma City Area Austin Area Tulsa Mailing Address Dallas/Ft. Worth Area Longview Area San Antonio Area Little Rock Area t il it y P o
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7300 Melrose Lane 4918 Burleson Road P.O. Box 581807 101 Industrial Boulevard 1913 East US Hwy 80 4702 B Dodge Street 29 Collins Industrial Place
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Oklahoma City Austin Tulsa Mansfield White Oak San Antonio Building 1C
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OK 73127 TX 78744 OK 74158-1807 TX 76063 TX 75693 TX 78217 North Little Rock, AR 72113
405.949.2332 512.477.6937 918.836.0066 817.640.5544 903.291.8305 201.333.0377 501.907.5884 Established 1985
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CPS-INFO#16©2011 PLC Enterprises, LLC