Genset room size

Generator Set Foundations

Considerations for Generator Set Foundations
Foundations supporting generator sets must meet flotation, alignment and vibration parameters for
successful operation. Specifications that consider the following criteria will help assure trouble-free
installation and operation.
Foundations must be able to withstand the installation’s weight and prevent deflection. To determine
the pressure exerted by a generator set, use the following equation:
P = W/A
Where:
P = pressure in PSI (kPa)
W = generator set wet weight in lbs (kg)
A = Area in sq. in. (m2) of the rails, pads or vibration mounts.
This pressure must be less than the load-carrying capability of the soil foundation pad. General load
bearing capabilities of underfoot are listed in Table 1.
Table 1 Bearing Load Capacities

Safe Bearing Load

Material psi kPa

Rock, hardpan 70 482
Hard clay, gravel and coarse sand 56 386
Loose medium sand, and medium clay 28 193
Loose fine sand 14 96.4
Soft clay 0 – 14 0 – 96.4

The foundation should weigh at least as much as the generator set’s wet weight. Use this equation to
calculate the necessary foundation depth:
Foundation depth = W/DxBxL
Where:
W = Total wet weight of gen set (lb or kg)
D = Density of concrete (150.b/cu.ft3 or 2,400 kg/m3)
B = Foundation width (ft or m)
L = Foundation length (ft or m)
This equation assumes a concrete mixture ratio of 1:2:3 (cement:sand:aggregate) with maximum 4
inch (101.6mm) slump and 29-day compressive strength of 3,000 psi (20.67MPa).
If no vibration isolators are used, the floor must support 125 percent of the generator set weight. If
generators sets are paralleled, possible out-of-phase paralleling could cause torque reactions. Here,
foundations must be designed to withstand twice the generator set wet weight.
Outside base dimensions should extend beyond the unit a minimum of 1 foot (304.8mm) on all sides.
Foundation footings must extend below the frost line.
The foundation should be reinforced with No. 8 gauge steel wire fabric of No. 6 reinforcing bars on 12-
inch (304.8mm) centers horizontally. Bars should be imbedded in the concrete at least 3 inches
(76.2mm) from foundation surface.

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Maintaining Alignment

Modern multi-cylinder medium-speed generators sets do not require massive concrete foundations to
maintain engine/generator alignment. In most applications, a single-bearing generator set can be
installed and operated on the base it was shipped on.
Two-bearing generators, generators driven from either end of one engine, tandem generators or
generators with tandem engines require much heavier boxed base that resists bending forces exerted
by the generator sets. The base also must prevent resonant vibration during operation.
Flexible Connections

Any supply line or hose connected to the generator set–including exhaust coupling and exhaust pipe
hangers, jacket water connections, heat recovery systems and fuel lines–must be fitted with a flexible
section that can withstand vibrations incurred by the operating generator set. These flexible
connections should be installed as close to the generator set as possible and be designed to prevent
line leaks or breaks.
Service Considerations

Convenience and serviceability can be designed into a generator set foundation. Consider specifying
conduit for electric starting systems, generator leads and fuel and water connections.

Generator Set Vibration Isolation

No isolation is required to protect a generator set from self-induced vibrations. Caterpillar gen sets are
designed to absorb all normal vibrations created internally as well as most external shock loads.
This is not true of the gen set environment. Idle gen sets, auxiliary equipment such as relays and
switches, and building structures can be adversely affected by vibration from an operating gen set.
Vibration Types

There are two types of generator set vibration: torsional and linear. Torsional vibration results from
combustion forces imposed on the engine crankshaft that is transmitted to the total rotating mass.
Except in unusual installations, proper matching of engine and generator set at the factory completely
avoids this type of vibration.
Linear vibration has many causes and can usually be linked to shaking and noisy machinery. Its exact
nature is often difficult to define without instruments, because total vibration measured is
approximately a sum of vibration sources.
Engines produce vibrations due to combustion forces, torque reactions, structural mass and stiffness
combinations, and manufacturing tolerances on rotating components. These forces create a range of
undesirable conditions, ranging from unwanted noise to high stress levels and ultimate failure of
engine or generator components. Vibrating stresses reach destructive levels at engine speeds where
resonance occurs. Resonance occurs when system natural frequencies coincide with engine
excitations. The total engine-generator system must be analyzed for critical linear and torsional
vibration. (See chart 1)
Chart 1

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Vibration Effects

There will always be some vibration in rotating machinery like an operating gen set, so it is good
practice to specify isolation of the unit. The unit should not rest directly on rock, soil, steel or concrete.
These materials can transmit vibrations long distances.
Resonance of certain gen set frequencies with the natural frequencies of building structural members
can cause damage to some types of construction.
Vibration measured is approximately a sum of all vibration sources. Testing can determine sources.
Separating the gen set from the surroundings can be done with a bulk isolator such as an inertia block
or with commercial isolators.
The bulk isolator is the more expensive and elaborate of the two systems. It consists of a massive
block on which the gen set is mounted. The block is surrounded by cork or fiberglass, separating it
from the surrounding structure.

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Rubber pads are sometimes used to dampen high frequencies which cause noise, but the most often-
used device is the spring-type isolator. It offers about 95 percent isolation of all vibration and
eliminates the need for an inertia block.
Spring isolators are placed under the gen set rails but are not bolted to the floor unless the unit is
paralleled with other generator sets or is in an earthquake-prone area. Spring isolators are most
effective when located directly under the engine and generator mounting feet.
Care must be taken to make sure the spring can accommodate the gen set’s weight. If the spring is
compressed completely, all vibration will be directly transmitted to the structure it rests on.
Consider Idle Units

Units that are not operating can be damaged by vibrations set up by nearby operating units. Because
the idled units have no oil pressure to keep internal components lubricated, the vibration can cause
severe damage. Here, spring isolators can minimize vibration effects.
Fuel lines, exhaust piping and electrical connections all transmit vibrations. It is a waste of effort to
provide mounting protection unless these connections are specified to have vibration-limiting
connections. Each connection must be isolated with flexible connections to provide maximum vibration
reduction.
Resonance of pipe systems can also be reduced by hanging supports at unequal distances. (See
figure 2). To attenuate low-frequency vibrations, specify spring-type isolator pipe hangers. High-
frequency vibrations can be minimized with rubber or cork cushioned hangers.

Figure 2

Specify hangers to be installed at uneven intervals to minimize pipe vibration problems.

It is possible to test complete systems to ensure vibrations are not excessive. If a structure is sensitive
to vibration from gen set operation, such test should be considered before the unit is commissioned.
Your CAT dealer can advise you how such tests can be carried out.
Vibration problems can cause considerable damage, and it is best solved when the specifications is
written. The addition of spring isolators or an inertia block as well as flexible connections on piping and
electric lines can prevent many difficulties later on.

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Generator Set Rooms

Electrical Room Space Requirements
Building service equipment must have an advocate early in the design process. It is far easier and less
expensive to plan for adequate space in the design phase than to compromise on unit size and retrofit
equipment to fit in cramped areas.

Basic Room Requirements

Minimum requirements set for the National Fire Protection Association (NFPA) in the National Electric
Code (NEC) is that a person must be able to complete service duties with enclosure doors open and
for two people to pass one another. If maintenance must be done at the rear of the cabinet, similar
access space must be available.

The NEC also requires 3 to 4 feet (1m to 1.3m) of aisle space between live electrical components of 600
volts or less, depending on whether live components are on one or both sides of the aisle. This
requirement holds even if components are protected by safety enclosures or screens. Installations over
600 volts require even wider aisle space, from 3 feet (1,) to as much as 12 feet (4m) for voltages above
75kV. Service rooms with 1,200 amps or more require two exits in case of fire or arcing. Because
transformers vary, make sure minimum wall clearances are met as specified by the manufacturer.
Specific rules and exceptions are spelled out by the NFPA in its recently revised NEC rules.

Gen Set Space Needs

recommended floor space between an engine and parallel wall space or another gen set should not be
less than the width of the engine. Overhead, there should be enough space allocated to allow
convenient removal of cylinder heads, manifolds, exhaust piping and any other equipment for service.
Consider specifying enough room for a chain hoist or overhead crane. Space fore and aft of the engine
should allow camshaft removal.
Batteries to start gen sets should be kept as near as possible to the engine to avoid long energy
robbing cables. The fuel tank should be located near gen sets to prevent long fuel line runs which can
tax fuel pumps. Access to this equipment for service must also be considered in the design phase.
Even the most reliable gen set, after thousands of hours of operation, will need some internal work.
Will there be enough room for engine or generator disassembly? Can the unit be removed without
major building alteration? You may want to specify a chain hoist or overhead crane into the room’s
design for these heavy chores.

Switchgear Considerations
Controls and switchgear are best housed in a separate air-conditioned room next to the gen set with a
window into the engine room. Switchgear that can’t be placed in a separate room should be located to
take advantage of incoming air to cool the switchgear.

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Proposed Room sizes

To meet the above manufacturer requirement the following

dimensions are used in the standard design preparation.

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Recommended Room sizes 30-500KVA

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