10 Challenges for Adding Gensets to an Existing Fuel System
Whitepaper ESS.WP.538
Introduction
Emergency generators and associated fuel systems are often designed for the addition of future generators. But sometimes not. In either case a generator add or modification project requires detailed planning and analysis. Here is an overview of good questions to ask, and details to consider.
1. Fixing Problems with the Existing System.
What is the user feedback on the system? Have there been any leaks, spills, overfills? Have there been any pump, valve, control failures? If integrated to the BMS has the data been accurate? Is there important information missing from the BMS data. Is there an alarm log history that indicates repeat problems?
2. Compare Control and Integration with Other Building Systems
How does the fuel system control and integration compare with other building systems. Are most other building systems delivering information for fast alarm response and predictive maintenance. Are data sets for other systems more extensive that the fuel system?
3. Safety Evaluation and Correction
Are all fuel storage tanks up-to-date with existing codes for secondary containment? Are fuel transfer pumps and filters contained with spill pans or curbs? Is the piping around generators protected with spill panels or curbs? Do tanks have ant-siphon protection? How about Overfill protection? Are emergency stops in-place to allow system dis-able in the event of emergency?
4. New Code Requirements or Insurance Required Upgrades
Are these new local building codes that require safety upgrades. Or has the insurance carrier provided a risk review requiring safety upgrades.
5. Check Storage Capacities for Required Run Times
Calculate the fuel consumption for the new and existing generators. Are the existing tanks adequate at 90% maximum capacity. How about at 75% capacity to allow for periodic testing between refills.
6. Check Adequate pump flow rates and pressure
Determine the required pump capacity with maximum consumption times 2 for 50% duty cycle on the pumps. Are the existing pumps adequate or is an upgrade needed. If upgrading check the power requirements for adequacy as well.
7. Add Filter – Polishing Capability
Newer engines designed for low emissions are more sensitive to dirty fuel. If none exists, consider the addition of a filter polisher to maintain good fuel quality.
8. Evaluate and Replace “Dumb” with “Smart” Controls
Are the existing fuel system controls integrated and allowing the facility to operate reliably, efficiently, and at low cost. Or would the facility benefit by smarter controls for greater reliability and integration. Is there a master controller for the fuel system as a point of integration. Could one be added to integrate existing day tanks and pumps into a better control system.
9. BMS Integration for Better Operations
Is the fuel system integrated into the Building Management System (BMS) system to allow remote monitoring and alarm notification. Examine what alarms are monitored and how they are received. Make a list of status and alarm requirements and incorporate into the controls upgrade.
10. Work sequence for Uninterrupted Service
Think about the points of tie-in for piping, electrical, and control elements of the system upgrade. What is the timing required for each? What is the risk of service interruption? Will temporary tanks or piping systems be required to accomplish the fuel system modifications? Will there be code or regulatory issues if temporary fuel storage is required? Contractors will prepare a detailed procedure for the work sequence based on this preliminary evaluation.