How to Measure Fuel in a Commercial Generator

Commercial generators are critical assets for maintaining uninterrupted power in commercial buildings. As a building engineer, ensuring these generators have adequate fuel is vital for operational reliability. Measuring fuel levels accurately can prevent unexpected power outages and ensure preparedness for emergencies. Here’s a step-by-step guide on how to measure fuel in a commercial generator.

Understanding Your Generator’s Fuel System

Before diving into measurement techniques, it’s essential to understand the type of fuel system your generator uses. Common fuel types include:

• Diesel
• Natural Gas
• Propane
• Gasoline

Each fuel type has different storage and measurement methods. This guide focuses on diesel and gasoline, the most common fuels for commercial generators.

Tools and Equipment Needed

• Fuel Gauge: Most modern generators come with a built-in fuel gauge. If not, you may need an external gauge.
• Fuel Dipstick: A calibrated rod used for manual fuel measurement.
• Fuel Flow Meter: Measures the amount of fuel flowing to the engine.
• Fuel Level Sensors: Ultrasonic or float-type sensors that provide real-time data.

Methods for Measuring Fuel

Using the Built-in Fuel Gauge

• Step-by-Step Process:
  1. Locate the Fuel Gauge: Typically found on the generator’s control panel.
  2. Read the Gauge: The gauge will display the current fuel level, usually in percentage or a fractional reading. If it is displayed in feet or inches, a supplementary Tank Chart may be needed to calculate the current fuel level.
  3. Cross-Check: Ensure the gauge is functioning correctly by cross-checking with manual methods periodically.

Manual Measurement with a Dipstick

• Step-by-Step Process:
  1. Safety First: Ensure the generator is off and cooled down to prevent any accidents.
  2. Access the Fuel Tank: Open the fuel tank cap.
  3. Insert the Dipstick: Slowly insert the calibrated dipstick into the tank until it touches the bottom.
  4. Remove and Read: Pull out the dipstick and check the fuel level marked on it.
  5. Compare: Compare the reading with the tank’s capacity chart to determine the exact fuel volume.

Using a Fuel Flow Meter

• Step-by-Step Process:
  1. Install the Meter: Attach the fuel flow meter to the fuel line as per the manufacturer’s instructions.
  2. Monitor Readings: The meter will provide real-time data on fuel consumption, helping to estimate remaining fuel.
  3. Calculate Fuel Levels: Use the consumption rate to estimate how much fuel is left in the tank.

Fuel Level Sensors

• Step-by-Step Process:
  1. Install Sensors: Place ultrasonic or float-type sensors in the fuel tank.
  2. Connect to Monitoring System: Link the sensors to a monitoring system for real-time fuel level data.
  3. Check Readings: Regularly monitor the system for accurate fuel levels.

Best Practices for Fuel Measurement

Regularly checking your fuel is an important part of ongoing generator maintenance. Performing routine fuel level checks gives you the peace of mind that the generator is always ready for use. Another essential part of maintenance includes keeping the fuel tank and measurement tools clean to avoid contamination. Clean tools will also ensure you’re getting accurate readings, along with calibrating fuel gauges and sensors for precise measurements. Finally, maintaining a log of fuel levels and consumption rates for quick reference will help you maintain better fuel management in the long run.

Accurate fuel measurement is crucial for the reliable operation of commercial generators. By using built-in gauges, dipsticks, fuel flow meters, and advanced sensors, building engineers can ensure their generators are always fueled and ready to provide backup power when needed. Regular maintenance and monitoring will help avoid unexpected outages and extend the life of the generator.

Peter Thornton, the Duthie Power Sales Engineer featured in the above video, is a seasoned veteran of the power generation and diesel engine industries. Click on the video to hear Pete share insights and practical tips to help building engineers keep their emergency power equipment running smoothly.

For more tips and best practices on generator maintenance, stay tuned to our blog. Your proactive approach to fuel management can make a significant difference in the overall efficiency and reliability of your building’s power systems.