Genesal Energy key to guaranteeing supply in large hotels

In Mexico, climate instability is a factor that cannot be ignored, especially in regions where weather phenomena such as tropical storms and hurricanes are frequent.

These can cause unexpected and prolonged power outages, affecting the operation of key sectors such as the hotel industry. To cope with these conditions, having a reliable energy back-up system, such as a generator, is essential.

Genesal Energy has designed and installed three generator sets in a renowned hotel chain in Mexico, ensuring that the establishment continues to operate safely and efficiently during adverse situations and guaranteeing the operation of emergency & IT systems, heating and air conditioning that ensure the safety and comfort of guests.

In the hotel industry, operational continuity is key to ensuring a safe and comfortable experience for guests. In this context, the installation of generator sets as a backup power source has become essential, especially in regions where power outages can jeopardize both safety and comfort.

Project objective: Safety and comfort, come what may

The main objective of this project was to provide a reliable back-up power source for the hotel, ensuring that essential services continue to operate during any power outage. Emergency systems, such as exit lights, fire alarms, automatic doors and security equipment. Maintaining comfort is also a priority, ensuring the operation of air conditioning, lighting and other basic services that directly impact the experience.

Thanks to this installation, the hotel now has a robust energy solution that ensures continuous power supply during critical situations. Guest safety and service comfort are assured, reinforcing Genesal Energy’s commitment to providing tailored energy solutions that meet the highest demands in any industry, including hospitality.

What solution did Genesal Energy engineer?

Genesal Energy designed and installed three open generator sets, each equipped with advanced features to ensure optimal performance and efficient integration into the hotel’s facilities. These generators have 600 litres baseframe integrated fuel tanks. In addition, an automatic fuel transfer system was incorporated to connect the daily tanks to a main tank, ensuring that the fuel supply is constant and efficient.

The units are equipped with a control panel that allows parallel operation between them, which facilitates management and ensures constant performance. A synchronisation board was also provided between the island of gensets and the grid. Motorised circuit breakers with trip coil were also integrated to protect the system against overloads and electrical faults. Safety was a priority in this design, including explosion-proof battery boxes, and hand pumps for both fuel transfer and oil drainage to facilitate maintenance.

Features

  • Open set.
  • 600L base frame integrated fuel tank.
  • Control panel for parallel operation between units.
  • Motorised automatic switch, with trip coil.
  • Battery protection box.
  • Automatic transfer system with electric pump.
  • Manual pump for safety fuel impulsion.
  • Manual pump for oil drainage.
  • Busbar for power output.

Genesal Energy strengthens energy security in the Dominican Republic

According to official data, the Dominican Republic has experienced sustained growth in energy demand in recent decades, driven by increased industrial, commercial and residential activity.

To ensure a reliable electricity supply, a robust infrastructure and systems that guarantee continuity of service, even in the face of unforeseen events, are required. Genesal Energy has designed and installed a generator set for a critical electrical substation in Guayubín.

The main objective of the project is that the substation can effectively manage the electricity coming from power stations and power plants, transform the voltage and connect to the large distribution lines that supply large areas of the country.

The importance of the genset in an electrical substation

The role of a generator set in a power substation is essential to the safety and stability of the system. Substations, as key nodes in the power grid, are responsible for the distribution of power to large regions, and a prolonged interruption in their operation could leave thousands of people without power. A generator set acts as an immediate backup in the event of failures, keeping control, protection and communications systems operational. It also ensures the continuity of critical services such as transformer cooling, plant lighting and equipment overload protection, minimising the risk of damage.

Our customer needed a solution to guarantee the supply of the substation’s AC auxiliary services. So a soundproofed generator set was designed, which can be activated automatically according to the substation’s requirements, providing the necessary energy at key moments.

The Guayubín electrical substation project is an example of how Genesal Energy provides innovative and customised energy solutions to strengthen the Dominican Republic’s electrical infrastructure. Thanks to the installation of this generator set, the substation will be able to operate reliably and efficiently, guaranteeing a continuous supply of energy at critical times and contributing to the energy development of the country.

Our Engineering Solution

Genesal Energy’s engineering team developed a soundproofed 3800mm canopy genset with a 600 litre fuel tank, tailored to the customer’s specific requirements. The genset power was customised to allow for a 350 KCM gauge connection, per phase, with terminals for a 185 mm² cross-section. In addition, the design included a control system that allows cable entry to manage multiple connections.

As the project progressed, the need was identified to install an additional 500-gallon (approximately 2,000 litres) external tank, located 10 metres from the generator set. To ensure a continuous flow of fuel, an automatic transfer system with a booster pump and solenoid valves was implemented, which involved several adaptations to the canopy and tank design.

Features

  • Calculation of the necessary sections for the inlet and outlet of gases in the room.
  • Automatic fuel transfer system, with maximum level buoy, minimum level buoy by gauge, transfer impulsion pump, solenoid valve to cut off or control the system, among others.
  • Machining of the tank and canopy for the appropriate adaptations of the transfer.
  • Oversized silencer model (-30dB).
  • Engine heating system 1000W.
  • 600 L fuel tank.

Uninterruptible Power, the Key to Industrial Success in the Heart of Guanajuato

Genesal Energy continues to strengthen its commitment to the industrial sector, offering power backup solutions adapted to the most demanding market needs. On this occasion, it has supplied a state-of-the-art open generator set for an automotive manufacturing plant in Guanajuato, Mexico. This equipment will provide contingency power to a new assembly line for painting, one of the most critical processes in the automotive production chain.

Backup generator sets in factories are not only a strategic advantage, but essential to ensure operational continuity. In high-demand sectors, such as the automotive industry, where every minute of production counts, having a backup power source prevents unplanned shutdowns that could lead to major economic losses and delays in the supply chain. In addition to protecting the investment, a generator set ensures that quality and safety standards are maintained even in the event of power failures.

Power to ensure operational continuity

Thanks to our genset, uninterrupted operation of the assembly line ensures the workflow is not affected by possible electrical failures. It is installed in a hangar near the paint line and has been designed to meet the customer’s main need: long autonomy. This is achieved by means of an independent 3000 litre double-walled steel tank, designed to provide an energy reserve in accordance with the specific requirements of the installation.

The generator set supplied in Guanajuato stands out for its advanced specifications, which ensure its ability to operate reliably in demanding industrial conditions. With this project, Genesal Energy reaffirms its commitment to accompany the automotive industry in its growth, offering high quality energy solutions.

Features

  • Open genset with independent control cabinet, it can be unbolted and placed close to the generator set.
  • Large self-supporting power cabinet with the possibility of top entry of 10 power cables of 300mm^2 by the end customer.
  • 3000 litres independent double-walled (Steel-steel) fuel tank.
  • Fuel flow meter installed in control cabinet on independent display.
  • Critical -40 dB(A) silencer.
  • Analogue oil temperature sensor.
  • Due to the installation at high altitude above sea level, precise calculations of the power of the unit at the final location.

 

How to connect a genset in industrial or commercial installations

Technician connecting a generator in an industrial setting
Connecting a generator set to the power grid of an industrial or commercial facility is a key process to ensure a continuous supply during grid failures.

In sectors such as industry, hospitals or data centres, where energy is vital, it is essential to know the correct steps and methods to make a safe and efficient connection.

Basic concepts for the connection of a generating set

Before proceeding with the installation of a generating set, it is essential to carry out an exhaustive analysis of the electrical demand of the installation. This involves calculating the power required for critical equipment, verifying current safety regulations and correctly sizing the system components.

Each installation has specific needs, so it is essential to design a system that guarantees a reliable supply and complies with protection standards.

Key requirements include

  • Critical load assessment: Identify which areas and equipment need continuous supply in the event of mains failure.
  • System planning: Determine the type of generator set, switchgear capacity, and the voltage and frequency to be supplied.
  • Regulatory compliance: Ensure that the design of the installation complies with low voltage regulations and that all relevant safety measures are in place.

General view of a shopping center where energy is essential

Methods of connection of a generating set to the mains

Direct connection of the generating set to the grid

To ensure efficient switching between the mains and the generating set, it is essential to use a switchboard. This device automatically detects any mains failure and switches over to the genset without manual intervention (in case of an automatic system). The ATS (automatic switchboard) is the key element in installations where the continuity of the power supply is critical, as it ensures that the change of the power supply is carried out without cuts or with a minimum cut-off.

Learn more about the mains/generator switching process here.

The installation process of an ATS includes the configuration of its parameters so that, in the event of any mains failure, the system can start the generator and transfer the load instantaneously. This type of automation is essential in sectors such as hospitals, data centres or telecommunications infrastructures, where any interruption may be unacceptable.

Connecting a three-phase genset

In high-demand industrial environments, three-phase gensets are often used to ensure a balanced power distribution. These generators operate using three phases of alternating current and can be connected in two main configurations: star or delta.

  • Star connection: In this scheme, all phases are connected to a single neutral point, which facilitates the balancing of distributed loads.
  • Delta connection: In this type of connection, the end of one phase is connected to the beginning of the next phase, creating a closed loop between the phases.

The choice between these two schemes will depend on the type of load, the power required and the infrastructure available in the installation.

Connection to critical systems

In critical facilities such as hospitals, telecommunications centres or industrial plants, it is crucial that certain equipment is always kept operational. For this purpose, secure lines are implemented that directly connect critical systems to the generator set.

These lines are designed to receive power immediately in the event of a grid failure. In addition, many of these systems include redundancies and continuous monitoring, ensuring that the generator set is always ready to start when needed. In these cases, it is common to use several generators connected in parallel to improve security and supply capacity.
Doctors in a hospital reviewing an X-ray

Steps to connect a generator set safely

1. Assessment of the installation’s power and requirements

The first step to a proper connection is to make a detailed assessment of the power required by the installation during a power outage. This includes identifying the equipment requiring continuous supply and determining the rated and starting powers to be provided by the genset.

It is crucial to correctly calculate the critical load to ensure that the selected generator is able to cover all the needs of the facility without overloading.

2. Configuration of the Automatic Transfer Switchboard (ATS)

The ATS is responsible for the automatic switchover between the mains and the genset. Its correct configuration is key to ensuring that the system reacts quickly and efficiently to failures in the mains supply. This includes adjusting the delay times, the sensitivity of the system to detect fluctuations in voltage and frequency, as well as the generator start and stop settings.

A well-configured ATS not only ensures efficient switching, but also protects both the generator set and the connected equipment from possible fluctuations or failures in the grid.

3. Installation of conductors and protections

To ensure the safety of the installation, it is essential to correctly select the conductors and protective devices, such as fuses, differential and thermal relays. In three-phase installations, it is particularly important to ensure that the three phases are balanced to avoid problems of overload in one phase and underutilization in the others.

The dimensioning of the conductors must be done according to the capacity of the generating set and the distance between the generator and the switchboards. In addition, independent earthing systems must be installed to protect both personnel and equipment against possible insulation faults.

4. Connection and synchronisation tests

Once the installation is complete, it is crucial to perform extensive tests to ensure that the genset can transfer the load correctly without interruption. These tests include:

  • Verifying that the ATS responds appropriately to a simulated mains failure.
  • Checking that the genset can take the full load of the installation without sudden variations in frequency or voltage.
  • Perform synchronisation tests for installations where several generators operate in parallel, ensuring that all generators work in a balanced way and without interference.

In addition, the quality of the power supplied by the generator set should be verified, ensuring that it meets the requirements of the critical equipment of the installation.

A detailed analysis of the power requirements, the proper configuration of the automatic transfer switch (ATS) and the implementation of protective measures are essential to ensure a reliable and continuous power supply.

The key to success in these installations lies in designing a system that allows critical equipment to continue operating without interruption, ensuring the safety and efficiency of the entire electrical infrastructure.

Energy safety in the fight against climate change: risks and opportunities

Landscape with wind turbines at sunset, symbolizing the transition to renewable energy with energy safety and the fight against climate change.
For several years now, one of the biggest challenges in the fight against climate change has been related to the energy safety supply.

Although progress has been made, the energy sector is still the largest emitter of greenhouse gases and further efforts are needed. Also, energy production needs to be renewable and adaptable to already occurring climate conditions. Erratic weather patterns, rising global temperatures and the intensification of extreme weather events challenge the ability of energy systems to provide secure, continuous and affordable supply highlighting this need for adaptation.

Growth in energy demand

Climate change, combined with population growth and economic development, increases energy demand globally. E.g. The use of air conditioning systems in countries with emerging economies and warm climates, where income growth is allowing greater access to cooling technologies. In 2000, the global energy demand for residential air conditioning in summer was 300 TWh, but this is projected to increase to 4,000 TWh by 2050 in regions such as India, Brazil and other developing countries.

As global temperatures rise, these countries will experience longer and hotter summers, which will increase cooling use and thus electricity demand. Although in the more advanced economies and colder climates the need for heating during the winter is likely to decrease, overall energy demand will continue to increase due to the use of air conditioning in the summer months. This change in energy consumption patterns will require a reassessment of global energy strategies, with particular attention to the growing needs of developing countries.

Impact on power generation

Climate change is also affecting power generation. Thermal power plants, which currently produce around 80% of the world’s electricity, are reducing their efficiency due to higher ambient temperatures. Thermal conversion is less efficient in extremely hot conditions. In addition, the availability cooling of water is decreasing forcing them to operate at reduced capacities or even to temporarily halt power production. Thermal plants are designed to operate under more stable climatic conditions and, although most energy transition plans involve the closure of most of these, it must be kept in mind that this process will be gradual. During this transition period, thermal plants will remain a key part of the global energy supply, especially in countries where the infrastructure for renewable energy is not yet fully developed.

Nuclear power plants are particularly vulnerable to extreme weather events, such as hurricanes or storms, which can damage their cooling systems and other critical equipment necessary for the safe operation of reactors. Events such as Hurricane Harvey in 2017, which affected nuclear plants in Texas, highlight the need to strengthen energy infrastructures in the face of such events.

On the other hand, hydroelectric power, which depends on the hydrological cycle, is also at risk. In regions such as the Zambeze River in Africa, hydropower generation capacity is projected to decline by up to 35% by 2050 due to reduced rainfall and rising temperatures. However, in Asia, projections suggest an increase in hydropower capacity, showing that climate change will affect different regions differently.

In addition, renewable energies such as solar and wind are also exposed to the effects of climate change. Increased cloud cover in certain areas will affect the efficiency of solar panels, while more frequent and severe storms could damage both solar and wind installations. Extreme weather events and changes in wind patterns will complicate the integration of these sources into electricity systems, which may require greater investment in energy storage technologies to mitigate their intermittency.

Diagram of the energy system adaptation cycle in response to climate change.

Threats to energy infrastructure

Energy transmission and distribution infrastructures are particularly vulnerable to climate change. Higher temperatures, rising sea levels, melting permafrost, floods and landslides will put energy transmission networks and pipelines at risk. In coastal areas, rising sea levels may damage pipelines and energy facilities, while in permafrost areas, thawing could affect the stability of infrastructure. In addition, heat waves and forest fires that are becoming more frequent also pose a threat to power lines, as has already been seen in countries such as the United States and Australia.

The fossil fuel sector, in particular oil and gas, is also exposed to extreme weather events. Tropical cyclones, such as Hurricane Katrina in 2005, can disrupt operations on offshore extraction platforms and affect onshore infrastructure, leading to disruptions in global energy production and supply. Although the melting of ice in the Arctic presents an opportunity for exploration of new oil and gas reserves – which could increase the global supply of these resources – the exploitation of these reserves would entail new environmental and logistical risks.

The role of generating sets in energy safety

In this context of increasing energy demand and infrastructure vulnerability, gensets emerge as a vital solution to improve energy security. They act as back-up systems that ensure a continuous supply of electricity during outages or interruptions. Particularly useful for critical facilities, such as hospitals, data centres, wind farms and emergency services, which cannot afford interruptions in their power supply.

In addition, gensets are versatile and can be used in a variety of applications, from industrial operations to residential areas, providing an independent power source that can be tailored to the specific needs of each user. In regions where the electrical infrastructure is more vulnerable to disruptions, gensets can provide an effective emergency power solution, ensuring that communities and industries continue to function even during the most severe weather events.

Finally, the deployment of cleaner and more efficient gensets, powered by renewable fuels or clean energy technologies, can contribute to mitigating greenhouse gas emissions, aligning with long-term sustainability goals.

In this sense, gensets not only act as a temporary solution to energy supply insecurity but can also be integrated into a broader climate change adaptation and resilience strategy, offering both energy security and opportunities to move towards a more sustainable future.

The UK’s largest pet care company entrusts its supply to Genesal Energy

Genesal Energy has designed a generator set with very specific needs for one of the logistics centres of the UK’s leading pet care company, Pets at Home.

Emergency generator sets are crucial in a logistics centre. They guarantee the continuity of daily operations protecting the supply chain and customer service.
A tailor-made canopy – adapted to the space of 8100 x 2100 x 2475 mm – was designed: a soundproofed unit that guarantees an average sound pressure level of 85 dB at 1 metre and has exhaust gas silencers with -35 dB attenuation on the roof. The power panel is located on the outside in order to facilitate connection.

Dimensional restrictions solved; another challenge was that the new equipment had to be compatible with the existing one. Also sorted out.
A safe energy source in the event of any supply failure. Customer’s satisfaction best friend.

Our Engineering Solution

Although this generator set would be installed in a 40′ HC container in its standard assembly version, our engineering team designed a 8100 x 2100 x 2475 mm canopy with the power panel installed outside in order to facilitate the connection of power cables by the customer.

Features

  • 8100 mm modular soundproofed canopy guaranteeing an average sound pressure level of 85 dB at 1 metre.
  • The unit was equipped with a liquid collection tray to contain possible coolant, oil or fuel leaks.
  • An exhaust gas silencer with -35 dB attenuation was installed on the canopy roof.
  • The canopy was fitted with an integrated air silencer module.
  • A power output cabinet was designed external to the genset, with the following features:
  • 2 x 3-Pole circuit breakers. One for the genset and the other one for an external genset.
  • Castle key to prevent the closing of both breakers at the same time.
  • Powerlocks connection for an external genset.
  • Powerlocks connection for a load bank.
  • Busbar.
  • This power cabinet allowed an external genset to be connected to supply the loads in the event of the genset not being available.

 

Guaranteed power for essential services in Western England

In the heart of Lancashire, Genesal Energy has successfully completed the installation of three soundproofed generator sets at a local authority in Blackpool.

We reinforce our commitment to the protection of critical spaces ensuring that patients and healthcare staff can carry out their activities without interruption in the event of a power failure.

In local government buildings, electrical power is not just a resource: it is the foundation on which many essential activities for the population are based. From issuing documents and processing paperwork to coordinating emergency services, any interruption in the power supply can cause delays, inconvenience and, in some cases, significant consequences for citizens.

Soundproof generator by Genesal Energy during installation.

Genesal Energy installed three generator sets of 330 kVA each, specifically designed to meet the hospital’s needs. The units, insulated not to exceed 75 dB(A) at 1 metre, were manufactured in specially dimensioned canopies and finished with C5M environmentally resistant paint. In addition, they are synchronised with each other by means of a DeepSea DSE8610 control system, which ensures perfect operability between the units.

Each generator has a 650 litre fuel tank and a transfer system that allows continuous fuel supply from an external tank at ground level. Anti-condensation heaters on the alternators and anti-corrosion treatment on the windings have also been added to ensure their operability in all climate conditions.

The careful design of this project not only responds to the high technical standards that these buildings require, but also to the importance of maintaining a safe environment for users and workers.

Soundproof generators installed by Genesal Energy at Blackpool Hospital.

Our Engineering Solution

Supply of an emergency network with the design, manufacture and commissioning of soundproofed generator sets which guarantee the operation and safety of the centre’s activities at all times.

Features

  • 3 x 330kVA Specially oversized soundproofed canopy 75db(A) @ 1m, C5M surface treatment in customised RAL.
  • DeepSea DES8610 Control panel for synchronisation between units.
  • 650 litres Integrated fuel tanks.
  • External fuel filling point with 3 x transfer pumps, solenoid valves, leakage sensors, fuel polishing systems, and connection boxes.
  • Anti-condensation heaters on alternator.
  • Anti-corrosion treatment on alternator windings, PMG and neutral contactors.

General view of the generators installed by Genesal.

What is it and how does the Mains/Genset switching work?

Power plant backlit against the sunset glow.
Mains/Genset switching is a key process in the installation of gensets, ensuring continuous power supply during grid failures. This mechanism is essential in critical sectors, where a lack of electricity can cause serious problems.

In this article, we explain in detail what Mains/Genset switching is, the different types of systems, and how to choose the most suitable for your installation.

What is a Mains/Genset switch?

Concept and definition

Mains/Genset switchover is the process of switching from the main power source (the mains) to a backup power source (the genset) when a mains failure is detected. This switching can be done manually or automatically and ensures continuity of power supply.

Importance in uninterruptible power supply

This process is essential in facilities that cannot afford a prolonged power outage, such as hospitals, industries or data centres. Thanks to switching, the generator set is activated to ensure that power continues to flow without interruption, avoiding economic losses and possible damage to sensitive equipment.
Imagen de industria con sistema de conmutación

Mains/Genset switchboards and diagrams

Mains/Genset switchboard: Function and components

The switchboard is an essential device in this process. It is composed of two power inputs: the mains and the generating set, and an output which distributes the electricity to the loads. While the grid is in operation, the switchboard keeps its input active, but in case of failure, it switches to the genset input.

Types of switching systems

Based on their operation, there are 3 types of switching systems:

  • Manual: Requires human intervention to switch from mains to genset.
  • Automatic: The system acts automatically as soon as it detects a mains failure.
  • Remote: Allows remote switching, which can be useful in decentralised installations.

Manual (local) switching

This is the simplest switching system. Manual switching requires an operator to physically intervene to switch from the mains to the genset. This type of system is usually used in installations where power outages do not have a serious impact or in cases where simplicity and low cost are a priority. The operator, in the event of a mains failure, must operate a switch or device to start the genset and transfer the load.

Advantages of Manual Switching

  • Reduced cost: Manual systems are more economical compared to automatic systems.
  • Simplicity: They are easy to install and operate in non-critical environments.
  • Direct control: The operator can decide when and how to switch.

Disadvantages of Manual Switching

  • Slow response time: Requires human intervention, which delays the reactivation of the supply.
  • Operator dependency: If no personnel are available, switching will not take place.
  • Risk of errors: Manual operation can lead to errors, such as failures in the switching procedure.

Automatic switching

Automatic switchover is the most advanced and efficient option. This system is designed to detect faults in the electrical network immediately and switch over to the generator set without human intervention. It is ideal for installations where continuity of power supply is crucial, as the process is fast and avoids prolonged outages.

Advantages of automatic switchover

  • Fast response: Switching is done in a matter of seconds, minimising outage time.
  • Increased reliability: No reliance on human intervention, reducing the margin of error.
  • Continuity of service: Ideal for critical installations where a prolonged outage could have serious consequences.

Remote switching

Remote switching allows remote switching between the grid and the genset to be performed remotely. This system is useful in decentralised installations or in large installations where physical access to the switching systems is not practical, such as telecommunications installations scattered throughout the territory.

The operator can activate the switching from a remote panel, a mobile device or via a programmed system.

Advantages of remote switching

  • Remote access: The system can be controlled from any location, which facilitates management in complex installations.
  • Operational flexibility: Can be integrated with other remote control and automation systems.
  • Reduced physical intervention: Reduces the need for physical travel to the equipment location.
  • Can be both automatic and manual (remotely).

Photograph of a city illuminated at sunset

Maintenance and considerations for Mains/Genset switching

Common problems and solutions in unstable networks

In areas with unstable power grids, switchboards can be damaged by constant power surges and outages. A common solution is to use surge arresters and opt for DC-supplied switchboards, which are less susceptible to mains fluctuations.

Maintenance of switchboards

Regular maintenance of switchboards is essential to ensure their proper functioning. It is recommended to check contactors and control relays, and to ensure that there is no wear or damage to coils or circuit breakers.

Mains/Genset switching is an essential component in any installation using generator sets as a backup power source. Selecting the right system and carrying out regular maintenance is key to ensuring that the power supply is continuous and uninterrupted.

Check this article for more information on connecting generators.

How much is a generator set worth: Key factors in calculating the price

Industrial generator being installed at a plant.

In the industrial sector, the choice of a genset is not only about finding the most economical equipment, but also about selecting the one that best fits the operational and strategic needs of the company.

Understanding which factors influence the price of a generator set is crucial to making an investment that guarantees reliability, efficiency and durability in the long term. We review them below.

Power

A critical factor that has a direct impact on cost. This value, expressed in kilowatts (kW) or kilovoltamperes (kVA), defines the load carrying capacity of the equipment. In an industrial environment, it is essential to select a generator set that not only meets current power demands, but also has room for future upgrades.

Higher power equipment is not only more expensive, but also requires a larger infrastructure for proper installation and operation.

Fuel type

Diesel generators, although more expensive than petrol generators, are preferred in industrial environments due to their durability, efficiency and lower maintenance costs.

On the other hand, gas gensets offer a more sustainable option with lower emissions, although their implementation requires the availability and cost of gas supply.

Technology and functionalities

The advanced features of a genset can significantly influence its price. Some aspects to consider include:

  • Automatic start-up: Ideal for ensuring operational continuity in the event of power outages.
  • Remote monitoring: Allows efficient and preventive management, reducing downtime and optimising maintenance.
  • Protection systems: Integration of systems to protect against overloads, short circuits and other operational risks.

Each of these features adds value to the equipment, but also increases its base cost.

Technician working on the installation of a new industrial generator.

Soundproofing options

The choice between an open-type or soundproofed genset will depend on its intended location. Soundproofed gensets are the choice in areas where noise control is a priority, such as hospitals or city centres, but are more expensive due to the additional sound insulation and materials required in their manufacture.

Applications and environment

The type of application for which the genset is intended also influences its price. Equipment designed for industrial use, capable of operating in extreme conditions or critical applications, is usually more robust and therefore more expensive.

When assessing the needs of a project, it is crucial to consider:

  • Environmental conditions: Equipment designed to operate in extreme climates, from sub-zero temperatures to desert conditions, will require specific modifications.
  • Regulations: Complying with emissions or noise regulations may require additional components that increase the price.

Industrial plant in a cold, snowy environment.

Summary of factors affecting the price of a generator set

  • Power: Directly proportional to the load capacity.
  • Fuel: Diesel, petrol or natural gas have different costs.
  • Technology: Automatic start, remote monitoring, or advanced protection. These are features that will increase the price.
  • Design: Open vs. Soundproofed. Soundproofing requires materials that come at an additional cost.
  • Application: Industrial, commercial, or extreme conditions.

By considering these factors, it is possible to choose the generator set that best fits the needs of each project, optimising the investment and ensuring reliable performance.

Genesal Energy is committed to offering tailored, high-quality solutions, backed by solid experience and specialised technical support.

How to calculate the generator you need

Technicians analyzing blueprints and details of an electrical project in an industrial setting.

Selecting the right genset is a critical task that goes beyond simply estimating power. An incorrect calculation can result in oversized equipment, which implies unnecessary costs, or undersized equipment, compromising the operation of the entire installation.

Below, we show you how to correctly calculate the generator set you need, considering all the technical factors involved.

How to proceed with power calculation

Firstly, you need to determine the required power, carrying out a load assessment. In order to do this correctly, it is also necessary to consider the start-up peaks caused by some types of loads such as electric motors.

Load assessment: The first step is to identify all the loads that the genset will have to feed. This includes machinery, electrical systems, safety equipment, and any other critical devices to be powered by the genset. It is essential to add up the constant powers of all these loads considering that all the loads might not be connected at the same time.

Consideration of start-up peaks: Some machinery has a peak electrical demand at start-up which can be between 2 and 5 times higher than their consumption in normal operation. Most commonly, these are the ones driven by electric motors, some examples and their classification are given below:

  • Light starting: Turbines and fans (2 to 3 times of normal consumption).
  • Medium start: Conveyor belts and compressors (3 to 4 times of normal consumption).
  • Heavy start-up: Cranes and lifting equipment (4 to 5 times of normal consumption).

Technicians working on the maintenance and inspection of a generator in an industrial plant.

Calculation will also depend on the type of motor drive. If the electric motor is powered by a frequency inverter (or other advanced system) the starting peak may vary. E.g. Direct starts, the most unfavourable case.

It is also important to know the moment each load shall be started as it may be the case that all the loads do not start at the same time, this is called the load-step start.

F.i. In order for the diesel engine to be able to handle the high starting peaks, a genset of twice as much power as the highest starting peak is considered.

Total power calculation: Sum of the constant powers identified in the load assessment.

Table for calculating the power of a generating set

The above calculations can be expressed in a table like this one:

Equipment / Load Constant Power (KW) Simultaneity factor Starting factor Start-up Power (kW) Load-Step Start Total Power (kW)
Machine A 5 1 3 15 1
Machine B 8 1 2 16 1
Lighting 3 1 1 3 2
Compressor 10 1 4 40 2
Fans 4 1 2 8 1
Total Constant Power 30 kW
Load-Step 1 Start-up 39 kW
Load-Step 2 Start-up 43 kW
Needed Power 86 kW (2 x 43kW)
Safety Margin (10%) 94.6 kW
Power Factor (0.8) 118.25 kVA

How to use this table

  • Equipment or load: List the equipment or loads to be connected to the genset.
  • Constant power (kW): Enter the rated power of each piece of equipment in kilowatts (kW).
  • Simultaneity factor: Indicate a figure to express how many loads are operating simultaneously.
  • Start-up factor: Apply a start-up factor for each equipment according to its type (e.g., 2 for light start-up, 4 for heavy start-up).
  • Starting power (kW): Multiply the power by the starting factor.
  • Starting step: Indicate the different steps to express which loads start simultaneously.
  • Total power (kW): Add the starting powers to obtain the total power required.
  • Safety margin: Apply a safety margin (10% in this case).
  • Power Factor: Divide the adjusted total power by the power factor (normally 0.8) to obtain the apparent power in kVA, which is used to select the genset.

Generator calculation formula

kVA = (Total Power in kW x Safety Margin) / Power Factor

The generator calculation formula allows technicians to accurately size a generator set based on real power demand and environmental conditions. The basic formula involves adding the constant load power (kW), considering start-up peaks, applying a safety margin (typically 10%), and dividing by the power factor (commonly 0.8) to convert kW to kVA. This ensures the selected genset can handle both steady loads and starting surges efficiently. Adjustments must also be made for altitude and temperature when applicable.

Snowy mountain landscape illustrating the challenges of operating generators in cold climates, where low temperatures can affect engine startup and efficiency.

Environmental conditions affecting genset power requirements

Extreme environmental conditions can have a significant impact on the performance and efficiency of a generator set. It is crucial to consider these variables when calculating the required power and selecting the right equipment.

Extreme temperatures

  • Low temperatures: In cold climates, engine start may be slower and engine oil may thicken, reducing efficiency and increasing wear. It is essential to consider a genset with engine & fuel preheating systems, as well as oil suitable for low temperatures.
  • High temperatures: Excessive heat can cause the engine to overheat and reduce the cooling capacity of the system. Generator sets in these environments should be equipped with enhanced cooling systems, such as larger capacity radiators or additional fans.

Altitude

At higher altitudes, air density decreases, which affects both combustion and cooling capacity. This results in a reduction of the power available from the genset. It is considered that for every 300 metres of altitude above sea level, engine power decreases by approximately 3-5%.

Adjustments required according to environmental conditions

  • Power adjustment: Recalculate the required genset power to consider losses associated with altitude and temperature.
  • Selection of suitable components: Ensure that the genset has specific components for operating in extreme environmental conditions, such as enhanced cooling systems or corrosion protection.
  • Additional maintenance and testing: Implement a regular maintenance programme that includes FATs in the actual environmental conditions in which the equipment will operate to ensure optimal performance and prevent unexpected failures.

Taking these environmental factors into account is essential to ensure that the genset will operate reliably and efficiently, regardless of the conditions it is exposed to.

Genesal Energy Engineering Department takes all these critical factors into account when designing and selecting the most suitable generator set for each project. We ensure that each piece of equipment is perfectly adapted to the specific environmental conditions and energy needs of our customers, guaranteeing optimum performance, durability and efficiency, no matter where.