Industrial generator at a production plant, illustrating the factors that influence how much a generator costs.

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

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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.

Engineers reviewing blueprints to calculate the generator you need in an industrial environment.

How to calculate the generator you need

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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.

Genesal Energy team celebrating its 30th anniversary.

30 years of Genesal Energy: innovation and sustainability driving a future of pure energy.

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We have manufactured around 1,000 high-quality generator sets per year, and we are present in more than 100 countries.

Genesal Energy team celebrating 30 years of innovation and sustainability in energy solutions.

Genesal Energy celebrates three decades of history, a path marked by innovation, sustainability and a firm commitment to customisation. Since 1994, we have proven to be a benchmark in distributed energy generation, consolidating our position as a key player both nationally and internationally.

In a world where the energy demand is constantly evolving, Genesal Energy has anticipated the challenges of the sector. From the design and manufacture of latest generation generator sets to the implementation of customised systems, our teams have always placed innovation at the heart of their activity.

The finest staff of professionals and their expertise have allowed us to develop projects on five continents, guaranteeing energy in remote areas, in key infrastructures and in critical environments. Whether in large industrial plants, hospitals or strategic facilities, our generator sets have ensured a stable and efficient supply, contributing to energy security.

Over the years, and led by our CEOs José Manuel Fernández and Julio Arca, Genesal has strengthened its presence in the international market with innovative and highly competitive solutions. Leaving our mark in more than 100 countries, opening subsidiaries in South America, and collaborating with organisations such as the UN and Iberdrola, among many others.

Our generator sets are meticulously designed and prepared to supply electricity 24/7 in all situations. Guaranteeing the safety of people and maintaining vital infrastructures in operation in the event of a service interruption in the network.

Thanks to a team of 150 employees who give their very best, always focused on the future and committed to innovation as an engine for growth. The involvement and level of professionalism of Genesal Energy’s Team has allowed us to create high-performing energy solutions adapted to the needs of each client in a constantly evolving market.

Greenesal: the commitment to a sustainable future

Sustainability is one of Genesal’s fundamental pillars, a strategic area for the development of the company. This involvement has driven the creation of Greenesal – our energy transition plan – which includes the objectives to be followed to make our activity more efficient and respectful with the environment.

In a context where the transition to cleaner energies is urgent, the company has incorporated environmentally friendly technologies and processes. Among the projects carried out, we have been the first company in the region to have a photovoltaic façade, managed with AI software, which will generate 11,000 kWh per year.

We have also promoted the first Energy Transition Chair in collaboration with the University of Santiago de Compostela with the aims of exchanging knowledge & generate more research linked to sustainability.

Also, among the main lines of work for the coming years is to complete the transition from diesel to gas and sustainable fuels and to incorporate new technologies in all our designs.

Genesal Energy’s 30th anniversary is not only an occasion to celebrate the road we have travelled, but also to look to the future with optimism and ambition. We continue to invest in research & development, leading the transformation of the energy sector towards more sustainable and efficient models.

Emergency supply: Guaranteed

We have implemented many projects on different continents that stand out for their uniqueness and the impact they have on local communities. Specialised designs & Innovative manufacturing for efficient and sustainable generators around the world.

We have been part of projects such as reinforcing the supply in one of the main brown sugar factories in Tanzania, guaranteeing the medical and vital care of one of the main hospitals in La Paz in Bolivia, or doing a real engineering feat to provide a data centre in Norway with sets capable of feeding the emergency network in the most adverse weather conditions.

Genesal Energy machinery is also present in major European infrastructures, such as the Greenlink (the colossal engineering project designed to bring clean energy to thousands of people through an immense underwater highway between the Irish Sea and Pembrokeshire in Wales), the main airports and the largest engineering research centre in Spain.

Genesal Energy continues to explore new frontiers after 30 years of success, ready to continue being a reference in the sector, worldwide.

Genesal Energy takes part in the construction of the world’s longest underwater tunnel

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Linking Northern and Southern Europe through new communication routes is one of the major engineering goals currently being realised.

Strong investments are being made in the development of infrastructures designed to reduce travel times and facilitate the movement of goods between countries.

One of them is the Fehmarnbelt tunnel, a mega construction that is pushing the boundaries of engineering. This unique $8 billion project will transform travel between Central Europe and the Scandinavian countries. Once completed, it will become the longest combined road and rail immersed tunnel in the world, spanning almost 20 km, crossing the Fehmarn Strait in the Baltic Sea and providing a direct connection between Northern Germany and the Danish island of Lolland.

It is a key component of the Scan-Med corridor, a transport network of more than 5,000 km, stretching from Malta in the south to Finland in the north.

A project of this scale demands the most reliable equipment to ensure its successful completion on time. To provide back-up power for the machinery involved in the tunnel’s construction, Genesal Energy’s engineering team designed and manufactured 16 generator sets, delivered in two phases.

These soundproofed units were customised with canopies of 3,800 mm and 2,900 mm, and fitted with fuel tanks of 630 and 350 litres, offering an autonomy of more than 17 hours at 100% load.

Due to the harsh environmental conditions, and in order to protect the alternators, a special marinisation treatment was applied to increase their resistance to highly corrosive atmospheres.

The generator sets were designed to operate in AMF mode, and are equipped with 3-way double valves to allow manual selection between the integrated tank or an external one for fuel supply.
This ensures a reliable energy supply throughout the construction phase, helping to keep the project on schedule.

Commitment and rigour

At Genesal Energy, we have built a solid reputation in the generator set sector, offering our customers products that stand out for their reliability, performance and quality.

We design and manufacture custom-made solutions tailored to each project’s technical requirements, delivering turnkey systems in which we take care of every stage.

This commitment has allowed us to take part in high-demand projects such as the Fehmarnbelt tunnel, where a reliable power supply is key to the project’s success.

Features

  • 16 soundproofed canopied generator sets: 16 with 3,800 mm length and 2 with 2,900 mm length
  • Integrated fuel tanks of 630 and 350 litres, providing more than 17 hours of autonomy at 100% load
  • Fuel tanks fitted with liquid retention trays and leak detection systems
  • Exhaust gas silencers installed inside the canopy, achieving a -30 dB reduction
  • Cyclonic filters for engine air intake
  • Motorised louvres at air inlet and outlet, which open only during operation
  • 3-way double valves to manually switch between integrated and external fuel tanks
  • Quick external connectors for fuel supply and return
  • C5-scheme paint surface treatment, compliant with ISO 12944:2018
  • ComAp InteliLite AMF 25 IL4 control panel
  • Alternators with anti-condensation resistors and special marinisation treatment
  • Powerlock switchboards for power output

 

Genesal Energy designs a new set to guarantee supply to supermarkets

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Genesal Energy provides innovative solutions adapted to the needs of any sector, including large food & drink companies.

In their premises, maintaining the flow of electricity is crucial to guarantee the good quality of the products and service.

Firstly, the preservation of perishable goods requires constant refrigeration to ensure their safety for consumption and, secondly, the support of the operation of critical systems such as computer systems, lighting systems or security cameras. If a supermarket suffers a power outage, the financial and reputational losses can be considerable, as well as causing serious disruption to customers and employees.

To avoid this type of situation, Genesal Energy’s team of engineers designed a solution for one of these in Getafe, Spain. In addition to guaranteeing the supply, it was also adapted to the needs and measurements of the dedicated space. The energy autonomy of the establishment was secured ensuring that it remains operational in events such as overloads or short-circuits.

Our solution

Our engineering department developed a soundproof generator set, with a 450-litre tank and a liquid collection container designed to hold all the fluids that could be leaked (oil, coolant, diesel…).

In addition, a trip coil was fitted in the circuit breaker which acts when there is a power cut, activating the automatic immediately.

Features

  • Calculation of necessary cross-sections for air inlet and outlet in the room.
  • Circuit breaker with minimum voltage trip coil for possible overload, short circuit or earth fault events.
  • Exhaust gas silencer -30dB.
  • 1000W preheating system.
  • Leak tray for liquid collection.

 

Three Genesal Energy gensets for a combined cycle power plant in Mozambique

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A step forward in Mozambique’s energy development

The Temane Combined Cycle Power Plant, located in Inhambane, is a vital energy infrastructure in Mozambique. Genesal Energy has provided the necessary equipment for emergency power supply to secure its operation. It represents a step forward in Mozambique’s energy development, providing an efficient, reliable and cleaner source of energy, while boosting economic growth and employment in the region.

Combined cycle power plants are known for its high energy efficiency, which can reach 60% compared to conventional plants. What they do is combine two thermodynamic cycles: a gas turbine cycle and a steam turbine cycle. This technology allows for higher efficiency in electricity production and lower pollutant emissions compared to traditional plants.

Located in an area with significant natural gas reserves, it produces 450 MW that will supply power for 25 years and will serve as a beacon for the construction of almost 600 km of high voltage transmission lines across the country meeting the demand of 1.5 million households. It will also enable infrastructure development and industrial growth in Mozambique.

Genesal Energy engineering team designed and installed three 2,450 kVA soundproofed generator sets in 40′ HC containers.

These sets will be connected in parallel to a common busbar, synchronising between them and with the grid during restoration of supply.

This is one of our projects within the energy sector.

A tailor-made solution

Inside the container, all the systems were integrated for optimum operation of the equipment. A completely customised base frame was made for the required engine-alternator set, fitted with silent blocks to dampen vibrations and prevent them from being transmitted to the rest of the machine.

The Temane power plant needed generator sets that could operate both as emergency groups supplying the loads required during a plant shutdown and in Black Start mode, in which the groups will be capable of supplying the loads necessary to start up the turbines.

In terms of design, each of the generator sets has a control room, a fuel tank room and an engine room. Also, auxiliary systems such as engine heating – to guarantee an optimum starting temperature-, anti-condensation resistances in the alternators, lights and sockets in the different rooms, manual and automatic fuel transfer control systems…
Due to the high temperatures in the area, an air conditioning system has been fitted for the control room and extractors for the rest of the rooms. Considering the strong winds, plates and anchor bolts for fixing the containers were manufactured and supplied. Eventually, attenuators – both exhaust and cooling air – to reduce engine noise levels were fitted.

To increase reliability and safety, the machines are equipped with a fire detection and extinguishing system; an Uninterruptible Power Supply (UPS) for critical services; battery chargers and redundant battery banks that guarantee the start-up of the generator set in any event. The entire communications network between Generator Sets, Master Panel and Combined Cycle Power Plant is fibre optic.

Features

  • 40’HC container with independent rooms for genset, tank and control panel.
  • 4000 litre double-walled (steel-steel) fuel tank installed inside the container.
  • Automatic fuel transfer system from mother tank.
  • Fire detection and extinguishing systems in the engine-alternator and tank rooms. NFPA switchboard.
  • Air conditioning in control room.
  • Forced ventilation with air extractors in the engine-alternator and fuel tank rooms, with PT100 probes to guarantee that the internal temperature does not rise more than 5ºC above the external temperature. Hygrostat for humidity control.
  • Plates and anchor bolts for container.
  • AGM type batteries.
  • Engine equipped with: low coolant level sensor (digital), oil temperature and pressure sensors (analogue).
  • Alternator equipped with: transformers, anti-condensation resistor, PT100 probes in alternator bearings (2 per bearing) and windings.
  • Neutral earthing resistor (NGR).
  • Separate master panel with Siemens S71200 PLC multimode fibre communication. Optical fibre in group.
  • Control panel equipped with:
    • 87G protection relay.
    • Ethernet RJ45 card for modbus TCP/IP communication.
    • ComAp Inteligen BaseBox and ComAp Intelivision 5.
    • IEC61850 communication protocol.
    • OM2 LC Duplex multimode canbus to fibre optic OM2 LC Duplex Converters.