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 L, 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.

An engineering feat to ensure power supply to a data center in Northern Europe

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We design five unique gensets capable of providing a DCP output of 3,000 kVA each.

In an innovative and technological implementation, our engineering team has designed five generator sets that have been installed in a Data Center in Northern Europe. These are ad hoc machines designed to provide a DCP power of 3,000 kVA and meet the stringent technical and regulatory requirements of the project.
We have reached this milestone hand in hand with manufacturers Baudouin, ComAp and Friga-Bohn. The generators were designed to ensure continuous uptime and data security in one of the world’s most critical and demanding environments, protecting the infrastructure against grid outages.
The integration of advanced technologies, customisation to detail and compliance with the highest standards of security and efficiency, consolidate this installation as a model to follow in the industry.

The importance of investing in emergency power generators

The installation of these generators responds to the critical need to ensure operational continuity in data centres, essential for the IT infrastructures of global companies. The benefits include:

  • Data Loss Protection: They provide an alternative power source to protect unsaved data and prevent damage to storage systems.
  • Cooling Maintenance: Enable continuous operation of cooling systems, preventing equipment from overheating.
  • Prevention of Costly Downtime: Minimise downtime that can result in significant financial loss.
  • Regulatory Compliance: Help companies comply with regulations that require robust contingency plans.

Innovation and security in every detail

This completely customised solution exceeded the customer’s most demanding specifications. The design of the container – with special dimensions of 13.5 x 3 x 3 m – includes a structurally reinforced base with pipes running underneath to facilitate connections to the fuel tank and a liquid collection tray that guarantees total containment in case of spills.
In addition, the container was given a C5 type surface treatment in accordance with UNE-EN ISO 12944-2:2018 – ideal for marine environments – guaranteeing exceptional durability and resistance.
To ensure that noise requirements were met the exhaust system was optimised including a thermally insulated (rock wool and aluminium) -30 dB silencer, maximising safety and minimising environmental impact.
In terms of equipment protection, 5,000 A circuit breakers and Power locks were installed, as well as an oversized busbar, specially designed to facilitate the customer’s electrical connection of the system.
Our engineering team also developed an independent cooling system with motorised louvres and a fully integrated & automated fire suppression system to ensure a fast and efficient response in case of an emergency. The incorporation of wide accesses, advanced control systems, fire protection and adverse environment features completed this project and made it a benchmark in the industry.

Requirements and Customised Solutions

  • Non-full-flow: In terms of the cooling system, V-arranged Friga-Bohn air-coolers were installed in a room separated from the generator room. They were sized for a maximum ambient temperature of 38ºC at 100% load. This configuration allowed outside operation of a full flow system, significantly reducing air interference in the operating area.
  • Low noise level: The generators were required to operate at a sound pressure level of no more than 85 dB at 1 metre, at 100% load.
  • Fire protection: A Novec fire detection and gas extinguishing system and sectorisation panels were integrated, ensuring EI60 fire resistance standards.
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Business collaboration

After a thorough analysis of the customer’s specific power requirements, generator set models and capacities were selected based on a detailed list of electrical loads. The choice of Baudouin’s 3,000 kVA DCP engines was not a gamble; these engines have been specially designed for critical applications and meet the highest standards of reliability and performance.
Regarding the control system – and as it was essential to ensure the highest availability of the equipment – redundant systems were installed. Namely, a redundant battery rack of eight units in total, separated into two groups of four. Also, a redundant two-stage starting system. First stage fitting two starter motors and managed by the engine ECU and a second stage with one starter motor managed by an ComAp controller. This particular control centre allows, in addition to real-time management and monitoring of the status of the generators, a flexibility that traditional control systems do not provide.

Features

  • V-arranged air-coolers were installed in a room separated from the generator room. They were sized for a maximum ambient temperature of 38ºC at 100% load. This configuration allowed outside operation of a full flow system, significantly reducing air interference in the operating area.
  • The generators were required to operate at a sound pressure level of no more than 85 dB at 1 metre, at 100% load.
  • A Novec fire detection and gas extinguishing system and sectorisation panels were integrated, ensuring EI60 fire resistance standards.

Genesal Energy secures supply at Europe’s leading engineering research centre

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Investment in innovation & research ensures the competitiveness of a company.

This is often materialised in a research centre or campus which search for the best suppliers and solutions.

Genesal Energy has designed a solution to secure the power supply of Europe’s largest enclosures engineering space. These 29,000 sq. metres premises are devoted to the research of customised enclosures for large buildings around the world, with a team of 350 engineers and architects.

Our solution was a 250 kVA generator set with an autonomy of more than 6 hours, vibration isolation and a silent engine that does not interfere with advanced test benches or thermal and acoustic performance tests.

Genesal Energy has eliminated the risks of power supply instability, power cuts or voltage variations, ensuring the progress of research.

Our engineering solution: research center generator

An open generator set with an engine-alternator direct coupling on a steel bedplate. The integrated 350 L tank provides an autonomy of 6.8 hours. Vibration isolation between the base plate and the monoblock was achieved by means of a rubber anti-vibration system. The integration of protections for moving parts and hot parts has also been taken into account, as well as emergency stop buttons and other elements necessary to operate the unit safely.

Features

  • Supply: 2,800mm bedplate.
  • Tank: 350 L integrated in the bedplate.
  • Silent model: GSA 365 (-25dB).
  • Control panel: ComAp InteliLite.

 

 

 

We equipped a children’s hospital with a generator to avoid incidents due to lack of power supply

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Genesal Energy has equipped a children’s healthcare center in Bebington (Wirral), in the northwest of England, with a generator.

The children’s hospital, located just 8 kilometers from Liverpool, will now have an additional generator to ensure essential care for children, preventing a power outage or any other technical incident from disrupting the normal activities of the center. In this way, the safety of the children is ensured, and they can be attended to at all times both medically and emotionally.

It is crucial for such facilities to have an emergency generator, as its use would help prevent and respond to various adverse situations that may arise in such a center. Thus, it provides confidence and flexibility to ensure the power supply in areas where it is unstable or non-existent, such as rural areas, hard-to-reach areas, or establishments that need guaranteed electricity 24 hours a day. It acts as a power backup and support in situations where the quality of the supply is deficient or prone to frequent interruptions.

  • Generator installation at Claire House
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Among the differentiating advantages of using an emergency generator is the uninterrupted power supply. In this regard, Genesal Energy ensures that critical operations continue during power outages, avoiding economic and productivity losses.

Similarly, generators for hospitals and healthcare centers keep essential medical equipment running, which is vital for the life and well-being of patients.

Thus, an emergency generator is an essential tool to ensure operational continuity, safety, and resilience in different scenarios.

Its ability to provide reliable power in emergency situations makes it a fundamental and strategic investment for many organizations and infrastructures, especially those providing social and child care.

Guaranteed Safety

On the other hand, security systems are essential. Genesal’s generator will allow surveillance cameras, alarms, and other security systems to continue operating in the event of an electrical failure or power outage. In so-called critical infrastructures, such as water treatment plants or pumping stations, the generator would ensure that basic services are not interrupted.

But this system can also be used for temporary events. In outdoor activities, the generator provides power for lighting, sound, and other necessary equipment, while in construction areas, it allows power to be supplied to tools and equipment in places where there is no access to the electrical grid.

In this regard, Genesal is also positioned as a reference in disaster mitigation, such as earthquakes, hurricanes, or other catastrophes, providing power for shelters, rescue centers, and other emergency facilities. It thus contributes to resilience in extreme situations.

Children’s hospital generator: Solution designed by engineering

The project developed by our engineering department consisted of providing an emergency network with the design, manufacture, and commissioning of a silent generator that guarantees at all times and in any incident the operation and safety of the center’s medical activities.

The generator has a power of 160/176 kVA, in a soundproof cabin, with a bunded type tank integrated into the cabin, a main switch panel, and an external power output panel. The cabin, in addition to rain guards on the door frames, also has a mesh to prevent animals from entering.

Features

  • Soundproof generator in a 3,400 cabin, with a fuel tank integrated into the chassis, capacity 450 L.
  • Liquid collection tray integrated into the chassis.
  • External power output panel with connection plates and auxiliary service terminals to facilitate customer connection.
  • Battery box for explosion protection.

 

Article on public-private collaboration

Public-private collaboration, what is its added value for Genesal Energy?

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Public-private collaboration roundtable participants
Collaboration between public and private entities (public-private collaboration) in the field of research, development and innovation (R&D&I) has proven to be a driving force for technological and economic progress. This synergy allows the combination of resources, knowledge and capabilities from different sectors, generating benefits that transcend both parties and have a positive impact on society as a whole.

Boosting R&D&I and Competitiveness

Private companies, thanks to their focus on competitiveness and their vision of the market, provide a practical and results-oriented perspective. On the other hand, public entities, such as technology centres, with their vast knowledge and experience in advanced research, provide a solid base of scientific and technical knowledge. This combination enables the leap from ideas to marketable tech products.

Moreover, this collaboration fosters the competitiveness of private companies. By improving products and processes, companies can differentiate themselves in the market and achieve a competitive advantage. Companies that develop such collaborative frameworks not only benefit individually, but the economic ecosystem as a whole is strengthened.

Resource Optimisation and Cost Reduction

Both research and development are costly and risky processes, especially for small and medium-sized enterprises. Collaboration with public technology centres makes it possible to share these risks and costs. Public institutions often have advanced research infrastructures and equipment that can be used by private companies, thus reducing the need to invest in expensive in-house equipment and laboratories.

In addition, this collaboration facilitates access to public funding and grants for R&D&I projects, which significantly reduces the financial burden for companies. This is especially beneficial in emerging sectors or in high-risk projects where profitability is not guaranteed in the short term.

Knowledge Transfer and Training

Public-private collaboration in R&D&I also promotes the transfer of knowledge and skills between academia and industry. Private companies can benefit from the education and training provided by technology centres, thus improving the skills of their staff and fostering a culture of continuous innovation.

Researchers and technicians in public centres can also gain valuable practical experience by working on market-oriented projects, enriching their perspective and increasing their ability to develop real-world solutions. This feedback is essential to maintain the relevance and quality of public research.

Success stories: the collaboration between Genesal Energy and AIMEN

An example of the benefits of public-private collaboration in R&D&I is the alliance we have established at Genesal Energy with the AIMEN Technology Centre (Northwest Metallurgical Research Association), to develop projects focused on the energy transition.

Thanks to this collaboration, Genesal Energy has been able to take advantage of AIMEN’s research and development capabilities, including its expertise in advanced materials, manufacturing processes and automation technologies. This alliance has resulted in the materialisation of two R&D&I projects focused on renewable gases:

  • H2GEN, which seeks to develop a new generation of generator sets capable of operating with hydrogen in order to be more environmentally friendly.
  • ENEDAR, which aims to improve the energy efficiency and sustainability of wastewater treatment plants through the recovery of WWTP (Wastewater Treatment Plant) sludge. Three other private companies and the University of Valladolid are also collaborating in this project.

In the following video Álvaro García Martínez, Energy & Large Industry Sales Manager at AIMEN, gives us his vision of the added value of this type of project.

How we manufacture a generating set

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Imagen de nuestra fábrica de grupos electrógenos

The manufacture of our generating sets is a complex process that covers different key phases, very much determined by the specific needs to be satisfied and always under the most demanding quality standards and controls.
Do you want to know it in detail?

Manufacturing phases of a generating set

Join us on this journey from the definition of the characteristics of the project to the generating set commissioning in its final location.

Distintos grupos electrógenos en la fábrica de Bergondo

1. Definition of the genset type

The starting point in the manufacture of an industrial generating set is the precise definition of its technical and functional characteristics, considering the specific needs of the project or the intended application. In this initial phase, crucial decisions are made that will determine the performance, reliability and lifetime of the equipment:

  • Fuel type: The type of fuel that will power the genset engine is selected, whether diesel, natural gas or other. Each fuel has advantages and disadvantages such as cost, efficiency, emissions and availability.
  • Power: The required power of the genset is determined, expressed in kilowatts (kW) and kilovoltamperes (kVA). This parameter depends on the power demand of the installation site and the power factor of the loads.
  • Engine type: The appropriate engine type is selected for the genset, considering factors such as rotational speed, fuel injection technology and applicable emission standards.
  • Alternator type: The alternator model suitable for the genset is selected. Each model has specific characteristics and applications in terms of voltage stability, overload capacity and transient response.
  • Cooling system: The appropriate cooling system is selected for the genset, both for engine and alternator, either air, water, oil or mixed. Each system has advantages and disadvantages such as thermal efficiency, noise level and maintenance.
  • Control and protection: The control and protections systems required for the genset are defined, including the control panel, start/stop systems, monitoring systems and overload, short circuit and fault protection devices.

Equipo de diseño Genesal

Further information on this issue: Classification and types of generating sets

2. Engineering Design

Once the features of the generating set have been defined, the engineering & design phase begins:

  • Assembly design: a team of expert engineers develops the drawings and calculations for the integration of all the components of the genset. This includes the design of the frame, engine and generator location, fuel tank, exhaust system, cooling system, control panel, protections and other essential elements.
  • Finite element analysis (FEA): tools are used to simulate the behaviour of the genset under different loads and operating conditions. This allows the design to be optimised and ensures the structural integrity of the equipment.
  • Material selection: Materials are carefully selected for each genset component, considering factors such as mechanical strength, thermal conductivity, corrosion resistance and durability.
  • Standards and regulations: Standards and regulations applicable to the manufacture of industrial gensets are strictly adhered to, including safety standards, emissions standards and quality standards.

Equipo de ingeniería

3. Technical documentation

Complete technical documentation of the genset is prepared, including:

  • User manuals: clear and detailed user manuals are developed that provide instructions for the installation, operation, maintenance and troubleshooting of the genset.
  • Electrical diagrams: Detailed diagrams are created showing the electrical configuration and operation of the genset systems.
  • Parts Lists: Complete parts lists are created that identify each generator set component and its corresponding part number.
  • Mechanical dimensional drawings: Dimensional and installation details of the equipment are explained.

4. Production planning

A detailed production plan is developed that defines the resources required, delivery schedules and manufacturing processes for the production of the genset, as well as the final operational tests.

5. Component manufacturing

The manufacture of the individual components of the industrial generating set involves high precision and quality control processes:

  • Machining of parts: metal parts – such as the frame, fuel tank and other structural components – are manufactured using high-precision machining techniques. High-strength and durable materials are used to ensure the reliability and service life of the equipment.
  • Electrical component manufacturing: Electrical components – such as the control panel, cables or electrical conduits – are manufactured to the highest standards. High quality materials are used, and rigorous testing is carried out to ensure the safety and proper functioning of the electrical system.
  • Assembly of sub-assemblies: Major subassemblies of the genset, such as the engine, generator and fuel tank, are assembled precisely according to established drawings and procedures. Advanced assembly techniques are used, and thorough quality checks are carried out to ensure the correct installation and operation of each sub-assembly.

Operario instalando componentes

6. Final assembly

In this crucial stage the complete genset is integrated: The frame, engine, generator, fuel system, exhaust system, cooling system, control and protection panel, and other components are carefully assembled on the main frame, following established procedures. Each component is checked for correct alignment, attachment and connection to ensure optimum performance.
Montaje final de un grupo

7. Testing

Exhaustive tests are carried out to verify the correct operation of the generating set as a whole:

  • Start & Stop test: The engine is checked to ensure that it starts and stops correctly, following the established procedures.
  • Load test: An Load Bank is connected to the generator to assess its power delivery capacity and the stability of the voltage and frequency.
  • Auxiliary systems test: Auxiliary systems such as the cooling system, exhaust system, lubrication system and control systems are checked for proper operation.
  • Noise test: The noise level of the generator set in operation is measured to ensure that it complies with the applicable noise standards.

Testeando el grupo

8. Quality control

Meticulous final inspections are carried out to ensure that the genset meets all established quality standards, both in terms of manufacturing and performance:

  • Visual inspection: A thorough visual inspection is carried out to detect any defects or anomalies in the body of the generating set.
  • Electrical tests: Additional electrical tests are carried out to verify the correct operation of the electrical system and the safety of the equipment.
  • Functional tests: Additional functional tests are performed to verify the performance of the engine, generator and auxiliary systems.

9. Packing and shipping

Once the tests have been completed and compliance with the quality standards has been verified, the generating set is prepared for shipment:

  • Packing: the generating set is carefully packed in a sturdy transport box or container, using suitable packing materials to protect it from damage during transport. Particular attention is paid to securing the equipment to avoid sudden movements that could cause damage.
  • Shipping: The genset is shipped to the end customer following established transport procedures. The shipment is carefully documented to ensure traceability and safe delivery of the equipment.

Grupo electrógeno en la grúa para el embalaje

10. Commissioning and After-sales Service

When the genset has arrived at its destination, it is time for commissioning:

  • Commissioning: A specialised technician provides the installation and commissioning of the generating set. The correct installation, configuration and operation of the equipment is verified.
  • After-sales service: From this moment on, the service is available to the customer for maintenance, repair and technical support of the generating set. Access to original spare parts and qualified technical personnel is provided to ensure the proper operation of the equipment throughout its service life.

Instalación y puesta en marcha de grupo electrógeno

This is how our energy is transformed from an idea to a tangible product that fits for each project.

Classification and types of generating sets

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3 tipos de grupos electrógenos diferentes

Generator sets are essential for providing a reliable source of electricity in several situations. From emergency power supply to industrial and commercial applications, this equipment is essential to ensure the continued operation of crucial sectors and services in society.

In this comprehensive guide, we will take an in-depth look at the classification and various types of generator sets available on the market, focusing on their characteristics and applications.

Generator classification:

Generating Sets by engine type

The most used on the market are those with diesel and gas engines. However, more recent technologies and trends are introducing new forms of power generation that seek to minimise environmental impact, such as hybrid gensets and Stage V gensets.

Grupos electrógenos diésel de Genesal Energy

Diesel engines

Diesel gensets are widely recognised for their robustness and reliability in power generation, making them ideal for applications requiring constant power and continuous operation, from industrial environments to power supply emergencies. Available in power ranges from 5 to 3,900 kVA, these generator sets are a widespread solution in the market.
They are essential for emergency power supply in critical services such as hospitals, shopping centres, and data centres. They are also used in industrial processes to provide a reliable and powerful power source.

Gas Engines

With an increasing focus on sustainability and emissions reduction, gas-powered generator sets are gaining popularity in a number of sectors. These engines offer a cleaner, more combustion-efficient alternative, making them ideal for applications where a smaller environmental footprint is required.

They are an ideal choice for cogeneration plants, where the heat generated as a by-product of electricity generation can be utilised, thus optimising the energy efficiency of the system.

Hybrid gensets

Hybrid gensets offer the possibility of combining multiple energy sources to supply electricity. For example, in a remote telecommunications station, electricity can be generated by combining a gas genset with windmills or solar panels.

This solution is particularly suitable for isolated locations without access to the grid, such as farms, cottages, hotels or mountain huts.

Instalación de grupos híbridos en la montaña

Generating Sets by emission regulations

Emission regulations have changed significantly in recent years, especially in the European Union, where regulations such as Stage II, Stage III and most recently Stage V have been implemented. These regulations set increasingly stringent standards to reduce the environmental impact of diesel engines, including those used in gensets.

Generator sets with not emissions-compliant engines

Non Emission-compliant engines are those that are not subject to specific regulations for the control of pollutant emissions. Unlike engines subject to regulations such as Stage V, these engines are not designed with advanced emissions control technologies. Although they may be less stringent in terms of emissions, their environmental impact can be considerably higher, making them less favourable in the current context of air quality and sustainability concerns.

Generator sets with Stage II engines

These engines must comply with specific emission limits for particulate matter and nitrogen oxides (NOx), which involves the adoption of more advanced emissions control technologies compared to non-emitting engines. Although not as stringent as the latest standards, Stage II engines represent a significant advance in terms of emissions reduction and environmental compliance.

Generator Sets with Stage III engines

These engines are designed with advanced emission control technologies to significantly reduce particulate matter and nitrogen oxides (NOx) emissions, making them more environmentally friendly and more compatible with increasingly stringent air quality standards.

Grupo diésel con motor Stage V

Generator Sets with Stage V engines

The European Union’s Stage V standard aims to regulate and reduce pollutant emissions not only in on-road vehicles, but also in non-road equipment such as generator sets. This regulation sets stricter limits for emissions encouraging the development and adoption of cleaner and more efficient technologies.

Stage V compliant gensets ensure a lower environmental impact and more environmentally friendly operation meeting the highest air quality standards.

Generating sets by mobility

Another way of classifying generating sets is according to their mobility, i.e. their ability to be moved to wherever they are needed. With this in mind, we can divide generating sets into two categories: stationary and mobile.

Stationary generating sets

Stationary generating sets are the preferred choice on most occasions to ensure a constant and reliable power supply in specific installations. For example, in industrial environments or in hospitals, where electricity is vital 24 hours a day, 7 days a week. Generally larger in size and capacity, these sets are designed to be permanently installed in a specific location and are specifically sized to meet the requirements of the premises.

Servicios esenciales: hopsitales y centros de datos

Mobile generator sets

Mobile generator sets, on the other hand, offer flexibility and versatility in situations where mobility is essential. These – generally more compact – units are ideal for being moved from one location to another. From fairs and festivals to power failures or even natural disasters, mobile generator sets provide fast and efficient power support wherever it is needed.

When purchasing or renting a generator set, it is crucial to consider not only the capacity and power of the equipment, but also its mobility and adaptability to different scenarios.

Generating Sets by type of start-up

We can also classify the groups according to the type of start-up. This can be manual or automatic.

Manual start

When the immediacy of switching between the mains and generator supply is not crucial, a manual start genset can be installed. These systems require human intervention to start the generator in the event of a power failure. Although they may require a quicker response from personnel, manual starts are ideal in applications where direct supervision of the starting process is preferred or where this transition is not necessary, such as in stand-alone off-grid gensets.

Automatic start

Gensets with automatic start are the preferred and most common choice in situations where an immediate response to power outages is required. These systems automatically detect a power failure and activate power generation instantly to restore power without delay.

From critical applications in hospitals and data centres to the protection of sensitive facilities, automatic start-ups guarantee a smooth transition between the grid supply and the backup generator, always ensuring continuity of power service.

Generator Sets by Soundproofing Type

Depending on the intended use of the generator set and the needs of the environment in which it is installed, these machines can be manufactured in open or soundproof configurations.

Open Generator Sets

Open generator sets are a more economical and versatile option that provides easy accessibility for maintenance and operation. Although they do not offer the same level of soundproofing as canopied models, they are suitable for applications where noise is not a primary concern, such as industrial facilities.

Key advantages of open generator sets include their more compact size compared to soundproof sets, making them ideal for small spaces, and easier maintenance tasks.

Soundproofed Generator Sets

Soundproofed generator sets are the right solution for noise-sensitive environments where quiet and comfort are essential. These generators are distinguished by their careful design and their ability to minimize the level of noise generated during their operation, making them an ideal choice for places such as hospitals, residential areas or office buildings. Canopied sets make it possible to maintain an environment free of disturbing noise, promoting a healthier, more productive and habitable environment.

The key to their effectiveness lies in their structural features, which are designed with high-quality sound-absorbing materials and advanced acoustic insulation systems. Allowing for a significant reduction of the sound level, making the environment quieter and more comfortable for those in their proximity.

 

Importancia de la insonorización en hospitales

Generator Sets by Voltage Type

Single-phase Generator Sets

A popular choice for applications where power demand is relatively low and considerable power is not required. They are particularly suitable for domestic use, small businesses and agricultural applications where the load is light, and simplicity is key. Their compact design and ability to operate efficiently as back-up systems make them a convenient and affordable solution for maintaining continuity of power supply in emergency situations or for occasional use.

Three-phase Generator Sets

The right choice for applications requiring high power and supply stability. They are suitable for industrial, commercial and construction environments where power demand is significant and constant levels of electricity are needed to power complex machinery, equipment and systems. Their ability to handle heavy loads and distribute power evenly between phases makes them a reliable choice for a wide range of demanding applications.

Imagenes de centros comerciales

In this practical guide, we have compiled the main classifications commonly used. Depending on the characteristics of the generating sets, they can also be classified according to their power, use or other aspects.