Operating Cost Calculation for Generator Sets

Operational Cost Analysis: Diesel vs Gas in Generator Sets

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Visual comparison of Genesal Energy generator sets highlighting operating costs for diesel and gas generator sets.
Choosing the right fuel type for a generator set is a critical decision that directly impacts operational costs and the efficiency of the power supply. The most common options are diesel generators and those powered by natural gas. This article provides a comparative overview of both systems, examining their advantages, disadvantages, and suitability based on the energy demands of each sector.

Factors Influencing the Operational Costs of a Generator Set

The operational cost of a generator set depends on more than just the fuel price. Other key factors include:

  • Fuel consumption according to load and operating hours.
  • Maintenance frequency and spare parts requirements.
  • Engine durability, depending on the type of fuel used.
  • Fuel supply availability and logistics at the project location.
  • Thermal performance and energy conversion efficiency.
  • Environmental regulations relating to fuel emissions.

These elements influence long-term investment, especially in industrial environments or critical applications where continuity of power supply is essential.

The most common options are diesel generators and those powered by natural gas.

Price Comparison: Diesel vs Natural Gas

Diesel has long been a reliable choice, but the price of natural gas is often more competitive, particularly for long-duration or continuous-use applications.

  • Diesel is subject to volatile pricing, influenced by global markets and specific fuel duties.
  • Natural gas generally offers more stable and predictable costs, making operational and financial planning easier.

Genesal Energy Diesel Generator Set and Fuel Fluid
Furthermore, long-term contracts with gas suppliers allow many industries to manage their operating energy costs more effectively.

Efficiency and Fuel Consumption: Diesel vs Gas Generators

Diesel generators typically deliver high efficiency under variable load conditions and quick start-up, making them ideal for short-duration or standby use. Their design allows for high power output within a short time frame.

In contrast, natural gas generators offer:

  • Lower specific fuel consumption in continuous, stable-load operations.
  • Cleaner combustion with fewer residues.
  • Improved thermal efficiency, particularly when used in combined heat and power (CHP) systems.
  • Lower noise and vibration levels, enhancing operational comfort.

Impact on Lifespan and Maintenance of Generator Sets

The type of fuel also affects equipment lifespan and maintenance needs:

  • Diesel engines require more frequent maintenance, including regular oil and filter changes and injector checks.
  • Natural gas engines generally allow longer intervals between servicing, with some models offering up to double the maintenance cycle compared to diesel engines.

However, gas engines require specific components, such as spark plugs and advanced air-fuel mixing systems, which demand specialised care.

Generator sets must meet new market challenges with the lowest possible operating cost and the highest commitment to sustainability.

Industrial Applications and Energy Demands Based on Fuel Type

The choice between diesel and gas depends on the specific power supply needs and application context:

  • Diesel generators: well-suited for emergency backup, quick starts, mobile use, and remote areas without gas infrastructure.
  • Gas-powered generator sets: ideal for continuous operation, thermal-electric cogeneration, and facilities with access to natural gas or biogas networks.

Industries such as manufacturing, logistics hubs, hospitals, data centres, public infrastructure, and agri-food facilities can benefit from either type depending on operational requirements.
Industry with High Energy Demand

Sustainability and Emission Reduction with Natural Gas

Natural gas is increasingly seen as a more environmentally friendly alternative to fuels such as diesel:

  • Significant reduction in NOx, CO₂, SO₂ and suspended particulate matter (PM10 and PM2.5), mainly generated by incomplete combustion in diesel engines.
  • Reduced impact on air quality, especially in urban or enclosed environments.
  • Lower odour and noise pollution.
  • Reduced risk of soil contamination in case of leaks.

In addition, using biogas or renewable natural gas brings operations closer to carbon neutrality, in line with European decarbonisation goals.

How to Choose the Best Option for Your Power Supply Needs

Deciding between gas and diesel depends on several key considerations:

  • Expected operating duration of the generator set (standby vs continuous).
  • Fuel availability and delivery logistics in the area.
  • Environmental restrictions and local regulations.
  • Climatic conditions and technical project requirements.
  • Available budget, covering both CAPEX and OPEX

For projects requiring long annual operating hours, gas is often more cost-effective in the long term. In contrast, for installations with sporadic use or urgent demand, diesel remains a robust and practical choice.

Trends and the Future of Fuel Use in Generator Sets

The shift towards a cleaner energy model is encouraging the adoption of alternative fuels, such as biogas, LPG, green hydrogen, or HVO blends (hydrotreated vegetable oil).

In addition, using biogas or renewable natural gas brings operations closer to carbon neutrality,

Hybrid systems that combine generator sets with renewable energy and battery storage are also gaining traction, offering more flexible and sustainable power solutions.

In the short to medium term, natural gas will remain a key solution for efficient and sustainable electricity generation, particularly in industrial settings and medium-to-large-scale projects.
Meanwhile, diesel generators will continue to play a vital role in applications requiring immediate response and proven reliability, such as hospitals, telecommunications, and emergency systems.
Hand touching a moss-covered log in a natural environment
Ongoing technological development, tighter environmental regulations, and the demand for flexible energy solutions will shape the sector’s future, where generator sets must meet new market challenges with the lowest possible operating cost and the highest commitment to sustainability.

Uninterrupted Power for Data Centers

Uninterrupted power for the New Era of Data Centers

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In an increasingly interconnected world, data centres have become the digital backbone of the global economy. The reliability of their power supply is crucial for their operation, as any interruption can lead to substantial financial losses and affect millions of users. In this context, Genesal Energy has established itself as a leader in emergency power generation, providing bespoke solutions for data centres across Europe and beyond.

Power that never fails

Our journey in the data centre sector is the result of more than 30 years of experience in designing and manufacturing generator sets for critical infrastructures such as data centers. Over time, we’ve strengthened our international presence with key projects in countries such as Norway, Germany, Spain and France, where our systems ensure power continuity in high-demand environments.

All our generator sets are ready to operate using renewable fuels such as HVO.

Some of the most notable examples include the supply of five generators in Norway and the installation of two units in Madrid, specifically designed to ensure the operational safety of data processing centres. In Germany, we developed generators with advanced noise reduction and emissions control systems, meeting the most stringent environmental regulations in the European market.
Data Center in extreme climate with Genesal Energy generator sets operating under snow and low-temperature conditions.

Engineering precision for a demanding sector

Every project is approached from an integrated engineering perspective, where customisation and reliability go hand in hand. Our generator sets for data centres feature:

  • Full compliance with Uptime Institute standards, supporting projects of up to 5250 kVA and enabling us to meet the demands of large-scale, high-availability facilities.
  • Fully tailored configurations: side-by-side layouts, radiator or air-cooled systems, custom acoustic enclosures, output switching for both critical loads and load banks via Powerlock connectors, direct generation at medium voltage (up to 15 kV), medium-voltage switchgear integration, and fire detection and suppression systems.
  • Redundancy systems to guarantee continuous operation under any circumstances.
  • Advanced automation, enabling real-time communication and seamless integration into Building Management Systems (BMS).
  • Emissions control technologies in line with the most demanding European regulations.
  • Custom testing protocols, including functional tests and simulations under real-world operating conditions to ensure performance in critical scenarios.

Technical Supervision of Electrical Systems in Data Centers

Sustainability and Ecodesign: Our commitment to the future

Our vision of industrial development is deeply rooted in sustainability. We are certified under ISO 14006, which supports our ecodesign approach, applied from the conceptual phase through to the final manufacturing stage. This methodology allows us to systematically reduce the environmental impact of our generators throughout their lifecycle.

All our generator sets are ready to operate using renewable fuels such as HVO (Hydrotreated Vegetable Oil), offering a practical solution for reducing CO₂ emissions without compromising performance.

Arquitectura sostenible con integración de vegetación en entorno tecnológico.

We also invest in R&D initiatives related to hydrogen as an alternative energy source and apply modular design and additive manufacturing techniques to increase efficiency and extend product life.

In addition, we align our products with European directives such as the Energy Efficiency Directive (EED) to ensure that our solutions are not only technically advanced but also aligned with long-term sustainability goals.

More than a supplier: A strategic partner

Our ability to offer the best lead times in high-power delivery is one of our key competitive advantages. In an environment where every minute counts, speed in implementation can be the difference between success and failure in a critical operation.

Our journey in the data centre sector is the result of more than 30 years of experience in designing and manufacturing generator sets for critical infrastructure.

We are involved in every stage of the project: from initial analysis and custom design to manufacturing, commissioning, and ongoing maintenance. This continuous technical support ensures that every energy solution meets the client’s exact needs.

Our approach, based on personalised attention and uninterrupted support, has made us a trusted strategic partner for the data centre sector.

Leadership in a growing market

Digital transformation is driving an increasing demand for reliable, efficient digital infrastructures. In this context, emergency power generation has become a cornerstone for the growth and expansion of data centres.

At Genesal Energy, we continue to demonstrate that our technology, experience, and commitment to sustainability are the guarantee of uninterrupted power for the most demanding environments in the new digital era.

Power Generator for Extreme Climates

Genesal Energy, delivering energy in the most extreme climates

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Securing energy supply in climates with extreme conditions, be it cold, heat or humidity, is a challenge that Genesal Energy is familiar with. In this case, the challenge of the project was to provide a solution in the extremely cold environment of Finland.

Faced with the need for reliable equipment to ensure the uninterrupted operation of the installation in the event of a mains power failure, we designed a generator set fully integrated into a 20 feet HC container, adapted to the demands of the environment and prepared to guarantee the continuity of the power supply. In addition, it had to be able to operate in low temperature conditions, be compact for easy transport and have the greatest possible autonomy. A technical challenge that we solved with a customised design.

Another key aspect of the design was the optimisation of space to increase the autonomy of the equipment.

To guarantee the correct operation of the unit in these climatic conditions, we incorporated a system of motorised grilles between the unit and the air outlet. These louvres allow air inlets and outlets to be closed, while the opening of an intermediate louvre creates a flow of hot air inside the container until the right temperature is reached. It is equipped with a heating recirculation pump to guarantee start-up in extreme conditions. At the same time, customised soundproofing ensures that the noise level is extremely low.

Another key aspect of the design was the optimisation of space to increase the autonomy of the equipment, so we designed a customised fuel tank with a capacity of 2,000 litres, with a double steel wall and strategically located at the entrance of the container. Its rectangular format allowed us to make better use of space without compromising accessibility.

Our Engineering Solution

Our team designed a solution totally adapted to the customer’s needs and focused on solving two problems: on the one hand, withstanding low temperatures, and on the other hand, increasing the autonomy of the unit as much as possible.

Features

  • Large capacity tank. 2.000 litres double walled (Steel-steel).
  • Recirculating heating pump.
  • Integrated silencer in container, GSI 490 (-30 dB).
  • 630 A, 3-pole, LSI circuit breaker.
  • Battery protection box with ventilation.
Mobile Generator Set for Wind Turbine Blade Recycling

Genesal Energy promotes sustainability in wind farms with a mobile generator set for the recycling of turbine blades.

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The energy transition and the fight against climate change have boosted the development of wind energy, making it one of the main renewable sources worldwide. However, this progress brings with it a significant challenge: the efficient recycling of wind turbine blades.

With an average lifespan of 20 years – extendable to 25 with proper maintenance – most components of a wind turbine are recyclable. However, blades present a unique challenge due to the composite materials used in their manufacture: glass & carbon fibre and resins. These materials are complex to separate, which raises costs and makes large-scale recycling difficult.

Genesal Energy has taken a step forward in search of sustainable solutions to this challenge. In collaboration with GDES Wind – a company specialised in the maintenance and inspection of blades in wind farms – we designed and installed a 45 kVA mobile generator set to power a machine specialised in the recycling of wind turbine blades. This equipment cuts the blades using diamond wire, offering an efficient and environmentally friendly alternative. The pieces are then efficiently treated as waste, generating mortar or useful pieces for new applications such as planters, canopies or pieces of furniture.

With this project, Genesal Energy reinforces its commitment to sustainability and the circular economy.

This genset – which complies with Stage V emissions standards – not only ensures a low environmental impact but also provides autonomy of up to 35 hours at 100% load thanks to its 350-litre tank. It is also equipped with a socket panel to power auxiliary tools, extending its functionality and operational efficiency.

A growing challenge in the wind power industry

Although most blades are currently reused in repowering processes or converted into architectural structures such as bridges or bicycle racks, this strategy will not be sufficient in the long term. According to WindEurope, up to 5,700 wind turbines per year will be dismantled in Europe from 2030 onwards, which means an increasing volume of retired blades that will require innovative solutions for recycling.

Grupo electrógeno móvil para eventos con diseño ligero.

Image 1: The trailer-mounted genset inside the customer’s warehouse.

The equipment designed by Genesal Energy to power the GDES Wind solution represents a key step in this direction, aligning with the principles of the circular economy and offering the wind sector an indispensable tool to sustainably manage the dismantling of wind turbines.

With this project, Genesal Energy reinforces its commitment to sustainability and the circular economy. We continue working to make energy not only cleaner, but also more socially responsible.

Features

  • Supply: 2600mm soundproofed canopy on trailer.
  • Stage V emissions-compliant engine.
  • 350L base frame inserted fuel tank.
  • Control panel: ComAp AMF 25 InteliLite4.
  • Socket panel.

Generator sets for events: keep the fiesta going

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Spain is a country of events, recordings, fairs, concerts, festivals or travelling sporting events that bring together thousands of people around and which depend on a stable electricity supply for their correct development.

Otherwise, the absence of reliable power can lead to problems with safety, the operability of technical equipment or even affect the audience’s experience. Therefore, for the music, events or audiovisual industry, having generator sets specifically designed for these applications is key to guaranteeing the success of any celebration.

Genesal Energy has designed a lightweight generator set for vehicle mounting, not exceeding the permitted road weight limits and facilitating access to the fuel supply from the same side as the HGV.

Reliability and efficiency are key aspects in the provision of energy in dynamic and demanding environments such as mass events.

The mobility of the unit was a determining factor, so it was necessary to optimise its design without affecting its performance and autonomy. To meet the requested requirements, our team developed a soundproof generator set with an aluminium canopy, a key choice to reduce its weight and improve its manoeuvrability. In addition, we incorporated a horizontal opening system with shock absorbers, which facilitates access to the interior of the genset for maintenance and refuelling in a safe and efficient manner.

Mobile generator set for events with lightweight design.
Resistance to vibrations and impacts

It has a 200-litre tank for greater autonomy and an anti-shock system to absorb vibrations and prevent structural damage. In this way, the mobility of the generator set will not be a handicap as the design ensures its solid condition for a longer period. Genesal Energy adapts its solutions to the needs of each client and application. Reliability and efficiency are key aspects in the provision of energy in dynamic and demanding environments such as mass events. Ensuring a continuous and secure power supply is our priority, allowing each event to run smoothly and meet the expectations of organisers and attendees.

Our Engineering Solution

Faced with this challenge, our team designed a soundproofed unit with a canopy made of aluminium to significantly reduce the weight of the unit and meet the limitation set by the customer. Another aspect to highlight is that this canopy had horizontal opening doors with shock absorbers to regulate its opening and closing when refuelling.

Features

  • Aluminium made Canopy
  • ComAp control panel
  • Integrated fuel tank with a capacity of 200l
  • Adjustable opening door dampers
  • Anti-shock system to reinforce structural solidity as it is a mobile unit.
  • Upper air outlet.

Genesal Energy reinforces Poznan heat network with an emergency generator set

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Genesal Energy has designed an emergency diesel generator set for a cogeneration plant in Poznan, Poland.

A key facility in the supply of heat and electricity for the city. In the search for efficient and sustainable energy solutions, heat networks emerge as a key alternative for the transition to more responsible consumption patterns.

This power plant supplies approximately 60% of the inhabitants of the city, as well as providing energy to industries, public institutions, shopping centres and other services. The incorporation of our generator set for energy plant ensures supply in the event of a plant shutdown, including battery chargers and part of the lighting network.

These installations consist of a generating plant and a network of pipelines and supply homes, hospitals, schools, shops and offices in an efficient and sustainable manner.

Our engineering team designed a unit that ensures a low sound pressure level thanks to the interior lining and a space divided into three separate rooms: the engine-alternator room, the control room and the storage room. In addition, the system has a Baudouin engine coupled to a Mecc Alte medium voltage (6300 V) alternator, mounted on an electro-welded steel base with anti-vibration blocks to minimise vibrations and noise.

For fuel storage, a 3.000 litres double-walled steel tank has been installed, equipped with a leak detection system. Exhaust gases are managed by stainless steel silencers integrated into the container eliminating the need for external installations. Finally, the container has undergone a C4 paint surface treatment in accordance with the ISO12944 standard, providing additional protection against corrosion and environmental wear and tear.

Genesal Energy emergency generator set installed at a cogeneration plant in Poznan, key to strengthening the urban district heating network.

Heat networks: an alternative to the traditional model

Heat networks consist of a centralised infrastructure for the production and distribution of thermal energy. These installations consist of a generating plant and a network of pipelines and supply homes, hospitals, schools, shops and offices in an efficient and sustainable manner.

Details of the generator set at the Poznan cogeneration plant.

Features

  • 40feet HC container, guaranteeing an average sound pressure level of 85 dB at 1m.
  • The walls were lined with 100 mm thick acoustic panels, guaranteeing EI120 fire resistance.
  • The container had 3 separate rooms: the engine-alternator room, the control room and the storage room.
  • A Baudouin engine was fitted with a Mecc Alte medium voltage (6300 V) alternator on an electro-welded steel base with anti-vibration blocks.
  • The coupling between the engine and the alternator is by means of an elastic coupling.
  • 3.000 litre double-walled (steel-steel) tank inside the container.
  • Tank fitted with a leak detection system.
  • The fuel supply and return pipes were double-walled, with a leak detection system.
  • High-capacity fuel filtration system.
  • Locks with electric lock and position contact were installed on the access doors to the group room and control room.
  • Fire extinguishers were installed in the group room and control room.
  • The control room was air-conditioned.
  • The exhaust gas silencers were made of stainless steel. They were integrated into the container, avoiding on-site installation.
  • The unit was fitted with motorised louvers at the air inlet and outlet.
  • Surface treatment with C4 paint, according to ISO 12944.

Hybrid Systems: Integrating Generator Sets with Renewable Energy

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In a world increasingly focused on sustainability and energy efficiency, integrating generator sets with renewable energy has become a key solution for optimising power supply in specific applications. These hybrid energy systems combine various energy sources in locations where the generator set is the primary source, and renewable energy is added to enhance autonomy, reduce fuel consumption, and lower emissions.

What Are Hybrid Energy Systems?

Hybrid energy systems are solutions that combine generator sets with renewable energy sources, such as solar photovoltaic or wind power, to generate electricity more efficiently and sustainably in specific applications. In the case of Genesal, additional flexibility would primarily come from incorporating battery energy storage systems (BESS), as solar or wind power cannot perform the same function as an emergency generator set.

These hybrid energy systems combine various energy sources.

It is important to note that, in terms of grid stability, emergency generator sets do not inject energy directly into the grid. Instead, they ensure the operational continuity of critical infrastructure, preventing disruptions in electricity generation.

How Do Hybrid Generator Sets Work?

A hybrid generator set operates in conjunction with a renewable energy source and, in some cases, an energy storage system. Its operation is based on:

  • Renewable energy capture: Solar panels or wind turbines generate energy when conditions are favourable.
  • Primary electricity supply: Renewable energy covers the main electricity demand when available.
  • Backup generator set: If renewable energy is insufficient, the generator set automatically activates.
  • Energy storage: Some systems incorporate batteries to store excess energy, reducing unnecessary generator starts and, consequently, emissions and operational costs.

Benefits of Integrating Generator Sets with Renewable Energy

Combining generator sets with renewable energy offers several advantages, including:

  • Reduced fuel consumption, lowering operational costs and environmental impact.
  • Lower environmental footprint, due to decreased greenhouse gas emissions.
  • Energy autonomy, ideal for locations without grid access.

It is important to clarify that energy efficiency is generally used in the context of energy demand rather than generation. While integrating renewables reduces fuel use, it does not affect the efficiency of the internal combustion engine, which continues to operate at its standard performance levels.
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Types of Hybrid Energy Systems

There are different configurations of hybrid systems, including:

  • Solar-diesel system: A combination of solar panels and diesel generator sets.
  • Wind-diesel system: Integration of wind turbines with electrical generators.
  • Storage-based system: Incorporates batteries to enhance energy management and optimise generator set usage.

The Role of Energy Storage in Hybrid Systems

Energy storage plays a crucial role in these systems, enabling:

  • Stabilisation of the electricity supply, smoothing fluctuations and improving power quality in modern systems.
  • Utilisation of surplus energy generated by renewable sources.
  • Reduced generator runtime, extending equipment lifespan and minimising emissions.

Applications and Sectors Benefiting from Hybrid Systems

Hybrid systems are widely used across various industries, including:

  • Rural and remote areas: Where grid access is limited or unavailable.
  • Industry and manufacturing: To ensure a continuous power supply.
  • Critical infrastructure: Such as hospitals and data centres, where stable electricity is essential.
  • Renewable energy projects: Requiring reliable backup solutions for variable generation.

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Challenges and Future of Hybrid Power Generation

Despite their benefits, implementing hybrid systems also presents challenges, such as:

  • High initial costs, although offset by long-term savings.
  • Need for advanced technologies, for efficient management of multiple energy sources.
  • Battery and equipment maintenance, to ensure performance and longevity.

Nevertheless, technological advancements and the growing demand for sustainable solutions are driving their adoption.
Parque solar

The Evolution Towards a More Sustainable Energy System

Hybrid energy systems represent the future of electricity generation, combining the reliability of generator sets with the sustainability of renewable energy and storage systems. Their implementation contributes to reducing environmental impact and enables a more resilient and cleaner electricity supply.

Article: Safety Measures for Generator Sets – Prevention and Best Practices

Safety Measures in Generator Sets: Prevention and Best Practices

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Technician performing maintenance on a generator set to prevent breakdowns and ensure proper operation.
Safety in the use of generator sets is essential to prevent accidents and protect workers. These units are crucial in various applications but also carry risks if not handled correctly. It is vital to follow specific regulations and recommendations during installation, operation, and maintenance. This minimises associated hazards and ensures the safe and efficient operation of electric generators.

Importance of Safety Measures

The implementation of safety measures when handling generator sets is fundamental to ensuring a secure environment for both operators and equipment. The risks associated with these generators require special attention and a rigorous management approach.

Risks Associated with the Use of Generator Sets

Some of the most common risks include:

  • Electric shocks: Accidental contact with energised parts can cause serious injuries or even be fatal.
  • Fires: Fuel combustion and overheating can lead to fires, particularly if storage or maintenance conditions are inadequate.
  • Exposure to harmful gases: Exhaust gases, such as carbon monoxide, are invisible and odourless. Inhalation can be fatal if proper precautions are not taken.
  • Excessive noise: The noise levels produced by generator sets can cause hearing damage if adequate protection is not used.

Safety Regulations to Follow

Safety regulations are essential to minimising risks associated with the use of generator sets. These rules provide a framework that all organisations must follow. Some of the most relevant include:

  • Local and national regulations: Compliance with the standards set by the relevant authorities is crucial for safety.
  • Manufacturer’s instructions: Following the manufacturer’s recommendations regarding installation, operation, and maintenance ensures the safe use of the equipment.
  • Personnel training: Properly training personnel involved in the operation and maintenance of the generator set is vital to preventing accidents.
  • Regular maintenance: Preventive maintenance based on specific regulations helps identify and correct potential faults before they become hazards.

Safe Installation of Generator Sets

The installation of generator sets is a critical process that requires meticulous attention to detail.
Proper assembly not only ensures efficient operation but also minimises potential risks associated with the equipment.

The risks associated with these generators require special attention and a rigorous management approach.

Component and Equipment Inspection

Before installing a generator set, it is essential to conduct a thorough inspection of all components and equipment. A preliminary check reduces the likelihood of failures and ensures that the unit is in optimal condition for operation.

Proper Ventilation and Exhaust Gas Management

Adequate ventilation is crucial to prevent the accumulation of harmful gases during generator operation. The following guidelines should be observed:

  • Ensure the installation area has sufficient airflow, directing exhaust outlets to open spaces.
  • Install mechanical ventilation systems if necessary, particularly in enclosed spaces.
  • Conduct regular checks on the exhaust system to prevent blockages.

Proper handling of exhaust gases contributes to personnel safety and extends the lifespan of the equipment.

Considerations During Transport

Transporting generator sets also requires specific safety measures to prevent damage that could compromise their future performance. Some key measures include:

  • Using appropriate lifting equipment to move the generator and avoiding manual handling whenever possible.
  • Securing external components to prevent movement during transport.
  • Inspecting the generator upon arrival at the installation site to ensure it has not suffered damage.

These considerations are essential to ensuring that the generator set functions safely and effectively from the outset.
View of Genesal Energy’s generator set production plant with technicians reviewing blueprints to ensure a safe and efficient installation.

Operational Safety Standards

The safe operation of generator sets is fundamental to avoiding risks and ensuring a continuous power supply. Certain rules and procedures must be followed to guarantee operability and protect all involved.

Access Control and Authorised Personnel

Access to areas where generator sets are located must be strictly controlled. It is crucial to limit entry to authorised and properly trained personnel. The following guidelines should be implemented:

  • Identifying all workers with direct access to the generator.
  • Prohibiting entry to unauthorised individuals, including visitors and employees from other areas.
  • Establishing clearly marked security zones.

Inspections and Preventive Maintenance

Regular inspections are essential for detecting potential failures before they become major problems. These inspections should include:

  • Visual checks of the generator set’s general condition, including electrical connections and ventilation systems.
  • Verification of the proper functioning of all safety devices.
  • Scheduled preventive maintenance according to the manufacturer’s recommendations.

Knowledge of safety procedures and efficient equipment operation is key to minimising risks.

Load Control and Generator Power Capacity

It is crucial not to exceed the generator set’s power capacity, as this can cause failures and compromise safety. The following precautions are necessary:

  • Installing devices to monitor the connected load and generator capabilities.
  • Training personnel on the equipment’s load specifications and limitations.
  • Prohibiting the connection of devices that exceed the generator’s maximum capacity.

Proper Use of Protective Equipment

The correct use of protective equipment is fundamental to ensuring the safety of personnel working with generator sets. Proper use of clothing and protective gear minimises the risk of accidents and ensures a safe working environment.

Protective Clothing and Personal Equipment

Appropriate clothing is an essential aspect that must not be overlooked. Personnel should wear specific attire designed to minimise risks, including:

  • Fitted clothing: Loose garments should be avoided, as they can become entangled in moving parts of the generator.
  • Safety footwear: It should be sturdy, non-slip, and provide adequate protection against sharp or heavy objects.
  • Protective gloves: Gloves should offer insulation against electric shocks and mechanical protection.
  • Eye protection: Safety glasses are crucial for protecting the eyes from flying particles during generator operation.
  • Hearing protection: Earplugs or earmuffs are recommended to reduce exposure to the intense noise generated by the equipment.

Personal protective equipment for working with generator sets: helmet, safety glasses and gloves.

Electrical and Mechanical Protections

In addition to clothing, electrical and mechanical protections are essential for maintaining a safe working environment. These protections include:

  • Ground connections: All metallic parts must be correctly grounded to prevent electric shocks.
  • Component insulation: Active generator parts should be properly insulated to avoid accidental contact.
  • Protective covers: Moving parts of the generator set should be protected with covers to prevent entrapment.
  • Soundproof enclosures: In industrial spaces, enclosures help reduce noise levels and protect the equipment from adverse environmental conditions.
  • Hazard area signage: Warning signs should indicate risk areas and restrict access to unauthorised personnel.

Safety in Generator Set Maintenance

Maintaining generator sets is crucial to ensuring their continuous and safe operation. Implementing proper procedures and training personnel are fundamental aspects of preventing accidents and ensuring equipment efficiency.

Disconnection and Safe Procedures

Before carrying out any maintenance work, it is essential to disconnect the generator set from the electrical network. This step is crucial to avoid electrocution and other potential accidents. The following procedures should be followed:

  • Conduct a visual check to ensure the generator is completely switched off.
  • Use lockout and tagout systems to indicate that the equipment is out of service.
  • Ensure all tools and materials are prepared before starting maintenance to avoid improvisation.

By following these guidelines, the likelihood of accidents is minimised, creating a safer working environment for personnel.

The safe operation of generator sets is fundamental to avoiding risks and ensuring a continuous power supply.

Maintenance Operation Records

Documenting all maintenance operations is essential for ensuring an accessible and clear history of the generator set’s condition. Keeping detailed records allows:

  • Performance evaluation of the generator over time.
  • Identification of patterns in recurring faults or problems.
  • Compliance with maintenance regulations, which is crucial for worker safety.

Implementing an organised record-keeping system facilitates maintenance management and ensures that all established guidelines are followed.
Genesal Energy technicians performing safety and functionality tests.

Continuous Staff Training

Training personnel responsible for generator set maintenance must be ongoing. Knowledge of safety procedures and efficient equipment operation is key to minimising risks. The following measures are recommended:

  • Conducting regular courses on electrical safety and emergency management.
  • Providing training on the proper use of personal protective equipment (PPE).
  • Updating personnel on industry innovations and regulations that may impact maintenance and safety.

This training not only enhances workplace safety but also improves the efficiency of generator set operation, extending its lifespan.

Article: Technology Trends for Generator Sets in 2025

Technological Trends in Power Generators for 2025

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Sunlight filtering through tree leaves, symbolising sustainability and renewable energy
Power generators have undergone significant evolution in recent years, adapting to the increasing energy demand and technological advancements. In 2025, the industry will focus on optimising efficiency, sustainability, and flexibility, aligning with the new challenges of the energy sector.

Technological Advancements in Power Generators for 2025

Innovations in electrical generators are geared towards improvements in automation, digitalisation, and energy efficiency. Key trends include:

  • Smart Monitoring: Through the integration of IoT and management software, generators optimise their operation, reducing costs and enhancing performance.
  • Enhanced Reliability: Ensuring an emergency power supply prevents operational issues in renewable energy plants, increasing their uptime.
  • Hybrid Systems: The combination of traditional generators with batteries allows for better energy utilisation and reduced fuel consumption.

Solar panels and wind turbine next to a symbolic lightbulb with green DNA, representing the integration of renewable energy and technology in power generation.

Renewable Energy and Its Impact on Power Generators

Renewable energy sources, particularly solar photovoltaic and wind, are becoming key players in the global energy landscape. However, they rely on non-controllable resources, making it essential to address their intermittent generation. Sudden power losses can lead to voltage dips or issues in plant electronic equipment. In the event of a failure or reduced generation, a reliable backup energy source is crucial. Power generators play a vital role in this sector due to their rapid start-up, power ramp-up capabilities, and flexibility in load acceptance and shedding.

More Efficient and Sustainable Generators

The primary goal in the sector is to minimise environmental impact while enhancing operational efficiency. Some strategies to achieve this include:

  • Low-Consumption Engines: Designed to optimise fuel usage and improve energy production.
  • Emissions Reduction Systems: Integration of filtration and catalytic technologies to minimise pollutants.
  • Alternative Fuels: The use of fuels such as HVO or biogas significantly reduces net emissions, minimising the environmental footprint of these systems.
  • Heat Recovery: Repurposing generated heat to enhance overall system efficiency.

Environmental regulations are driving the development of technological solutions to lower greenhouse gas emissions. Manufacturers are investing in new technologies to ensure power generators are cleaner without compromising performance.

Growing Demand for Power Generators

The rising energy demand has led to an increased need for reliable solutions. Key industries, such as technology and healthcare, require effective backup systems to guarantee a continuous power supply.

In 2025, the industry will focus on optimising efficiency, sustainability, and flexibility, aligning with the new challenges of the energy sector.

The growth of data centres, for example, has created significant demand for generators to ensure operational continuity. With the rise of digitalisation and cloud data storage, an uninterrupted power supply is crucial to prevent data loss or disruptions to essential services.

Another factor driving the demand for power generators is the expansion of renewable energy. While these energy sources are essential for a more sustainable future, they also pose intermittency challenges. Electrical generators serve as a vital backup solution to complement renewable energy production.
Genesal Energy Stage V generator set with open canopy, designed to meet European emission regulations and ensure maximum energy efficiency.

Climate Change and Its Influence on Energy Generation

Extreme weather conditions have impacted grid stability, increasing the necessity for alternative energy systems. Power generators are evolving to meet these challenges, integrating technologies that enhance their performance in adverse conditions.

For instance, the rise in wildfires, hurricanes, and storms has led to prolonged power outages in various parts of the world. In such cases, power generators have proven to be a reliable solution to ensure energy supply in hospitals, critical infrastructure, and affected communities.

Future Outlook for Power Generators

The path towards more efficient and sustainable energy generation is already underway.

Another factor driving the demand for power generators is the expansion of renewable energy.

The development of new technologies will enable power generators to be not only more fuel-efficient but also smarter. These systems’ ability to anticipate failures, regulate their operation according to demand, and synchronise with other energy sources will contribute to the creation of more resilient and sustainable energy infrastructures.

The operational flexibility and high reliability of power generators make them the perfect backup solution for the future industry, which is expected to be defined by the proliferation of critical systems and increasing electrification.

First generator set company to receive ISO 14006 certification

We are the first generator set company to obtain ISO 14006 certification

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Genesal Energy’s ISO 14006 Certification

A firm step towards sustainability in distributed power generation

Genesal Energy has achieved another milestone that reinforces our commitment to sustainability: we are the first company in the generator set sector to obtain ISO 14006 certification. This recognition endorses our commitment to eco-design as an essential part of our business strategy, ensuring that we reduce the environmental impact of our solutions without compromising their reliability and quality.

ISO 14006 certification accredits the integration of eco-design in our manufacturing processes.

Each of our generator sets minimises its environmental impact throughout its life cycle. This achievement not only reinforces our position within a sector in constant evolution but also allows us to respond to a growing demand from customers who are looking for solutions adapted to increasingly demanding regulations in terms of sustainability and environmental efficiency.

Ecodesign for a more sustainable future

Ecodesign allows us to optimise the use of materials, reduce waste and minimise the environmental footprint of our products without affecting their performance. In strategic sectors such as Data Centres, where reliability and sustainability are key factors, offering energy solutions certified under eco-design standards makes us a strategic partner for companies seeking to reduce their environmental impact and align with global decarbonisation objectives.

Logo and ISO 14006 Certificate
To achieve this milestone, we have implemented several actions focused on improving the environmental impact of our products. We have optimised design to reduce the use of materials and integrated new methodologies into our manufacturing processes, such as 3D printing of components, which allows us to reduce the waste of resources. We are also working to incorporate biofuels and other sustainable alternatives that reduce emissions during the equipment testing phase.

These initiatives are in addition to a comprehensive Life Cycle Assessment (LCA), which identifies continuous improvements at every stage of the product from concept to end of life.

‘Achieving ISO 14006 certification is a reflection of our long-term vision and our willingness to lead the sustainable transformation of our industry. We not only respond to current market needs but also anticipate future requirements to offer our customers solutions that meet the highest environmental standards,’ explains Julio Arca Ruibal, co-CEO of Genesal Energy.

With this certification, we reaffirm our role in the energy transition and consolidate our position as a benchmark in distributed energy generation with the lowest possible environmental impact. Genesal Energy continues to move forward to offer solutions that not only provide energy but do so in a responsible and sustainable way.

PROJECT CO-FINANCED BY THE XUNTA DE GALICIA