Articles Archives - Genesal Energy

Technician contemplating how to connect a generator

How to connect a genset in industrial or commercial installations

19 November 2024/in Articles, Communication/by Gestor

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

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

Basic concepts for the connection of a generating set

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

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

Key requirements include

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

Methods of connection of a generating set to the mains

Direct connection of the generating set to the grid

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

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

Connecting a three-phase genset

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

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

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

Connection to critical systems

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

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

Steps to connect a generator set safely

1. Assessment of the installation’s power and requirements

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

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

2. Configuration of the Automatic Transfer Switchboard (ATS)

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

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

3. Installation of conductors and protections

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

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

4. Connection and synchronisation tests

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

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

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

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

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

Energy security in the fight against climate change

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

19 November 2024/in Articles, Communication/by creativo

For several years now, one of the biggest challenges in the fight against climate change has been related to the energy safety supply.

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

Growth in energy demand

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

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

Impact on power generation

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

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

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

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

Threats to energy infrastructure

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

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

The role of generating sets in energy safety

In this context of increasing energy demand and infrastructure vulnerability, gensets emerge as a vital solution to improve energy security. They act as back-up systems that ensure a continuous supply of electricity during outages or interruptions. Particularly useful for critical facilities, such as hospitals, data centres, wind farms and emergency services, which cannot afford interruptions in their power supply.
In addition, gensets are versatile and can be used in a variety of applications, from industrial operations to residential areas, providing an independent power source that can be tailored to the specific needs of each user. In regions where the electrical infrastructure is more vulnerable to disruptions, gensets can provide an effective emergency power solution, ensuring that communities and industries continue to function even during the most severe weather events.
Finally, the deployment of cleaner and more efficient gensets, powered by renewable fuels or clean energy technologies, can contribute to mitigating greenhouse gas emissions, aligning with long-term sustainability goals.

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

Image of an electrical grid with mains/generator switching

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

19 November 2024/in Articles, Communication/by Gestor

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

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

What is a Mains/Genset switch?

Concept and definition

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

Importance in uninterruptible power supply

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

Mains/Genset switchboards and diagrams

Mains/Genset switchboard: Function and components

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

Types of switching systems

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

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

Manual (local) switching

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

Advantages of Manual Switching

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

Disadvantages of Manual Switching

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

Automatic switching

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

Advantages of automatic switchover

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

Remote switching

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

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

Advantages of remote switching

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

Maintenance and considerations for Mains/Genset switching

Common problems and solutions in unstable networks

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

Maintenance of switchboards

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

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

Check this article for more information on connecting generators.

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

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

21 October 2024/in Articles, Communication/by creativo

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

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

Power

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

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

Fuel type

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

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

Technology and functionalities

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

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

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

Soundproofing options

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

Applications and environment

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

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

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

Summary of factors affecting the price of a generator set

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

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

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

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

How to calculate the generator you need

21 October 2024/in Articles, Communication/by creativo

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

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

How to proceed with power calculation

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

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

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

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

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

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

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

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

Table for calculating the power of a generating set

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

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

How to use this table

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

Environmental conditions affecting genset power requirements

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

Extreme temperatures

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

Altitude

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

Adjustments required according to environmental conditions

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

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

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

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

29 August 2024/in Articles, Communication/by genesal

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

25 July 2024/in Articles, Communication/by creativo

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.

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.

Further information on this behalf: 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.

3. Technical documentation

Complete technical documentation of the genset is prepared, including:

Manuales de usuario: Se desarrollan manuales de usuario claros y detallados que proporcionan instrucciones para la instalación, operación, mantenimiento y solución de problemas del grupo electrógeno.
Esquemas eléctricos: Se crean esquemas detallados que muestran la configuración eléctrica y el funcionamiento de los sistemas del grupo electrógeno.
Listas de piezas: Se elaboran listas de piezas completas que identifican cada componente del grupo electrógeno y su número de pieza correspondiente.
Planos mecánicos dimensionales: Se explican detalles dimensionales y de instalación de los equipos.

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.

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.

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.

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.

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.

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

25 July 2024/in Articles, Communication, News/by creativo

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.

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.

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.

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.

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.

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.

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.

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.

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