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

Safety Measures in Generator Sets: Prevention and Best Practices

12 March 2025/in Articles, Communication/by Gestor

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.

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.

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.

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

12 March 2025/in Articles, Communication/by Gestor

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.

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.

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

10 March 2025/in News/by creativo

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.

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

Engineering, Sustainability, and Innovation: Key Pillars for Meeting European Taxonomy Standards

27 February 2025/in Articles, Communication/by creativo

“The transition to a low-carbon economy requires a fundamental transformation in the way businesses operate, and the EU Taxonomy is essential for guiding and supporting this transformation.” – European Investment Bank (EIB)

Energy transition is at the heart of European policies, with the clear aim of reducing greenhouse gas emissions and promoting sustainability through activities aligned with the European Union’s environmental objectives. However, the generator sector, often perceived as having a significant environmental impact due to the use of fossil fuels, has been excluded from the European Taxonomy for sustainable economic activities. This situation has sparked a debate about the role that power generators can play in the energy transition.

In this article, we explore how the generator sector, particularly emergency generators, cannot only meet the expectations of the European Taxonomy but also lead the way in the energy transition towards a more efficient and environmentally friendly industry.

Let’s Start from the Beginning: What is the European Taxonomy?

The European Taxonomy is a classification system designed to help identify and guide investments towards environmentally sustainable economic activities. This classification enables investors, businesses, and policy makers to make informed decisions about which activities can contribute to the EU’s climate and sustainability goals, aligning with the European Green Deal.

Taxonomy establishes a set of key pillars that define what qualifies as a sustainable economic activity and the criteria that must be met for an activity to be considered aligned with the EU’s environmental targets.

These pillars, essential for ensuring that investments flow into sectors that genuinely contribute to a greener and more sustainable future, are as follows:

Climate Change Mitigation: This principle advocates for the development of activities that help to reduce greenhouse gas (GHG) emissions, which are responsible for global warming. Activities that contribute to climate change mitigation include the adoption and expansion of renewable energy sources and those that enhance energy efficiency in buildings, industry, and transport.
Additionally, mitigation involves transitioning to sustainable mobility models, such as electric vehicles, and promoting agricultural and land-use practices that sequester carbon instead of releasing it, such as regenerative agriculture or reforestation.
Climate Change Adaptation: This refers to activities that increase the resilience of natural and human systems to the impacts of climate change. It is one of the most crucial pillars, especially given that the effects of climate change are already evident and will continue to intensify in the coming decades.
Adaptation activities include improving urban infrastructure to make it more resistant to extreme weather events such as floods or heatwaves. Also included in this category are initiatives that promote sustainable water management and the adaptation of agriculture to new climatic conditions, with drought-resistant crops or more efficient irrigation techniques.
Protection and Restoration of Ecosystems and Biodiversity: The loss of biodiversity and the degradation of natural ecosystems are among the most severe consequences of climate change. For this reason, the Taxonomy encourages activities that help preserve existing ecosystems and restore damaged ones, contributing to the long-term sustainability of life on Earth.
This includes reforestation projects, the creation of protected areas to conserve natural habitats and endangered species, as well as sustainable agricultural practices that protect soils and water bodies. Furthermore, the protection of marine ecosystems and the restoration of aquatic habitats are also essential for maintaining biodiversity and ecosystem services such as water purification and climate regulation.
Circular Economy: This pillar promotes activities aimed at minimising waste and maximising the reuse of resources, such as recycling, material reuse, and the design of products that are easily recyclable or require fewer resources for production.
However, the circular economy is not only about waste reduction—it is also linked to reducing the extraction of natural resources by promoting the recovery of materials from discarded products, thereby reducing pressure on ecosystems and minimising the carbon footprint.

For an activity to be considered aligned with the European Taxonomy, it must meet a set of specific technical criteria that significantly contribute to the objectives mentioned. These criteria focus not only on activities that generate a direct positive environmental impact but also on the principle of “Do No Significant Harm” (DNSH) to other objectives. This means that, in addition to positively contributing to one of the pillars, an activity must not harm other sustainability aspects, such as biodiversity or human health.

This comprehensive approach ensures that investments and activities aligned with the Taxonomy are not only environmentally responsible but also promote sustainable economic development that is socially inclusive and does not cause long-term damage to natural resources.

Why Should This Not Be the Case? The Crucial Role of Power Generators

The exclusion of the generator sector from the eligible activities under the Taxonomy could overlook the fundamental role these machines play in the energy transition. Emergency generators are essential for ensuring the security and reliability of electricity supply. As the integration of renewable energy sources into the power grid increases, so does the need to secure a stable and reliable energy supply. Renewable energy sources such as solar and wind are inherently variable, which can lead to fluctuations in electricity generation.

In this context, emergency generators act as a safeguard for the power grid, rapidly compensating for any drop in generation and maintaining grid stability.

Furthermore, technological advancements have made it possible to design emergency generators that use sustainable fuels, such as HVO (hydrotreated vegetable oil), and emission reduction technologies. Solutions such as gas post-treatment systems, including diesel particulate filters (DPF), selective catalytic reduction (SCR), and urea injection, enable generators to operate with a significantly lower carbon footprint, aligning with the EU’s sustainability goals and contributing to the transition to a low-carbon economy. Additionally, the limited use of these generators—typically operating only a few hours per year—minimises their environmental impact, as their emissions are negligible compared to continuous energy generation sources.

Moreover, new innovations enable generators to be more fuel-efficient and minimise emissions. The adoption of technologies such as thermal insulation systems enhances not only safety but also the operational efficiency of these generators. This makes emergency generators an integral part of sustainable infrastructure, ensuring grid stability while supporting the integration of renewable energy and providing reliable backup power when it is most needed.

A Case Study from Genesal Energy

At Genesal Energy, we have developed several projects that serve as clear examples of how the generator sector can adapt to the sustainability standards imposed by the European Taxonomy. Recently, we carried out a project that demonstrates that, through engineering, it is possible to integrate solutions into these machines that reduce their environmental impact without compromising their reliability and efficiency.

A key aspect of this project was compliance with highly stringent emissions regulations in Belgium. To achieve this, advanced gas post-treatment systems were incorporated, including diesel particulate filters (DPF) and selective catalytic reduction (SCR) with urea injection. These technologies minimise pollutant emissions to the maximum, aligning with the most demanding environmental standards.

Additionally, the generator design included solutions that optimise energy efficiency and ensure safety in harsh environments. Custom load steps were implemented to improve energy consumption, and fuel heaters were added to ensure operability in low temperatures with ATEX (Explosive Atmosphere) certification for maximum safety. Leak detection systems and liquid collection trays were also installed, reinforcing environmental protection.

<blockquote class=”bq-border”>To ensure efficient and safe operation, the project incorporated an independent electrical room equipped with a remote control panel, allowing remote management of the generators.</blockquote>

Medium-voltage grounding resistors and a medium-voltage switchgear with automatic circuit breakers were also added to integrate with the plant’s installation requirements.

Finally, special attention was given to reducing acoustic impact, incorporating soundproofing solutions to keep noise levels below 80 dB at 1m under normal operating conditions, significantly reducing noise emissions. Motorised grilles were also included to isolate the generators from the environment during inactivity periods, optimising efficiency and extending their lifespan.

This case demonstrates that, thanks to new technological solutions, sustainability can be a fundamental aspect of the generator sector, enabling compliance with the strictest European Taxonomy and environmental regulations while contributing to the transition to a cleaner and more efficient energy model.

Most Common Failures in Generator Sets

21 February 2025/in Articles, Communication/by Gestor

Generator sets are essential tools for energy supply in various situations. However, they can experience failures that affect their performance and reliability. It is crucial to understand the main causes of these failures and how to prevent them.

Proper maintenance can extend the lifespan of the generator set and ensure its proper operation.

Main Causes of Failures in Generator Sets

Generator sets can suffer from various failures, primarily due to a lack of maintenance or improper use. Below are the most common causes that can affect their performance.

Fuel Issues

One of the most frequent problems is related to fuel. Running out of fuel or using the wrong type can prevent the generator from starting. Some common causes include:

Lack of fuel: The generator will not function if the tank is empty.
Incorrect fuel type: Using an unsuitable fuel can damage the engine.

Battery Failures

The battery is essential for starting the generator set. Its failures can be caused by:

Loose connections: Poorly connected cables can prevent startup.
Discharged battery: Particularly problematic if the generator is not used frequently.
Sulfate accumulation: Can obstruct contacts and prevent proper operation.

Oil Leaks

Oil leaks affect both the efficiency and safety of the generator. If unchecked, they can lead to fires. Regular oil level inspections are essential to prevent this issue.

Switches and Fuses

These components are crucial for the protection of the generator set. Failures can result in unexpected shutdowns. Regular maintenance and timely replacement of damaged fuses or switches are vital.

Insufficient Energy Production

A lack of power output can have several causes, such as:

Overload: Connecting too many devices can exceed the generator’s capacity.
Connection system issues: Checking cables and connections is essential for proper operation.

Air Leaks in the Fuel System

Air infiltration into the fuel system is a common issue when the generator remains inactive for extended periods. It leads to difficulties in starting. Proper system maintenance can prevent this situation.

Electrical Panel Failures

The electrical panel can experience failures due to prolonged use or vibrations. Generally, replacing the faulty component is required to restore its function.

Exhaust System Issues

The exhaust system must function correctly to prevent combustion gases from entering the generator’s housing.

Regular checks of silencers and joints are vital to ensuring safe generator operation.

Maintenance and Failure Prevention

Recommendations for Regular Maintenance

Preventive maintenance should include scheduled activities to ensure the generator operates correctly. Key recommendations include:

Regular oil changes and replacement of air and fuel filters.
Scheduled inspections to detect and resolve issues before they become major failures.
Cleaning components to remove dirt and debris that could affect performance.

How to Prevent Overheating

Overheating can cause severe engine damage. Implementing preventive measures is essential.

Importance of the Air Filter: A clean air filter allows the proper airflow to the engine, which is essential for efficient combustion and preventing overheating. Regularly inspecting and replacing the air filter is recommended.
Checking the Coolant Level: Maintaining the correct coolant level in the cooling system prevents overheating. Inspecting the system for leaks or decreasing fluid levels is crucial.

Strategies to Prevent Damage

Taking precautions to protect the generator can prevent severe long-term damage. The following strategies are recommended:

Protecting the Generator from Moisture: It is essential to keep the generator in a dry environment. Moisture can cause corrosion and electrical failures. Using appropriate covers and keeping the storage area clean and dry is crucial.
Avoiding Generator Overload: Overloading the generator beyond its designated capacity can damage internal components. Understanding the generator’s rated power and controlling the number of connected devices is essential.

Technical Aspects and Professional Consultancy

Proper generator set operation requires not only good maintenance but also the evaluation of fundamental technical aspects.

Professional consultancy ensures that generators operate under optimal conditions and that technical issues are efficiently resolved.

When to Consult a Technician

It is essential to know when to seek professional assistance to ensure the generator’s performance. Key situations include:

Recurring failures: If the generator frequently experiences issues, a technician can diagnose the root cause.
Poor performance: If the generator is not producing the required energy, professional intervention is crucial.
Advanced maintenance: For inspections that require in-depth technical knowledge, hiring a specialist is advisable.

Importance of a Properly Sized Generator Set

Choosing a well-sized and reliable generator set is fundamental to ensuring optimal performance. A high-quality generator offers significant advantages, including:

Greater durability: Recognised brands manufacture generators with high-quality materials, making them more resistant.
Lower maintenance costs: A good generator includes high-quality components that reduce the risk of failures and repair costs.
Better performance: These units are generally more efficient in power production, leading to lower fuel consumption.

How to Extend the Generator’s Lifespan

Proper maintenance and handling of the generator are essential to prolong its lifespan. Several strategies can be adopted, including:

Scheduling regular maintenance: Regular inspections help identify problems before they become major failures.
Using quality fuel: Suitable fuel improves engine performance and reduces internal component wear.
Controlling the operating environment: Keeping the generator in a dry and well-ventilated location enhances its longevity and reduces the risk of corrosion.

Article: Difference Between a Generator Set and a Generator

Electric Generator vs Genset: Key Differences

21 February 2025/in Articles, Communication/by Gestor

What is the difference between an electric generator and a generator set? Both devices have the same objective: to provide electrical power. This is why the two concepts are often confused.

Technically, an electric generator is a component designed to convert mechanical energy (motion) into electrical energy. In contrast, a generator set is a complete system that integrates an electric generator and an internal combustion engine, allowing it to function autonomously.

Defining the Concepts

Understanding the fundamental concepts of electric generators and generator sets is essential for correctly using both terms.

Electric Generator

An electric generator is a device that transforms mechanical energy into electrical energy. This transformation occurs through a rotating system where a rotor generates a magnetic field that induces a current in the stator.

Electric generators are commonly used in power plants to generate electricity that can be stored and consumed later. They require an external power source, such as diesel engines (which would form a generator set) or steam turbines, to provide the necessary mechanical energy.

Generator set

A generator set combines an internal combustion engine with an electric generator (also known as an alternator) in a single unit. This equipment is self-sufficient and designed to generate electricity in emergency situations or locations without access to the electrical grid.

When activated, the engine burns fuel to produce mechanical energy, which the alternator then converts into electrical power, ensuring an immediate and reliable energy supply.

Why Is There Confusion Between the Terms?

In everyday use, many people think of an electric generator as a compact unit, such as portable models used in homes or small businesses during power outages. These devices, typically with a capacity of up to 10 kVA, are accessible and practical, ideal for powering household appliances or basic tools.

However, this concept is incorrect. These small units are not just electric generators but small generator sets, as they integrate both an internal combustion engine and an electric generator in a single self-contained unit.

On the other hand, the term generator set is often associated with large industrial electric generators, like those manufactured by Genesal Energy. These units are designed for large-scale projects, with power outputs ranging from 10 kVA to several MVA, and are essential in industrial, healthcare, energy, and critical infrastructure sectors.

This misuse of terminology can lead to confusion when selecting the right equipment or understanding how it functions.

How to Choose the Right Equipment

The choice between an electric generator (or rather, a small generator set) and an industrial generator set depends on the intended use:

Small domestic or commercial applications: Low-power portable units (up to 10 kVA) are usually the best option. Although they are commonly called electric generators, they are technically compact generator sets.
Industrial or large-scale applications: In these cases, it is necessary to opt for industrial generator sets with higher power capacities, capable of ensuring a continuous and reliable power supply, like those in our catalogue.

Although “electric generator” and “generator set” are often used interchangeably in everyday language, it is important to understand their technical differences and applications.

In essence, every generator set contains an electric generator, but not all electric generators are complete generator sets.

Additive Manufacturing and the Path to Sustainability

Additive manufacturing
and the road
to sustainability

4 February 2025/in Articles, Communication/by Gestor

Sustainability has become a priority in all industrial sectors. The need to balance economic growth with environmental preservation is driving the search for innovative technologies to reduce environmental impact at all stages of the industrial process – including product manufacturing.

In this context, additive manufacturing is emerging as an innovative and effective solution for its potential to reduce the amount of raw materials required and waste generated, to the extent that it is already considered one of the fundamental pillars of 4.0 Industry.

What exactly is additive manufacturing?

Traditionally, products are made by removing material from a solid block through various processes, such as cutting, drilling or enamelling. In contrast to this process of ‘subtractive manufacturing’ is ‘additive manufacturing’, where the production of goods is done through the aggregation of material coatings. This addition is done layer by layer until the shape previously defined in a digital model is achieved, so that only the exact amount of material needed to create the part is used.

Fundamental principles
of additive manufacturing

The starting point for any additive manufacturing piece of work is the digital design of the part. Three-dimensional models are translated into two-dimensional layers that can be built up successively using a 3D printer. The materials used vary widely and include plastics, metals, ceramics, composites and even biomaterials.

The main current additive
manufacturing technologies are:

Fused deposition modelling (FDM): uses heated and extruded thermoplastic filaments to build the part layer by layer. It is one of the most accessible and common technologies, especially in domestic use and prototyping.
Selective Laser Sintering (SLS): Uses high-power lasers to fuse powder particles of material, such as plastic or metal, to form solid structures. It is ideal for complex and durable parts.
Steriolithography (SLA): Solidifies photosensitive liquid resins layer by layer using an ultraviolet laser. Produces parts with great detail and high quality surface finishes.
Direct Metal Laser Sintering (DMLS): Designed for metallic materials, this technology fuses metal powders using lasers. It is widely used in the aerospace and medical industries for its ability to create high-precision, high-strength parts.
Binder Jetting: Uses a binding agent to bind layers of powdered material together, which are then solidified by secondary processes such as sintering. It is an efficient technology for mass production of complex parts.

The impact of additive
manufacturing on sustainability

Reducing material waste

One of the most obvious benefits of additive manufacturing is the drastic reduction in material waste compared to the traditional subtractive process. For instance; when manufacturing metal components by milling, up to 90% of the raw material is wasted; whereas, with additive manufacturing, this waste can be almost non-existent. This advantage is particularly relevant in the manufacture of high-cost components, such as titanium in the aerospace industry.

Design optimisation and energy efficiency

The ability to manufacture complex geometries without great costs allows the design of optimised components that would not be feasible using traditional techniques. For example, lightweight lattice structures created through additive manufacturing offer an optimal weight-to-strength ratio, reducing energy consumption during the use of the final product.

Furthermore, the weight reduction often achieved through additive manufacturing – either through the new designs allowed or through the use of a new material for the manufacture of components – can translate into substantial fuel savings in key sectors such as freight transport. This, in turn, means reducing CO₂ emissions and thus the impact on climate change.

Local and decentralised production

Another advantage of additive manufacturing is on-demand production close to the point of use. This decentralisation drastically reduces the need for transportation and warehousing, two of the main contributors to greenhouse gas emissions in traditional supply chains. In addition, the ability to manufacture parts on-site in remote areas reduces dependence on a complex logistics system.

Use of recycled materials

The development of more sustainable materials is driving the adoption of additive manufacturing in contexts such as eco-design. Bioplastics such as PLA (polylactic acid), derived from biological raw materials such as corn, represent viable alternatives to petroleum-based plastics.

Similarly, the use of recycled materials is also on the rise, allowing 3D printed products to contribute to the advancement of the circular economy.

Genesal Energy’s commitment
to additive manufacturing

Although Genesal Energy had already tested additive manufacturing in the context of the NextFactory project, it was not until 2024 that it took the final step towards integrating this technology into its industrial processes. As part of a project co-funded by the Regional Goverment, the company has acquired a state-of-the-art 3D printer with the aim of reducing the carbon footprint of its generator sets.

One of the first initiatives has been the application of this technology in the design of the company’s standard line of generator sets. After appropriate calculations and various modelling and material application tests, it has been demonstrated that the use of 3D printed components not only reduces material waste, but also optimises the performance of the equipment. The results have been so promising that we plan to expand the use of these techniques to the rest of the range in the future.

On top of the environmental benefits, this technology also opens up new possibilities for product customisation and the manufacture of complex parts that improve the operational efficiency of gensets. This reinforces Genesal Energy’s commitment to innovation and sustainability in the customised energy sector.

We toast to energy that thinks about the future.

Genesal Energy raises a toast to “energy that thinks about the future”

22 January 2025/in Communication, News/by Gestor

Genesal Energy looks to the future with determination and enthusiasm, promoting projects that combine innovation, sustainability and knowledge. This year we have taken key steps towards a future that will be marked by the constant development of technology and energy transition. Namely, we have tested sustainable fuels in our generator sets, developed our own hydrogen electrolyser, and made our social commitment clear with the creation of the Genesal Energy Foundation.

We have increased our turnover by 15% in 2024.

Without a doubt, 2024 has been a year to celebrate: the challenges and goals achieved, the joint effort of those who are part of Genesal Energy, our 30th anniversary, each customised project done with care and attention. Every step brings us closer to a brighter, more efficient and responsible future.

Three decades after our founding, Genesal Energy keeps growing every year, and reaching in 2024 a turnover of 27 million euros as a business group. At a time of changes in the distributed energy sector, we look to the future with the security that comes from experience.

The data centre sector, a manageable challenge

Data Processing Centres – which are driving digital transformation at a global level – are a market in continuous growth which demands precision, reliability and adaptability. This year has been key to consolidating our position as a benchmark in energy solutions for this type of critical facility.

We attended the Data Centre World in London, one of the most important trade fairs in the sector, where we presented our latest innovations in generator sets designed to ensure maximum reliability and sustainability. For two days, at the leading forum for data centre professionals, we shared our cutting-edge solutions adapted to the most demanding standards.

We also organised an event in Madrid, where data centre experts enjoyed training talks, networking and special activities in collaboration with leading engine manufacturers such as Baudouin.

These actions reinforce our vocation to always be close to our customers and professionals in the sector, offering them tailor-made solutions that guarantee the best energy performance.

Technological innovation and sustainability

2024 was also the year of major advances on our path towards a more sustainable future, with key projects such as the integration of Hydrotreated Vegetable Oil into our gensets.

HVO, a second-generation biofuel, is obtained from raw materials as simple as used cooking oil and its possibilities are immense.

It lasts up to ten times longer than diesel and its performance is maintained at extreme temperatures, also lowering the carbon footprint.

Moreover, the commitment to Hydrogen is becoming more and more tangible. Through the H2OG project, we are developing hydrogen production equipment – our own electrolyser -. In the medium term, this knowledge will lay the foundations for the optimal integration of this energy vector into our management and storage system. In addition, it will also provide us with the keys to ensure that our generator sets run on this fuel.

This project began with the design of a small-scale electrolyser, which allows us to validate its operation and guarantee the expected results. Before building the final, larger equipment, it is allowing us to solve not anticipated problems before its final integration into the production system. This, in turn, results in cost reductions.

Technological innovation continued with the implementation of projects such as the creation of an augmented reality application that enhances the customer experience by allowing them to visualise and explore generator sets ‘in situ’ in a virtual environment.

Commitment to the future: from The Chair to Genesal Foundation

Sustainability and technological progress have always guided our vision, and we reaffirm our values through the initiatives of the Energy Transition Chair, culminating in the creation of the Genesal Energy Foundation, which will mark a new stage in our social work.

From the Chair, we have developed meetings such as the Seminar on the Corporate Carbon Footprint for SMEs and the Sustainable Fuels Seminar, spaces designed to promote knowledge and provide tools that promote the energy transition. We also organised the third edition of the award for the Best Final Degree or Master’s Project in Energy Transition, supporting young talent and innovative ideas that will shape the future of the sector.

Another milestone was the seminar Women STEM and Energy Transition, an initiative that seeks to promote female participation in the technology and energy sectors, achieving sustainable and inclusive development.

The year ended with a major event: the creation of the Genesal Energy Foundation, an entity that was created with the aim of being a driving force for change. This project represents our desire to go beyond the business sphere and actively contribute to a more equitable and environmentally friendly society.

Solid growth and New Awards

Undeniably, the last twelve months have been marked by continuous growth, with a 15% increase in turnover and an expanding team. These results were added to external recognition, such as the Potencia 2024 Award in the category ‘Auxiliary Machinery’, which positions Genesal Energy as a top player in innovative high-power solutions. A recognition to the professionalism of the team of engineers who design the units and the rest of the team who make them a reality.

The opening of a new technical assistance site in the Basque Country marked an important step in the national expansion.

Meanwhile, on an international level, we have participated in more than a hundred projects on almost every continent.

We have managed to ensure the supply in sugar factories in Tanzania, guarantee the medical and vital care of one of the main hospitals in La Paz in Bolivia, or provide a data centre in Norway with generators capable of supplying the emergency network under very adverse weather conditions.

Genesal Energy’s gensets are also present in major European infrastructures, such as Greenlink (bringing clean energy to thousands of people between Ireland and Wales), the main airports or the largest engineering research centre in Spain.

2024 closes a chapter full of achievements but opens an even more exciting one. Here’s to the commitment, passion, humility and hard work of all the people who make it possible for Genesal Energy to continue writing its history. Because the best is yet to come, and together we are ready to face it.

Biogas and biomethane: key players in the circular economy and the energy transition

13 January 2025/in Articles, Communication/by Gestor

“Biogas and biomethane stand out within the bio circularity ecosystem for their ability to offer immediate and viable solutions in the ecological transition.”

Margarita de Gregorio, CEO of Biocirc.

One of the fundamental aspects in the fight against climate change is the economy. Currently, the linear economy, based on the ‘extract, produce, consume and dispose’ model, contributes significantly to the environmental crisis by prioritising economic profit and ignoring sustainability. This way of acting leads to a depletion of natural resources, the generation of large amounts of waste and the emission of greenhouse gases.

It is therefore crucial to move towards what is known as the ‘circular economy’. This new economic system promotes the management and recovery of waste to keep it in the production cycle for as long as possible. This helps to reduce both the consumption of raw materials, and the amount of waste generated.

The part of the circular economy that addresses the production cycle of those sectors whose raw materials are of biological origin is known as bio circularity. This approach makes it possible to replace raw materials of fossil origin with others of renewable origin, while at the same time reusing organic waste, contributing to the decarbonisation of multiple sectors and to a more sustainable management of waste.

In this context, biogas and biomethane play crucial roles thanks to their ability to regenerate natural systems and contribute to the energy transition. But first things first…

What is biogas and biomethane?

Biogas is a renewable, carbon-neutral gas produced from the anaerobic digestion of organic matter, i.e. from the biodegradation of organic waste in the absence of oxygen. Thus, during this process, which takes place in an airtight tank or digester, the carbohydrates, proteins and lipids present in the waste are broken down by a series of bacteria, releasing a mixture of gases known as biogas. In addition, digestate, a biosolid with high fertiliser capacity, is also obtained as a by-product.

The composition of biogas varies depending on the waste used as raw material or substrate, although it is usually between 50-75% methane (CH₄) and 25-45% carbon dioxide (CO₂), with small amounts of other gases such as hydrogen sulphide (H₂S), ammonia (NH₃), volatile organic compounds (VOC) and water vapour.

Of the aforementioned, the methane concentration is the most relevant factor, as it determines the calorific value of the fuel. 1 m³ of biogas with a composition of 50% CH₄ would produce 5 kWh of energy, replacing 0.50 m³ of natural gas; whereas, if the methane composition is raised to 65%, the same cubic metre of biogas would produce 6.40 kWh of energy, replacing 0.65 m³ of natural gas. [These calculations are based on the lower calorific value of natural gas (10.83 kWh/m³)].

On the other hand, before being used as energy, biogas must undergo a process to remove impurities that can cause damage to the installations and reduce the efficiency of the system. H₂S, for example, is highly corrosive and can damage motors, turbines and other equipment if it is not removed adequately. In addition, water vapour reduces the calorific value of the biogas, which is why it is essential to separate it.

After this process, biogas is suitable for use as a fuel in the production of heat in gas boilers or in the generation of electricity through combustion engines, among others.

However, to broaden its applications, biogas can undergo an additional process, known as ‘upgrading’, for the production of biomethane. This process involves the almost total elimination of CO₂ and other residual compounds, raising the methane concentration to more than 95%. The result is a renewable gas with energy-characteristics comparable to fossil natural gas.

The advantage of biomethane over biogas lies in its higher calorific value and its ability to replace natural gas, thanks to its high methane content. This allows biomethane to be injected directly into the existing gas grid, extending its use to sectors such as transport, industry and residential. Its integration into existing infrastructure makes it an immediate decarbonisation solution, especially compared to other renewable gases, which require the development of specific infrastructures. Moreover, if biogenic CO₂ capture is carried out during its production, biomethane can achieve negative carbon emissions.

Opportunities in the valorisation of organic waste

The dual benefits of biogas and biomethane – as a renewable energy source and a climate mitigation tool – are sufficient to take them into account in the transition to a sustainable, low-carbon energy system. But their use has advantages that go far beyond the simple production of energy, as the production of these biofuels is also emerging as an innovative and sustainable solution for the valuation of organic waste produced by various economic sectors.

Currently, part of this waste is managed inefficiently and it often ends up polluting soil, water and the atmosphere itself, which has a high environmental impact. In this context, anaerobic digestion can play a key role in managing waste such as the following:

Livestock sector: Livestock waste, such as manure, slurry, animal bedding and cleaning water, can lead to the incorporation of heavy metals into the soil, the pollution of water by excess nitrates or the emission of ammonia into the atmosphere if not properly managed.
Agricultural sector: Agricultural residues, including pruning, wood and herbaceous waste, are often inefficiently managed through indiscriminate burning or abandonment, contributing to environmental degradation, fires and the spread of pests.
Food sector: Slaughterhouse rejects, waste from the fishing industry, organic waste and liquid by-products from the dairy industry, or fruit or vegetable scraps that are not reused can end up rotting in landfills, where they emit methane, a gas with a warming potential 21 times greater than CO₂.
Municipal Solid Waste (MSW): The organic fraction of municipal solid waste (MSW), such as food waste or domestic pruning, can be biodegraded and reused to produce energy or natural fertilisers. This process also contributes to achieving the recycling targets set out in Law 7/2022 on Waste and Contaminated Soils, which allows further progress towards a circular economy by reducing municipal waste.
Wastewater Treatment Plants (WWTP): Sludge generated in wastewater treatment represents a costly challenge for WWTPs, as its management can account for up to 50% of operational costs. Anaerobic digestion can reduce the volume of sludge and generate biogas, turning a problematic waste into a renewable source of energy.

In other words, biogas and biomethane stand out not only as renewable energy sources and tools for decarbonisation, but also for their ability to reduce dependence on fossil fuels, bringing greater flexibility to the energy system.

Their ability to decarbonise sectors that are difficult to electrify is particularly valuable in the transition to a cleaner energy model.

In addition, anaerobic digestion technology is already well established, and the necessary infrastructure is available, making biogas and biomethane an immediate solution.

A crucial added value of these sources is their contribution to the circular economy, since, as we have seen, they allow the revalorisation of organic waste generated by various sectors. Not only do they significantly reduce waste, but they also create new opportunities in sustainable and circular value chains, especially on a small scale and in rural environments. This approach favours the dynamisation of these areas, while contributing to the fulfilment of the objectives of the bioeconomy in Spain, promoting a more balanced and sustainable model of economic development.

Picture 1. Biogas value chain

Biogas and Biomethane Genesal Energy gensets

Genesal Energy is fully aware of the enormous potential of renewable gases and the importance of the circular economy. We participate in projects that promote the valorisation of waste to transform it into valuable resources such as biofuels. These gases can be used on gas power gensets, taking a further step towards a sustainable energy model by not only using a renewable source instead of conventional fossil diesel, but also a source generated from the reuse of waste that would otherwise end up representing an environmental problem.

Hand in hand with FACSA, SMALLOPS, AIMEN and UVA, we are part of the ENEDAR project – ‘Improving the energy efficiency and sustainability of wastewater treatment plants through the valorisation of WWTP sludge’, financed by the Ministry of Science, Innovation and Universities and the European funds NextGeneration UE/PRTR.

Genesal Energy is here responsible for designing and validating the operation of a generator set powered by fuels from the anaerobic digestion of sewage sludge from a pilot plant; reaffirming our commitment to the energy transition and the creation of immediate and practical solutions for a sustainable future.

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.