Dereating: how Temperature and Elevation Affect Generators

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Testing a generator derating ambient temperature

In certain environmental conditions, generators can suffer power losses. Preventing these will allow us to ensure the maximum efficiency of our equipment.

All engines and alternators are capable of offering 100% capacity when they operate in standard or not so demanding environmental conditions, but when they must function in environments with high ambient temperature or at a high elevation above sea level, their capacities may be reduced.

The engine manufacturers, for instance, usually guarantee a certain performance provided that some values are not exceeded (generally a temperature of 25ºC and 1000 m above sea level). If these values are exceeded, the user has to bear in mind that, very likely, the engine will not perform at its top capacity.

This loss of power in function of temperature and elevation is known as derating, and is something which has to be very much taken into account when it comes to sizing a generator.

Generator dreating in conditions of altitude

Just as it happens to us human beings as we climb higher above sea level, the lack of oxygen and the low pressure affect the performance of the generator.

Elevation affects all kinds of engines, but this effect is more prevalent in atmospheric engines, which depend upon atmospheric pressure for the air to reach the cylinders adequately.  These losses of power may even occur at elevations below 1000 meters.

In the case of turbo engines, the turbine is capable of countering this air deficit. Therefore, generally, the power derating of this type of engines starts to occur at an elevation of 1000 meters above sea level and its effect is inferior to that affecting atmospheric engines.

The alternator also suffers at a higher elevation, given that with less air it tends to overheat. In general, the majority of manufacturers guarantee that the alternators will not lose power until reaching 1000 meters above sea level. At higher values, the average loss of power is generally of 3% for 500 m of elevation.

Generator performance at high temperatures

Generally, temperature affects generator engines starting at 40ºC. Above this ambient temperature: 

  • The air is already very hot and its quality is no longer optimal to generate good combustion when mixed with fuel. This generates loss of power.
  • The fuel may reach the engine at an excessive temperature, and combustion will not take place in adequate conditions. 
  • The efficiency of the cooling system will be diminished. As a result, if the radiator is not correctly sized, the generator can stop functioning due to an excessive water temperature. 

Generator derating ambient temperature

As far as the alternator is concerned, it is also affected by high temperatures. The majority of manufacturers guarantee the power of their alternators, as long as they operate at an ambient temperature of below 40°C. At higher values, the derating in an alternator is generally of 3% for each additional 5º C.

The importance of having foresight

Given all of the above, when sizing a generator, it is crucial to have a clear understanding of the environmental conditions under which it will operate, i.e.: the inferior and superior limits of ambient temperature and barometric pressure in the setting-up location, as well as the elevation above sea level at which the equipment will be located. 

With this clear information provided, we, the engineers, shall be able to foresee and counter the effects of power derating, selecting the most adequate engines and alternators for each equipment.

If your project will be carried out in extraordinary environmental conditions, we at GENESAL ENERGY can advise you and size your generator in such a way that your ideas never lack power.

Genesal Energy consolidates its growth

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The company expands its headquarters by 3,000 square meters in order to increase its production capacity.

Genesal consolida su crecimiento en 2019

Genesal Energy consolidates its growth in order to tackle a 2020 full of projects in Spain and in the demanding international market

The company continues its international expansion in strategic sectors and countries with personalized customer service as well as services like the Technical Assistance Service

Power plants, electric substations, DPCs, hospitals, airports, food and telecommunication sectors. Genesal Energy is present in all of these industries thanks to the versatility and high specialization of its equipment. With more than 25 years’ experience (this year the Galician company celebrates its anniversary) and with branch offices in Mexico and Peru, the company is closing 2019 with constant and controlled growth and with its mind on a new year full of projects. Because Genesal Energy’s objective is to continue growing internationally with a presence in new markets like the Asian giant Taiwan, but also nationally by increasing its production capacity with new installations adding up to 3,300 square meters at its central headquarters in Bergondo (province of A Coruña).

Here are some success stories and challenges for the future.

New rental product lines:

The search for new lines of business within an increasingly competitive market is one of Genesal’s commitments, and the rental line, with some excellent results at the end of the first year of its launch by the company is an excellent example. Reliability and robustness define these gensets destined for the rental market. Following the success of this product line and the official presentation in Mexico, where four generators were subsequently delivered, the company will continue its commitment to these rental products throughout the 2020 fiscal year. They are special products, custom made so as to make maintenance easier, and fitted with state of the art GPS systems for their immediate geolocation in case of theft.

Emergency energy for large health centers: Toledo Hospital (Spain) and Montero Hospital (Bolivia)

Electricity is vital in hospitals and its absence can have fatal consequences, which is why it is necessary to have state-of-the-art emergency generator systems. Among the projects carried out by Genesal in 2019, a special mention should be given to the supplying of four generators to the new hospital in Toledo which will open in the first semester of the year. They are four generators of 2250 and 2500 kVA which will function in parallel. Outside Spain, Genesal Energy offers a turnkey service to Montero Hospital (Bolivia): three 410-450 kVA generators, which are soundproof, one of them automatic, the other two in parallel with the air outlet on the upper side in order to fit in with the installation.

Gaining ground in the wind energy sector: from Los Llanos to Monte Cristi

This year Genesal has strengthened its presence in the field of renewable energy with a good number of wind farms in its portfolio. For example, in 2019, the company supplied emergency equipment for the substations in Oriche and Venta Vieja, in the province of Teruel, Montilla del Palancar (province of Cuenca) and in Serra das Penas (province of Lugo), and also for the wind farm in Los Llanos (province of Málaga), an installation for which we manufactured and delivered turnkey equipment. Internationally, we delivered a 100% personalized generator for the wind farm in Monte Cristi (Dominican Republic), whereas for the Agua Clara wind farm on the same Caribbean island, Genesal’s Engineering Department designed and manufactured a hurricane-proof generator for the whole park, which has 25 air generators, supplying power for 250,000 persons.

Biomass plants: the Viseu and Fundão stations

In Portugal there are two stations considered prime examples in the production of clean and renewable energy. They are the biomass plants located in Viseu and Fundão, repectively. Genesal installed special tailor-made equipment in both of these facilities.

More projects in Mexico: the combined-cycle power facility Topolobampo III

Genesal Energy’s strong presence in Mexico results in numerous projects, some of which are on a very large scale. Such is the case of the Topolobampo III combined-cycle power facility, whose founding in the municipality of Ahome was encouraged by the Mexican Federal Electricity Commission (CFE), and which will supply power to more than 2.5 million people. It will start operating in 2020 and the emergency power for it will be supplied by Genesal.

Tailor-made generators for the Saudi Embassy in Chad

The embassy of Saudi Arabia in Chad also uses emergency power from this Spanish brand. Concretely, the order consisted of three sets of tailor-made generators of two different powers: of 2 x 1.000/1.100 (ojo, en español, también está mal, sobra un 0) kVA, 2 x 1.500/1.650 kVA and 2 x 25-27 kVA respectively, supposed to work in parallel.

Bigger presence in Asia: entry into Taiwan

The growth witnessed in Southeast Asia over the last two years was strengthened in 2019 with the addition of a new market: Taiwan. Said country is one of the most powerful economies in the world and Genesal entered its market through several projects. In total, we have supplied the Government 13 generators. It’s our aim to continue to expand the market with new operations.

New year, new challenges

The good results obtained in the 2019 fiscal year, which has seen a constant growth, induces optimism once again. The company, after 25 years of presence in the energy sector, has now grown up and expanded its central installations in Bergondo (province of A Coruña) by 3000 square meters. The new space is meant to provide the necessary production capacity in order to tackle the new challenges by an orderly growth, given that Genesal Energy’s main aim is always the customer, who should never feel unsupported, the company states.

An example of this commitment to close attention and personalized projects -a hallmark of our company- is the boost received by the Technical Assistance Service (SAT) Department -now an indisputable benchmark in matters of remote management and multi-branding- a section which is closing the year with a steady growth and the modernization of its vehicle fleet, a process which takes into account the latest developments in ergonomics.

As far as the expansion plans are concerned, Genesal Energy will maintain its international vocation. In this regard, although Europe and Latin America are its main markets, the company pays very special attention to others, such as Qatar and Taiwan, as well as the African market, a real challenge for the energy sector.

 

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Remote management, added value in Genesal Energy’s Technical Support Service

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Remote management and SAT

Our Technical Support Service closed 2019 with sustained growth and the modernization of its vehicle fleet, which incorporates the latest ergonomic improvements.

Guaranteeing the reliability of our gensets and offering the best customer service are the pillars of Genesal Energy’s Techical Support Service, which in the last years has grown spectacularly. Our Technical Support Service is our maintenance, installation and reparation service which offers specialized attention with a clear objective: to achieve the best performance of the equipment to fully comply with the client’s needs.

“We’re a reference company when it comes to remote management and multi-brand service”, Marga González, Technical Support Manager, explains, adding that predictive maintenance (remote management and supervision system) has turned the Galician company in a reference company, both nationally and internationally, in the detection of possible breakdowns as well as the status of any unit through a stationary or mobile internet connection. Adjustments are also carried out remotely, impacting action time directly “as it is reduced considerably”, the area manager points out.

Comfort and security

More than 30 professionals form this business line which last year closed its accounts with a sustained growth in maintenance and has modernized its vehicle fleet through the incorporation of the market’s latest ergonomic improvements in order to avoid staff fatigue and make their job more comfortable. “We don’t consider it an expense, but an investment in quality for the peace of mind of our clients and employees. It’s a win-win”, says Marga González.

Their own load banks and a 24 hour service are the hallmark of Genesal Energy’s Technical Support Service. “Knowledge and innovation allow us to provide exclusive and personalized solutions, tailor-made for our clients”, says González.

Case Studies

The update of four gensets for an important television network has been one of Genesal Energy’s Technical Support Service’s latest projects. In this case, the existing controllers for parallel operation were substituted for three state-of-the-art control panels, and new circuit breakers were installed.

Our Technical Support team also carried out the update of the genset fleet of the substations of an important global electrical company in order to carry out predictive maintenance works. For this project, the substitution of more that 30 control panels, communication cards, pressure, temperature and fuel sensors were carried out in record time in order to comply with the client’s needs.

Another succesful project consisted in the study of the Modbus mapping of the genset fleet of an important telecommunications company to integrate the predictive maintenance of its units into its management and remote control system. For its execution, Genesal Energy analyzed almost a hundred mappings according to the features of each piece of equipment, their operation, environmental factors, climate…

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Risks and Consequences of Using Generator Sets at a Low Load

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Minimum load for generators

Generator sets are designed to work at their maximum power and their correct care and maintenance is, therefore, essential for them to function optimally. All the equipment must work at a minimum of 50% power load and their continued use at inferior percentages – that is to say at a low load – is counterproductive and may have serious consequences.

Main symptoms of something malfunctioning

One should be concerned when:

  1. The engine gives off oil mixed with fuel through the exhaust manifold – including the exhaust outlet or the muffler.
  2. There is oil spillage, dripping of oil of a very dark colour, as if burnt.
  3. The exhaust gives off a white smoke, more smoke than usual is seen or there is soot coming out of the exhaust outlet.
  4. The valves and tubing are clogged by dirt (presence of cinder).

Effects of low load running

“We saw engines working continuously for 24 hours at a tenth of their load and exhaust manifolds with six centimetre holes reduced to one centimetre by the accumulated cinder and oil”, Genesal Energy Technical Director Guillermo Docampo explains.

Negative effects of low load:

  1. Large accumulation of soot (cinder) in the pistons, in the grooves of the piston rings, in the valves and the turbocharger. If, subsequently, the engine functions at full load the pistons may be blocked by faulty lubrication.
  2. Low temperatures will result in insufficient combustion of the fuel, which, in turn, will cause the lubricating oil to be diluted and lose its properties because part of the fuel has mixed with the oil.
  3. Grinding of the cylinder liner. Excessive wear.
  4. The non-consumed fuel and the lubricating oil will also penetrate the exhaust manifold and will possibly exit through its seals, being very obvious -almost scandalous- because of its burnt aspect and by the stains it causes ((see photo below)).

Non-consumed fuel exiting through its seals

Why does low-load functioning in a repeated and continuous way cause an increase in oil consumption?

In reality, when an engine works at a low load, the ideal working temperature of the engine is not attained. This favours oil flow towards the upper part of the piston, because a correct adjustment within the piston-rings-cylinder assembly was not achieved. This is due to the lack of dilation resulting in an increased consumption of oil; the oil flows more easily between the valve guides and the stems due to a greater clearance because there was no sufficient warming.

How to prevent malfunctions? Is it possible to reduce the risks?

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The importance of the load profile and consumption of a generator set

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Technical article: load profile and consumption of a generator

Knowing the type of loads that we must power is vital in order to correctly determine the power rating of a generator set.

The power that a generator set manages isn’t an absolute and static value. Its level tends to fluctuate according to certain factors and processes, and it does so differently in each type of unit.

For this reason, calculating the power a generator set needs to function is not a simple operation. Different variables must be taken into account which, if not considered, can cause serious issues in our installation.

For instance, an overload in any of the phases can cause overheating and voltage imbalances. This can cause damage both in the generator set and the equipment connected to it.

Start-up: the first step load

The generator set is going to be limited during its start-up by what is called the first step load, that is: the total transient load that the genset is initially capable of enduring until reaching its stable regime with some transient variations in voltage and frequency.

This is why it’s important to verify the characteristics in the nameplates of the equipment connected to the generator set, and to be aware of the possible transient effects which they may suffer during its start-up processes. 

Certain equipment such as pumps or motors with variable drives, for instance, may increase their current temporarily during commissioning. 

Likewise, elements such as UPS’s (uninterruptable power supplies) can cause harmonic distortions which must be contemplated in our calculations.

Which parameters affect the dimensioning of loads? 

  1. The first parameter to contemplate is the type of load. As we’ve pointed out, some units experience transient increases in current during start-up. With this in mind, we’ll pay special attention to the following loads:
  • Uninterruptable power supplies (UPS). The alternator’s rated power is oversized depending on the installation.  
  • Big motor loads. They can increase starting power to up to 6 times the power, depending on the type of start-up.  
  • Lighting loads (with special attention to sodium vapour lighting and metal halides). 
  • Systems with Variable Frequency Drives (VFD). These can cause an oversizing from 40 to 100%. 
  • Other loads which are especially sensitive to transients and voltage and frequency variations. 
  1. Another factor we must keep in mind is the type of start-up of the motor in question. This is due to the fact that each type of starter requires a specific starting current, which must be higher than the unit’s rated current. Thus, we find that:
  • Electric motors with star-delta starting: its “starting current” will be equal to three times the rated or operating current. 
  • Direct starting motors: demand 6 times nominal current. 
  • Starter motors with variable frequency drives: special attention must be payed to its technical sheet as normally the ramp and increase in speed is configurable. 

Other important aspects to consider for genset load calculation

To finish carrying out this entire calculation of power with maximum precision, other variables must be kept in mind such as: 

  • Power factor during start-up.
  • Starter power.
  • Rated power factor.
  • Rated power
  • Efficiency
  • Number of start-ups

Ultimately, we must be extremely rigorous in this calculation. To avoid any surprises, it’s vital to know the type of load we’re dealing with as well as its behaviour. All, with the objective of the generator set always powering a balanced load, without generating unexpected peaks.

 

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10 Benefits of having a power generator set

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Technical article. 10 benefits of power generator sets

In a world increasingly dependent upon energy, technology and data, it is a priority to have a reliable and sustainable supply of electricity. This is precisely what generator sets offer us.

However, the virtues of these devices go beyond what meets the eye and it is worth knowing them. We compiled a list of 10 fundamental benefits so that none of them is left out:

What are the main advantatges of having a generator set?

1. Uninterrupted Power: The Importance of Ensuring Continuity

Electricity supply no matter what. Generator sets are meant for you to always have electricity whatever happens. This means that problems with the electrical network will no longer be critical for you, given that you will be constantly backed up by an autonomous generation solution which is 100% effective.

2. Say Goodbye to Downtime: Boosting Productivity

Farewell to losses: relying on the backup of a generator set in your business allows you to forget about time and productivity losses supposed by power blackouts.

3. Empowering Autonomy: Expanding Possibilities

More autonomy, more possibilities: when using an energy distribution solution such as a genset you are no longer dependent on the limitations imposed by the infrastructure of the electrical network. This means more peace of mind and, most of all, more freedom when it comes to conceiving your business projects and letting them fly.

4. Mobile Power Solutions: Enhancing Flexibility

It allows you more mobility: generator sets allow you to have a power supply in areas lacking an electrical network. Therefore, they eliminate obstacles when it comes to carrying out projects and they contribute to the development of remote or disadvantaged areas.

5. Tailored to Your Needs: Customized Designs

Your project is in charge: at present, the design of gensets is tailored to the clients’ needs and the features of their projects. According to your requirements, you will be able to choose: between engines using different fuels, between stationary or mobile generators, between hybrid and marine generators, as well as between different profiles of power delivery and of use.

6. Adding an Extra Layer of Protection: Ensuring Security

An additional security layer: the consequences of a power outage go beyond the mere issue of productivity. A sudden “blackout” can cause severe damage to our devices and machinery and this is something that can be avoided if we have the backup provided by an emergency genset.

7. Sustainable Energy: Reducing Environmental Impact

It contributes to sustainability: as opposed to the great impact left by the emissions produced by thermal power stations, generator sets offer a model of energy production which increasingly allows one to leave the least possible environmental footprint. The present-day trend is represented by generators using fuels with low CO2 emissions, like natural gas or liquefied petroleum gas (LPG). Moreover, these are low noise devices, producing no sound pollution.

8. Long-Term Value: Making a Sound Investment

It is an investment which pays off: A generator set will give you an extremely valuable service and will continue to do so for a long time. Most certainly, with appropriate use and maintenance, you will have a safe, long-term investment.

9. Streamlined Energy Production: Enhancing Efficiency

More efficient energy production: statistics show that electricity losses in the Spanish network of transport and distribution amount to 8% of all available production. Using distribution solutions such as gensets, one manages to reduce such losses. Moreover, we contribute to avoiding overloads in the network during the peak hours.

10. Cutting Costs: Maximizing Savings

You save in consumption: gensets allow you to reduce costs, by helping you manage the electricity demand in a more economical way. For example, you can use them as a backup during peak hours, in order to avoid excessive consumption. According to calculations, you can save up to 40% in this time slot.

 

In short, a generator set brings you peace of mind, opens up a large spectrum of business opportunities and all this in an effective and sustainable way.

Do you think it could be an interesting solution for you as well?

At Genesal Energy we have a wide experience in the design of personalized generator sets and we’re here to help you turn your project into reality.

 

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In a generator set, reliability is key

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Premio Pyme del año 2019

We’re SME of the year!

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Energía de Hoy interviews Alexander Blanco López, head of the Operations Management department

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Operations Management is one of our most strategic departments. The magazine Energía de Hoy expressed interest in finding out how it works, its development and its operation. We’re sharing with you the interview that the magazine had with its Head of Department, Alexander Blanco López, in order to get a closer understanding of this area.

Alexander Blanco López is the Head of Operations Management at Genesal Energy. He studied Industrial Design in Ferrol and upon obtaining his post-graduate qualifications in the University of A Coruña he began working in Genesal Energy in January of 2007. Throughout these past 12 years, Blanco has grown professionally in the company. He is currently the Head of Operations Management, coordinating the interrelationship between the company’s different departments.

As you’ve made it known to the public, 2018 has been a very positive year for the company both in the international as well as the domestic market. What is Genesal Energy’s success based on?
From my point of view, our success is based on, above all, our versatility. In Genesal Energy we advise our customers, we assist them from the beginning because not only do we manufacture gensets, we also carry out “turnkey” projects which means we’re on top of everything during the whole process. We design and manufacture custom-made units, we take care of the installation, commissioning and subsequential maintenance works. I think that’s the key. While other big companies only manufacture, for us, the process starts when the client has an energy requirement and lets us know about it, and from that moment onwards we assist them, advising them and accompanying them at all times. Our link with the client doesn’t end in the factory. In reality, at Genesal Energy we’re really devoted to a comprehensive and highly personalised service. We don’t believe in the concept of mass production. Every sale the sales department closes we take on as a personalised project and a relationship of trust.

What perspective do you have for 2019?
We want to continue growing. 2018 was a very good year, the company took a great leap forward. For this reason our goals are centered around at least maintaining the levels achieved in the last fiscal year, where turnover grew 40% from 2017. The objective is to maintain these numbers, to consolidate them and to continue in the path of continuous and sustained growth.

This year you’ll be launching the new canopies by ranges. What will be their main features?
We’re finalizing the development of the first model of the new canopies so that the client, when they receive our gensets, perceive great quality. We’ve wanted to take it a step further and improve key aspects like utility and maintenance without them having an impact on the cost. The new canopies will adapt better to our our new production systems. In Genesal Energy we install different brands, both in the realm of engines and alternators and now, with this new generation of canopies, the sound attenuation of the gensets will improve and maintenance works will be simplified. This improvement has been promoted by the experience we’re acquiring not only in our own market, but also in other external markets where the requirement levels are higher, by taking note of this and trying to achieve excellence.

The development of products for the international market is without a doubt one of your strengths. Where does Genesal Energy operate exactly? Do you expect to expand this market short or medium term?
At Genesal Energy we carry out projects across the five continents and we have a magnificent relationship with big companies who develop projects worldwide and who we support. In this sense, the commercial department treats all our clients as if they were the only one, as they really are the ones who help to not only maintain us where we are, but also to improve and continue growing. It’s because of this that all throughout the month of January, a team of the Genesal Energy sales department travelled around the world to continue strengthening the relationships with clients and suppliers.

Offering a comprehensive service to your clients also contributes to the success of this company. What does this service entail?
We offer complete support to the client: telephone assistance, in situ, we visit their site, we take care of the set-up of the genset in any type of installation. We respond to any of their technical queries. On the other hand, once they’ve made a purchase order, we carry out a custom-made design, we manufacture the product, we carry out tests in our headquarters in Bergondo (100% of the manufactured units are tested before leaving the factory, at 110% of the load), we send over the genset, install it, and then we carry out another test in situ. We also offer our after-sales maintenance service throughout the whole lifespan of the genset.
At Genesal Energy, we don’t leave any part of the process on the sidelines. We’re aware of every detail, from the most basic elements to the genset’s maintenance works, both in the preventive and corrective sense. And if any fault should occur, we’re always there, implementing remote maintenance systems through which we know the status of the genset in real time and are made aware of any problems that could arise, carrying out the necessary preventive actions before a mains failure could occur and the genset is no longer working. We look for excellence for our customers, we know they make large investments in machinery that costs a lot of money, so we must guarantee their correct operation.

Source: Interempresas Media – Energía de hoy Magazine