Generator installation and mounting

/in , /by

Generators are categorized based on their installation and mounting methods. Understanding these categories is essential to select the right generator installation for each project’s specific needs.

Whether it’s mobile generators for remote construction sites, stationary emergency generators inside factories, or outdoor units operating in urban areas, each setup requires specific conditions that define its design and generator mounting type.

Although requirements can vary, three main factors define the installation and arrangement of a generator:

  1. Mobility – Will the generator remain permanently in one place or move between different locations?
  2. Environmental Exposure – Will the unit be installed indoors or outdoors?
  3. Noise Control – Does the location demand minimal noise emissions?

By addressing these questions, you can determine the most suitable generator installation and mounting solution.

Main types of generator installation

Despite the fact that there is an infinity of personalization options, there are 3 types of installations according to the parameters mentioned above.

1. Open stationary installation

This type of installation is foreseen for projects in which the generator is installed inside a building and it does not need to be moved once installed. Consequently, the generator does not need any casing to protect it from inclement weather, nor does it have any mobility device.

The generator will be installed on a steel bedplate (with or without an integrated fuel tank), capable of sustaining the static mechanical requirements, as well as the vibrations to which the generator will be subjected throughout its service life.

2. Sationary sound-damping installation

When the generator will be exposed to bad weather conditions, will be stationary and the sound level it produces will have to be low, this type of installation is the ideal one.

The generator is encapsulated in a galvanized steel cabinet, protecting it from inclement weather. The inner part of the hood is covered by sound-damping material, which allows for the reduction of the sound level which is emitted. Therefore, this type of installation is adequate in applications where noise is a crucial factor.

3. Mobile sound-damping installation

This is the type of generator which is usually seen in provisional installations (events, film shootings etc.). Its differentiating feature is that this type of generator must have the possibility to be moved to where energy is required; consequently, it will be installed on a trailer.

The device is placed on some special anti-vibration dampers, capable of sustaining the sheer stress (or lateral deformation) which can happen during circulation: factors such as braking, acceleration or bumps. In this way, one manages to protect the monoblock (the engine-alternator group) and to ensure the generator’s functioning and durability.

Custom Generator Installation Solutions

At Genesal Energy, we provide generators adapted to these three generic categories of installation and arrangement. They can be further personalized in order to adapt in the best way possible to the specific applications that our customers need.

Speed regulation on generators: power without ups and downs

/in , /by

Technical Article. Pic of a man manipulating speed of a generator set.

What we demand of a generator is a stable power delivery. And a constant engine speed is crucial in achieving this.

A speed generator set must maintain a consistent engine speed, as this directly affects power frequency and overall performance.

The famous Swiss architect Le Corbusier said that machines are “a fantastic perfection tool”. However, experience tells us that even the most sophisticated machinery is not perfect. Although the mechanical systems are designed to be balanced and deliver based on optimal parameters, one must take into account that there are always some factors which can alter their efficiency.

The speed of an engine, for example, may be affected by a drop in voltage or by power surges. And, in the case of generators, such variations are of critical importance, given that the engine speed directly determines its operating frequency.

Logically, this can entail a problem, because the thing that interests us about a generator is that it be capable of maintaining the most stable power possible around a certain value.

The good news? Everything is foreseen and technology provides us with the solutions for the engines never to lose direction.

Generator speed control systems: ensuring reliable power output

At present, the engines powering electrical generators contain a speed regulator for speed control.

The function of this regulator is to detect any imbalance in the engine speed and to cause it to revert quickly to its optimal working regime.

Thanks to this device, our generator’s engine will always keep a constant rhythm. In this way, the generator will be capable of always complying with the requirements of the load, giving us the power that we need to obtain.

Moreover, the speed regulator acts as a security device, because it protects the engine from excessive speeds which can cause the engine to break down.

What controls engine speed in engines that power generators?

Engine speed in generators is controlled by a speed governor, also known as a generator speed controller. This device monitors the engine’s RPM and adjusts the fuel supply to maintain a stable speed under varying load conditions. In modern generator sets, this can be mechanical, electronic, or a combination of both systems.

Genesal Energy: reliable engines

At GENESAL ENERGY, we offer you diesel generators equipped with three different types of governed engines:

  • Engines with mechanical controls
  • Engines with mechanical controls and inbuilt electronic controls
  • Electronic engines

All of these are designed to recuperate the working frequency, both after a load impact and after a sudden drop thereof.

The response to the drop in frequency will depend on:

  1. The inertia of the engine itself.
  2. The inertia of the alternator.
  3. The characteristics allowed by the installed AVR (Automatic Voltage Regulator).

At the same time, in the engines with mechanical speed regulation, we apply a parameter called “speed drop” or “droop”. This parameter represents the percentage of over-speeding that the engine is experiencing when it is operating without a load, compared to the nominal speed (at full load). Once we have calculated this, we can configure the engine so that it quickly stabilizes when a load is applied to it.

 

 

 

All regulators need a certain period of time in order to act. At GENESAL ENERGY, we carry out all the necessary adjustments and tests to ensure that the regulators control the engine speed and the generator frequency correctly. In this way, we give a reliable response to our clients’ requirements.

DISCOVER MORE OF GENESAL ENERGY’S PROJECTS

Click!

Configuración web

/by

a:7:{s:8:”location”;a:1:{i:0;a:1:{i:0;a:3:{s:5:”param”;s:12:”options_page”;s:8:”operator”;s:2:”==”;s:5:”value”;s:14:”theme-settings”;}}}s:8:”position”;s:6:”normal”;s:5:”style”;s:7:”default”;s:15:”label_placement”;s:3:”top”;s:21:”instruction_placement”;s:5:”label”;s:14:”hide_on_screen”;s:0:””;s:11:”description”;s:0:””;}

Statement COVID-19

/in , /by


Dear suppliers and clients:

Due to the global pandemic caused by COVID-19 and following health recommendations as well as those by other administrations, at Genesal Energy we have adopted a series of preventive measures, while attempting to alter the company’s normal operation as little as possible, and remaining within the provisions, in their totality, contained in the Royal Decree 463/2020, of the 14 th of March, through which the current state of emergency has been declared for the management of the health crisis caused by the COVID-19. Therefore, from today onward, and, in principle, while the state of emergency lasts, all Genesal Energy staff members that are able to work from home will begin telecommuting, and new work shifts have been established in the different divisions in order to optimize resources in this exceptional situation. These decisions, which affect internal organization, have been made in order to minimize the impact of COVID-19 and as a question of social responsibility. This is our contribution to avoid spreading the virus and to be able to resume normal operation as soon as possible.

Although the company will continue, through all means possible, to operate at its usual level, we urge our suppliers and all clients who work with us to please cooperate by prioritizing communication via email (genesal@genesal.com) or through the e-mail address of each relevant staff member, as this will be the main channel of communication during the following weeks. In all cases, contact via our telephone number 981 674 158 will remain open.

On behalf of each staff member of the Genesal Energy group, we express our support to those affected by the coronavirus as well as our gratitude and solidarity to all health personnel who is working hard to keep the virus under control.

Sincerely,
Genesal Energy Board of Directors.

How do variables affect Generator Sizing?

/in , /by

Analyzing the effect of voltage and frequency drops is indispensable for deciding which engines and alternators are more adequate for a generator.

Voltages are not a static phenomenon. They fluctuate resulting in peaks and drops during certain phases of the equipment’s functioning.

In fact, when we speak about circuits we distinguish between two types of situations:

  • The steady condition: It is the stationary situation of normal functioning in which the voltage ows in a balanced state according to the conditions determined by the network.
  • The transitional state: it occurs in certain periods of time in which the voltages and electrical intensities vary, before the circuit comes to its steady state and becomes stabilized.

The voltage variations occurring during these transitional periods are known as variables.

When do variables occur?

Logically, the normal situation in which variables occur is when we cause a circuit to pass from one condition to another, i.e. at the moment of connecting or disconnecting the equipment.

In fact, when we switch on and off a generator, short voltage peaks are triggered. Although they tend to end by themselves, we must not take them easily. Why is that? Because if the alternator and the engine happen not to be capable of coping with them, major functioning problems may ensue in the generator.

A matter of analysis

For this reason, in the process of designing and sizing a generator, it is indispensable to carry out a strict variable analysis.

Do you want to know the keys to be able to do this analysis?

Fill in the form to receive the complete article with all the details.


At Genesal Energy we advise our clients and offer them the solution which best adapts to their project.

Discover how to configure your generator set

Click!
Technical article. Gas vs Diesel

Diesel vs. Natural Gas Generators: Key Differences and Use Cases

/in , /by

Technical article. Gas VS Diesel

The two most common generator types on the market are diesel engine powered generators and those using gas powered engines.

Apart from the fuel powering them, they have other distinctive qualities which make them more or less adequate according to the use we want to give them.

Let’s see what they are.

Note: In this article, “gas” refers to natural gas or liquefied petroleum gas (LPG), not gasoline (petrol). These are commonly used in gas-powered generators, not to be confused with petrol-fueled engines.

Diesel generators

The reliability of a classic

For quite a long time, diesel engine generators have been a standard in the market. Their good reputation was the result of a great flexibility of application, both in industrial and household areas, as well as their robustness and reliability.

This type of generator may be used as a main power supply, as well as for co-generation or emergency applications. They are fully autonomous and may, therefore, function in places which have absolutely no power-supplying networks.

What advantages have made diesel generators so popular?

  • They are more easily disassembled and installed than gas units, making their installation wherever needed a simpler task, while also using a fuel which is easily accessible and more economical than gasoline.
  • They are robust and sustainable, capable of ensuring many hours of yearly operation.
  • Diesel fuel gives high efficiency to the equipment using it because it burns at a much higher temperature than gasoline.
  • Diesel fuel is also very safe because it is less flammable than other types of fuel.

The main disadvantage of this type of generator, as in the case of any machinery which includes a diesel engine, is that it causes high levels of polluting gas emissions. Therefore, the present day diesel generators incorporate an additional antiparticle filtration system that ensures its conformity with the legislation in force.

Natural gas powered generators

Clean and economical energy

Gas engine generators have gained much popularity due to their great reliability, cost efficiency and sustainability.

This type of generator can be used as a primary power source, in co-generation applications or as an emergency source and its engine may be fuelled by liquefied natural gas (LNG) or liquefied petroleum gas (LPG). The latter is a gaseous fuel obtained from the distillation of oil.

Generators powered by LNG fuelled engines get their fuel from the natural gas distribution network, whereas LPG fuelled generators are connected to a tank which will have to be periodically refuelled.

What are the benefits of natural gas powered generators?

  • They are more respectful of the environment, because the gas causes less emission than other non-renewable fuels (such as coal, diesel or gasoline).
  • They are economical, because gas is the most affordable fuel, second only to coal (which is not an option due to its high emission level).
  • They are high-efficiency generators in co-generation applications.
  • When fuelled by an underground natural gas network, the fuel supply is not conditioned by inclement weather or problems with the communication infrastructure (which do condition diesel generators that need periodic refuelling).
  • They are highly compatible and easy-to-use units, given that it is possible to install them in remote locations, using high capacity tanks.
  • They are very quiet generators.

Among the disadvantages of this type of generator, one must consider the following:

  • Liquefied natural gas (LNG) powered generators are less autonomous than diesel engine ones because it is absolutely necessary to connect them to a distribution network.
  • In the case of LNG equipment connected to the network, one has to take into account that any catastrophe or natural disaster can affect the supply system.
  • Gas is an exceptionally flammable fuel and entails a bigger fire hazard than diesel.
  • The engine and control system are much more demanding, which can result in the product’s final price being higher.
  • They require a more punctual and complex maintenance.

Diesel vs Gas Generators: Which One Should You Choose?

Deciding between a diesel or gas-powered generator requires careful consideration of various factors. Each type has its own set of advantages and disadvantages that make them suitable for different applications and environments. Here are the key factors to consider:

1. Application and Usage

  • Primary Power Source: If you need a generator for continuous operation, such as in remote locations without a power grid, diesel generators are often preferred due to their robustness and fuel efficiency.
  • Emergency Backup: Both diesel and gas generators can serve as reliable backup power sources. However, gas generators, especially those connected to a natural gas line, can provide uninterrupted fuel supply during emergencies without the need for refueling.

2. Environmental Impact

  • Emissions: Gas generators produce fewer emissions compared to diesel generators, making them a more environmentally friendly option. This can be a critical factor if you are concerned about meeting stringent environmental regulations or minimizing your carbon footprint.
  • Noise Levels: Gas generators are generally quieter than diesel generators, which can be important in residential areas or locations where noise pollution is a concern.

3. Fuel Availability and Cost

  • Fuel Costs: Diesel fuel is typically more expensive than natural gas, but it provides higher energy efficiency, which can offset the cost over time.
  • Fuel Supply: Gas generators connected to a natural gas line have a continuous fuel supply, whereas diesel generators require regular refueling. However, in areas without natural gas infrastructure, diesel may be the more practical choice.

4. Maintenance and Longevity

  • Maintenance Requirements: Diesel generators are known for their durability and lower maintenance needs. Gas generators, while efficient, often require more frequent and complex maintenance due to the nature of the fuel and engine.
  • Lifespan: Diesel generators tend to have a longer operational lifespan, making them a more cost-effective option in the long run for high-demand applications.

5. Safety Considerations

  • Flammability: Natural gas is highly flammable, posing a greater fire hazard compared to diesel. Diesel fuel, being less volatile, is considered safer to store and handle.
  • Reliability: In situations where natural disasters might disrupt gas supply lines, diesel generators offer greater reliability as they can operate independently of external fuel supply networks.

What About Gasoline Generators?

In some markets, especially in North America, “gas-powered generator” often refers to gasoline-fueled engines. While these are common for small portable generators, this article focuses on natural gas and LPG-powered equipment, typically used in industrial and backup applications.

Frequently Asked Questions

1. What is the difference between a diesel and a natural gas generator?

Diesel generators run on diesel fuel and are known for their durability, fuel efficiency, and high performance in demanding environments. Natural gas generators use either piped natural gas (LNG) or liquefied petroleum gas (LPG), offering lower emissions and quieter operation.

2. Which generator is more efficient, diesel or natural gas?

Diesel generators are typically more fuel-efficient and better suited for continuous use or high-load applications. However, natural gas generators may offer better cost efficiency in areas with existing gas infrastructure.

3. Are natural gas generators more environmentally friendly than diesel?

Yes. Natural gas generators produce significantly fewer emissions, including NOx and particulate matter, making them a more environmentally friendly choice compared to diesel generators.

4. Can a natural gas generator run during a power outage?

Yes, especially if it’s connected to a natural gas grid. These generators can provide uninterrupted fuel supply during emergencies without the need for manual refueling—unlike diesel units.

5. What are the maintenance differences between diesel and gas generators?

Diesel generators require less frequent maintenance and are generally easier to service. Gas generators may require more specialized maintenance due to their fuel system and engine complexity.

6. Which type of generator lasts longer?

Diesel generators usually have a longer lifespan thanks to their robust design and lower engine RPMs. They’re ideal for intensive use and long-term reliability.

Conclusion

Choosing the right generator depends on your specific needs and circumstances. At Genesal Energy, we understand that every project is unique. Our experts are here to help you assess your requirements and recommend the best solution tailored to your needs. Whether you prioritize environmental impact, fuel efficiency, or operational reliability, we provide comprehensive guidance to ensure you make an informed decision.

For personalized advice and more information, please contact us at:

consultas@genesal.com +34 900 730 124

Dereating: how Temperature and Elevation Affect Generators

/0 Comments/in , /by

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 or altitude 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 dereating factor 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

/0 Comments/in , /by
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.

 

Get to know our 2019 projects

Download PDF

Click

 

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

/0 Comments/in , /by

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…

Find out more about our maintenance service

Click!

Risks and Consequences of Using Generator Sets at a Low Load Operation

/in , /by

Minimum load for generators

Generator sets are designed to operate close to their rated power, and maintaining them properly is essential to ensure optimal performance. Every generator has a recommended minimum load, typically around 50% of its rated capacity. Operating below the generator minimum load for extended periods can lead to serious issues and reduced lifespan.

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).

The effect of low load on generator performance

“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.

The effect of low load on a generator includes serious internal damage over time, particularly due to incomplete fuel combustion and oil dilution. These issues directly impact engine health and efficiency.

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

Important: Do not run an engine generator set without a load for more than 15–20 minutes unless strictly necessary. Prolonged operation without load can lead to internal damage, high oil consumption, and a shortened lifespan of the equipment.

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?

REQUEST THE FULL ARTICLE

Request the full article in the form below if you want more information on how to prevent failures and reduce risks when using generator sets at low load.