The Importance of Generator Maintenance

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“Backup power isn’t a luxury – it’s a need. This blackout has shown us something essential: the importance of being prepared.”-Ángeles Santos, Director of HR and Institutional Relations at Genesal Energy

At 12:33pm CEST on the 28th of April, the Iberian Peninsula experienced an unprecedented event: a massive blackout that affected more than 55 million people. For hours, entire regions were left in the dark, with services interrupted and widespread uncertainty that exposed how vulnerable the power grid is to unexpected failures.

The consequences were immediate, impacting every sector of society: supermarkets closed, ATMs stopped working, traffic lights went out, telecommunications were disrupted, transport collapsed, petrol stations were out of service, industry ground to a halt – and the list goes on. The incident clearly demonstrated our deep dependence on a continuous and reliable power supply to keep daily life running.

And it’s not just about day-to-day activity; some sectors require an uninterrupted power supply under all circumstances. Hospitals, for example, rely on electricity to operate life-saving equipment like cardiac monitors and ventilators, and to carry out emergency procedures. Thanks to emergency generators, many of these facilities were able to continue operating normally.

Beyond the immediate impact, the blackout served as a stark reminder of the need for effective backup power solutions such as generator sets – and the need to guarantee their availability through proper maintenance. Being prepared isn’t just about having the equipment installed but ensuring it will respond when it’s needed most.

City skyline at dusk during a blackout, with darkened buildings and a partially lit sky.

The Importance of Grid Security

The Iberian power system is made up of various energy generation plants (wind farms, solar parks, hydroelectric stations, combined cycle plants, etc.), which are interconnected by high-voltage transmission lines. These lines in turn connect to transformer substations, which lower the voltage from high to medium or low levels, before distributing electricity to points of use via medium and low-voltage networks.

Generator maintenance is essential in any sector that depends on these systems.

So, every time we switch on a light or plug in an appliance, we’re setting off a complex process that is constantly monitored to ensure energy generation matches demand – maintaining a fine balance between what’s produced and what’s consumed. However, the system is vulnerable: any failure can cause a power outage in a matter of seconds, as the recent blackout has shown.

That’s why many sectors – particularly those considered critical – must be equipped with backup power systems to guarantee supply continuity in the event of a grid failure:

    • In healthcare, a power outage can be life-threatening, as many patients rely on machines that must remain continuously powered. Emergency procedures cannot be delayed due to a lack of electricity.
    • In sectors such as data-centres and telecommunications, uninterrupted power is essential to maintain operations, prevent data loss and ensure emergency communication.
    • In industry, stopping production processes can cause damage to equipment, faults and major financial losses due to delays and downtime.

Girl with a flashlight during the blackout. Supermarket in the dark.

Ensuring an uninterrupted power supply – and with it, the safety of people and the resilience of industry – is not only a necessity, but a moral responsibility. In this context, emergency generator sets play a vital role as an alternative energy source.

How Do You Make Sure a Generator Responds When Needed?

It all starts with a proper installation and a configuration that allows for automatic response. A generator set includes key components like the engine, alternator and control panel. But its true value lies in its ability to activate without human intervention, thanks to the automatic transfer switch (ATS) – a device that detects a power cut, starts up the generator, and transfers the electrical load in a matter of seconds. This immediate reaction keeps power flowing during even the most critical moments.

But for this seamless response to work, one element is just as important as the system design itself: maintenance.

The Value of Maintenance: Ready for the Unexpected

Generator maintenance is essential in any sector that depends on these systems. It helps detect wear and tear, prevent unexpected breakdowns, and correct minor faults before they escalate and compromise system performance.

These tasks cover both the mechanical and electrical components and are carried out with the generator both stopped and running. Checks include:

    • Electrical, hydraulic and pneumatic connections
    • Fuel system (pump, filters)
    • Lubrication system (oil level and replacement, filters)
    • Cooling system (coolant level and condition, radiator cleaning)
    • Battery condition (charge level, electrolyte levels, terminal cleaning)
    • Exhaust system (silencers and emissions)

Genesal Energy technician repairing a generator set

Adjustments are made depending on the overall state of the equipment. Load tests are also carried out regularly to ensure all operating parameters remain within optimal limits, and alarm and safety systems are verified to guarantee an effective response if triggered.

Thanks to this process, critical infrastructure – including hospitals, data centres and industrial plants – can continue to operate in emergencies. Lives are saved, information is protected, essential services remain functional, and the supply chain stays active. In short, maintenance turns generators into a true guarantee of continuity.

More Than Just a Response: The Broader Benefits of Preventive Maintenance

In addition to ensuring an immediate response during a power failure, preventive maintenance brings a host of long-term benefits that directly impact safety, efficiency and operational profitability:

    • Safety. Proper maintenance prevents internal failures that could lead to accidents such as fires or explosions, protecting both people and property.
    • Improved performance and lifespan. Regular checks and adjustments reduce premature wear and tear, ensuring the genset runs in optimal condition.
    • Lower costs. Early fault detection helps avoid costly repairs. A well-maintained generator also consumes fewer resources (fuel, coolant, etc.).
    • Regulatory compliance. In many sectors, having generators is not only essential, but so is complying with specific maintenance regulations. Avoiding fines is also part of good management.
    • Business reputation. A preventable failure due to poor maintenance can severely damage a company’s image – especially if it puts customer service at risk.

The Genesal Energy Experience

Genesal Energy knows that the key to ensuring energy continuity lies in foresight and maintenance. A generator is only useful if it’s ready to run when the time comes. That’s why, in addition to designing and manufacturing tailor-made power solutions, we offer a comprehensive Technical Support Service (SAT) to accompany each customer throughout the entire lifecycle of their equipment.

Through it, we define, design and implement maintenance plans tailored to the specific needs of each installation, with 24/7 expert support. We also handle generator installation and commissioning, ensuring everything is ready to respond to any contingency.

One clear example of this capability was our response to the blackout on the 28th of April. Given the scale of the event, we activated a crisis unit to resolve as many incidents as possible, prioritising the most urgent. Thanks to the commitment and professionalism of our technicians, we managed to restore power to numerous critical locations, delivering energy where it was needed most.