Generator Sets designed to offer Maximum Performance even in the most demanding conditions

Key points to keep in mind

Introduction
Use of Generator sets
Extreme conditions and their consequences
Characteristics of Generator sets
Genesal Energy can help you

INTRODUCTION

There are several mechanical and climatic factors that require a special design for the generator set.

Extreme environments such as seismic zones or areas where significant mechanical vibrations occur, areas with high levels of pollution or salinity, extreme climates (hot or cold), high levels of humidity or even the effect of altitude, can seriously affect the generator set’s performance. This can never happen. Generator sets must be designed to guarantee the reliable energy supply in every situation regardless of its complexity.

The harshness of the environment can affect different physical, mechanical and electrical parameters such as thermal management, mechanical resistance, oxidation, surface treatments, fuel, lubrication, electrical insulation, etc. To correctly design the generator set, it is necessary to know where it will be located, and under which climatic, mechanical and electrical conditions it will be operating. Thus, it is fundamental to provide a series of characteristics, elements or parameters allowing the genset to function at full capacity in every situation.

To correctly design the generator set, it is necessary to know where it will be located, and under which climatic, mechanical and electrical conditions

USES OF GENERATOR SETS IN EXTREME CLIMATIC CONDITIONS

The regions with an extreme climate are usually remote and isolated areas that, due to their energy and other needs, make it necessary to count on a generator set to maintain its operation.

Due to the isolation of these areas, energy resources are not easily accessible and consequently, sometimes there is no electrical grid to be connected to, or if there is, it is neither reliable nor stable.

Therefore, it becomes necessary to have a permanent or emergency supply of electrical power and this is where the generator set comes into play. Its robustness, adaptability and reliability, together with an adequate configuration and dimensioning, make it capable of operating safely in the face of extreme environments. The use of generator sets in these demanding situations implies that both mechanics and electronics are put into a greater stress; for this reason, a correct maintenance plan is even more important, as well as the gensets’ adaptability to harsh operating conditions.

it becomes necessary to have a permanent or emergency supply of electrical power and this is where the generator set comes into play.

EXTREME CONDITIONS AND THEIR CONSEQUENCES

There are different factors affecting each extreme situation, whose consequences imply the need of adapting the design in order for the generator set to operate in an efficient way.

Some of them are:

Vibrations, seismic activity, shocks

When gensets must work in environments where vibrations or mechanical shocks can be produced, it is fundamental that they have resistant structures that can withstand such stress conditions. Structural calculations are carried out to ensure that no plastic deformation occurs in the materials.
It is also important to prevent elements such as the silent-blocks from resonating at the vibration’s usual frequencies. Genesal Energy carries out a particular study of each project, calculating the most suitable antivibration system.

Polluted or particulate air

In these cases, the most delicate items are the air cooling and ventilation systems. Unless the genset is installed in a confined room with clean air, both air filtering systems and enclosures must be provided in order to protect it from dirt as its accumulation may cause thermal and performance problems. It is possible to mount heavy duty air filters in the engine, and also install IP45/IP54 alternators, dust filters in the genset’s air inlet, motorized louvers, etc.

Corrosive atmospheres and saline environments

The use of a protective enclosure is necessary to reduce the genset’s exposure as much as possible. In this kind of atmospheres, the biggest problem is the corrosion of elements and surfaces, and this requires special treatments and suitable paints for the environment in which the generator set is installed. The most suitable treatment is applied depending on the type of environment, always in accordance with ISO12944-2:2018 Paints and Varnishes, Protection of Steel Structures against Corrosion by Protective Paint Systems. Another key point is to protect the alternator against corrosion to prevent it from breaking due to the deterioration of the windings.

Desert and hot climates

Heat is another factor that can affect the genset’s operation. Special care must be taken in terms of cooling, particularly of the engine and alternator, without forgetting other elements such as circuit breaker or batteries. To do so, engine and alternator must be oversized according to the derating curves providing by the manufacturers, and so the engine radiator must be. Another issue to be considered is that dry weather tends to create dusty environments and particulate air.

Other details to bear in mind are the loss of viscosity of the lubricating oils, which can lose effectiveness, or the fuels’ increase in volume/pressure at high temperatures. Lubricants adapted to the environmental conditions must be used.

Arctic climates

In principle, arctic climates are beneficial for a better cooling -considering that the generator itself provides heat too-; however, the problem comes when the operation is not continuous, and the generator shall start in cold. In this situation, lubricants, fuel, and even the battery electrolyte may gel and even fall to freeze, and if this happens, the consequences would be catastrophic. For this reason, good thermal insulation or heating systems which do not depend on the generator itself are much needed.

Humid environments

They are associated with cold climates. Sometimes moisture can produce condensation inside the equipment, which is really harmful for many components of generator, especially for the electrical and electronic elements. In these cases, heating systems are necessary to avoid condensation.

Altitude

When the generator set is installed at a higher altitude, the air density decreases and the oxygen level is reduced, which starts being significantly noticeable from 1000 m onwards.
The lack of oxygen changes the engine combustion conditions, but this is not the only thing happening: the air density lowering reduces the efficiency of the cooling – the air exchange is reduced.

On the other hand, the circuit’s rigidity and electrical installations are affected and consequently they need to be reinforced. To do so, the generator set (both engine and alternator) must be oversized, as occurs with temperature.

As discussed, the generator set’s design becomes quite complex in the face of these variety of extreme environmental conditions. Depending on each particular situation, it is necessary to take a series of extra measures in order to adapt the equipment to the place in which it will be operating.

CHARACTERISTICS OF GENERATOR SETS IN HARSH ENVIRONMENTS

As argued, each generator set is designed with specific characteristics depending on the type of environment, although they also have a series of common features.

In the face of these extreme conditions, generator sets must be supported by a chassis and protected by an enclosure in order to avoid the inconveniences described above. The enclosure must be designed adapting to the specific needs in each case, considering the climatology of the equipment’s location. Robustness, tightness, treatments, or the insulation degree of the enclosure will be determined by the location.

In all cases, details such as the fuel to be used, cooling and lubrication systems must be studied and designed aiming to keep the generator’s maximum performance and correct operation in the particular environments. We cannot forget many of them are emergency equipment intended to provide up to 110% of their power in a very short time from the starts (a few seconds).

Also, the sizing of the cooling and heating systems must be studied in detail.

On the other hand, the electrical system of the generator set definitely has to be one of the most resistant, and to achieve such resistance, the different components are selected considering the climatology of its location. Also, batteries are one the of the most fragile components and therefore must be selected very carefully with regard to the availability and reliability of the generator set.

In conclusion, extreme environments make necessary to carry out detailed studies and to redesign many components of the generator set aiming to adapt them to the specific environment of their particular location. The correct adaptation will turn the generator set into a reliable, effective and efficient equipment.

GENESAL ENERGY CAN HELP YOU

Extreme climates require a complex engineering development and at Genesal Energy we carry out this task with the maximum guarantees. We are backed by years of experience and a great knowledge. Our large team of technicians and engineers will be ready to help you at all times and under any circumstance. We manufacture made-to-measure solutions as per your particular requirements, and our 24/7 service will quickly start up your generator in the event of a breakdown.

At Genesal Energy, all the links in the chain are essential to offer a top product. We design, develop, manufacture and install generating sets in the most remote places and in the most adverse climatic or geographical conditions; however, our involvement does not end alone with the delivery. Maintenance plays a crucial role in our company: we count on the latest technologies in remote management and supervision, and a large stock of spare parts available.

Genesal Energy is always ready to provide the most efficient solution. A bespoke generator set adapted to each client. You can find us at consultas@genesal.com.

Generator Sets designed to offer Maximum Performance even in the most demanding conditions

Key points to keep in mind

INTRODUCTION

There are several mechanical and climatic factors that require a special design for the generator set.

To correctly design the generator set, it is necessary to know where it will be located, and under which climatic, mechanical and electrical conditions

USES OF GENERATOR SETS IN EXTREME CLIMATIC CONDITIONS

it becomes necessary to have a permanent or emergency supply of electrical power and this is where the generator set comes into play.

EXTREME CONDITIONS AND THEIR CONSEQUENCES

There are different factors affecting each extreme situation, whose consequences imply the need of adapting the design in order for the generator set to operate in an efficient way.

Some of them are:

Vibrations, seismic activity, shocks

Polluted or particulate air

Corrosive atmospheres and saline environments

Desert and hot climates

Arctic climates

Humid environments

Altitude

CHARACTERISTICS OF GENERATOR SETS IN HARSH ENVIRONMENTS

GENESAL ENERGY CAN HELP YOU

OTHER ARTICLES OF INTEREST

Energy Transition: Generator Sets Importance

All you need to know about fuel tanks: types, materials and location

Generator Sets: The Keys To A Good Installation

What is the energy transition?

Do you need a generator set?

GENESAL ENERGY

INTERNATIONAL

We operate in over 30 countries worldwide.

EUROPE | AFRICA | LATIN AMERICA | MIDDLE EAST

R&D+i

GENERATOR SETS

CERTIFICATIONS

COMUNICATION

APPLICATION

SAT | AFTERSALES

Members of