Generator installation and mounting

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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.

We’ve supplied 18 new super-soundproofed generator sets to the Chilean market

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In Latin America, as well as in Europe, there are many countries with a growing demand for gensets providing low sound levels (therefore contributing to a greater social well-being), which are also guaranteed to be able to cover power requirements, whether it be for continuous use or in emergency situations.

One of these countries is Chile, a market with great possibilities and in constant expansion in the energy sector (especially in the field of renewable energy), for which we’ve designed, manufactured and supplied a total of 18 super-soundproof gensets.

The generator sets were tailor-made according to the client’s needs, and two different models were designed (five gensets of 500/550 kVA and 12 of 1000/1100 kVA), but with a common denominator: their great level of sound attenuation: 65 dB at seven metres distance at the point of maximum emission.

To achieve this, the engineering team and the sales department, which at Genesal Energy always work hand in hand, kept the basic cooling requirements into account, without surpassing the length and width of the 40’HC shipping container which encases the generator sets.

Double-walled fuel tank

Specifically in the 550kVA unit, we also installed a medium voltage step-up transformer, and in the 1.100 kVA, a 3.000 litre double-walled fuel tank inside the container, as well as control cabinets, silencers, etc.

On the other hand, to achieve a sound level of 65dB it was necessary to decrease the sound levels by 43’5 and 48 dB respectively. To reach this goal, we selected different materials and solutions, some applied in exactly the same way in both models, but others had to be adapted due to the unique characteristics of each unit, which went beyond their engine’s respective power ratings, to be able to comply with the technical specifications requested by the client.

Finally, once the open-field tests of the prototypes had been carried out following the indications and procedure set by the applicable regulations, the results were as follows:

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  • GEN1100TC: 64.5dB (A) at 7m distance
  • GEN550TC: 64.5dB (A) at 7m distance

These are the main features of both models manufactured for Chile by Genesal

GEN550TCGEN1100TC
PRP power500 kVA.
1000 kVA.
STP power500 kVA.
1100 kVA.
Voltage400/230 V + 23kV transformer.
400/230 V
Frequency50 Hz.50 Hz
RPM1.5001.500
Engine brandMTUMTU
Alternator brandMECCALTE WITH PMG.MECCALTE WITH PMG.
TypeSoundproof in 40 HC container.
Soundproof in 40 HC container.
Specific installation roomsThree independent areas
Two independent areas
Fuel tank1.500 L integrated in the base frame.3.000 L double-walled and approved according to Chilean regulations
Sound emission level56,3dB (A) 7m64,5dB (A) 7m.
PaintISO 12944 C5M.ISO 12944 C5M.
CouplingElastic between engine-alternator.
Elastic between engine-alternator.
Control systemCOMAP (possibility for parallel operation).DEIF (possibility for parallel operation).
Circuit breakerSchneider, removable and motorized.Schneider, removable and motorized.
Cooling systemRemovable for maintenance.
Removable for maintenance.

We’ve supplied emergency power to one of the most luxurious business centres in Manchester

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At Genesal Energy we’ve supplied emergency power to one of the most luxurious business centres in Great Britain, located in Manchester, one of England’s most important cities.

Protecting business centres against possible mains failures is essential to guarantee their correct operation, as meetings, events and other activities pertaining to the business world are carried out inside.

Upon analyzing the business centre, which has offices, meeting rooms and a high capacity training centre, and having listened to our client’s needs, we manufactured and supplied a 2,250 kVA generator set prepared to operate in parallel with the mains. The genset was designed made-to-measure, and had to also comply with low sound emissions.

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Features

  • 2,000 L double-walled fuel tank installed in its own independent room inside the container.
  • Genset designed to achieve 85 dBA@1m.
  • Deep Sea control panel prepared for parallel to mains operation and a motorized breaker.
  • Power cabinet with busbar for the power cables, which were connected up to a protection box prepared to withstand corrosion on the outside of the container, to which the client would connect the necessary power busbar.
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Speed regulation on generators: power without ups and downs

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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.

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We continue growing in the renewable energy industry: emergency power for two new wind farms in Mexico

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At Genesal Energy we continue committing ourselves to the renewable energy sector, and one of our latest projects has been in Mexico, where we participated in the construction of two large wind farms.

They are the San Carlos and Santa Cruz wind farms, with more than 100 wind turbines to supply power to the state of Tamaulipas, with more than 3,4 million citizens.

The San Carlos wind farm, now under construction, will generate 198 MW and have 60 AW132 3300 IEC IIB TH120 wind turbines. With an investment of more than 215,7 million dollars and located between Villagrán and San Carlos, it will occupy 171 hectares and will be one of the largest wind farms in Tamaulipas. Genesal Energy is participating through the design, manufacture and supply of three emergency generator sets (two open units of 462 kVA and another 220 kVA soundproof genset) to supply power to various substations.

On the other hand, in the Santa Cruz wind farm – in near proximity to the US border – there will be a total of 42 AW132 TH120 wind turbines. The installation will generate 138 MW. Genesal is supplying a customised emergency genset of 113-125 kVA for the wind farm.

CFE Certification

In both cases, the generator sets have been designed and manufactured by our engineering department following CFE specifications, the Mexican government’s official accreditation which backs foreign companies when opting for great projects and public tenders in the Mexican territory.

Through the participation in the San Carlos and Santa Cruz wind farms, the company’s has reinforced its strategy to aim for renewable energy, especially in strategic markets such as Mexico, Oman and the Dominican Republic, amongst other countries.

GEN462FA and GEN220FI

  • Above-ground approved double-wall 1500L fuel tank in steel-steel, complying with the autonomy required by the client.
  • Alternator anti-condensation heater.
  • Both the generator set and the monoblock have been painted in the colour requested by the client.
  • IB-lite module for Modbus TCP/IP communication, which allows remote monitorization and access through a computer with Internet connection.
  • Analogical voltmeter and ammeter following client’s requests.
  • DNP3 gateway.

GEN125FI

  • Genset prepared for start-up via external command.
  • IB-lite module for Modbus TCP/IP communication, which allows remote monitorization and access through a computer with Internet connection.

 

The Navarra University Clinic opts for Genesal Energy power

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The Navarra University Clinic is one of the most renowned health centres in Spain and a benchmark internationally in numerous specialties, oncology treatment and palliative care.

In buildings of these characteristics, having emergency power is essential, and a key element in these facilities.

From our headquarters in Bergondo, in A Coruña, we designed, supplied and installed three high precision generator sets. The units in question are stationary 1,280/1,415 kVA generator sets, designed according to our client’s needs. Their goal, to always ensure power supply to the health professionals at the clinic. Because power is vital.

Features

  • 1,280/1,415 kVA stationary generator set.
  • Mitsubishi engine.
  • Mecc Alte alternator.
  • 50 Hz, 1,500 rpm, 400/230 V.
  • 2,000A Schneider automatic breaker.
  • Ethernet module to provide the possibility for remote management.

Our power conquers Africa: special gensets to withstand the extreme heat

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Ensuring power supply in isolated areas is one of the guarantees that Genesal Energy provides its clients.

Our gensets are prepared to withstand extreme climate conditions, from temperatures below zero to the highest on the planet.

One of our latest projects has taken us to Africa, a continent full of contrasts and a real challenge from an energetic point of view. In Gambia, Guinea Bissau and Guinea Conakry, we’ve supplied emergency power for electric substations in these three countries. We designed, manufactured and supplied nine completely customised gensets, adapted to operate in the different substations.

We searched for the best solutions for our client which would completely cover their needs, that’s why the nine gensets have been designed to operate in perfect condition in isolated areas and at temperatures of up to 45°C.

Características

  • Spare parts kit for extensive operation.
  • 1000L fuel tanks for increased autonomy.
  • Fuel filters with water separators to ensure operation with low-quality fuel.

Statement COVID-19

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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?

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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?

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

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We supplied an emergency genset with an aseismatic system for the Carrasco electrical substation (Bolivia)

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Guaranteeing power supply in extreme situations is one of Genesal Energy’s specialties. Genesal’s emergency genset designs are always carried out according to the client’s needs.

The Carrasco electrical substation, in Cochabamba (Bolivia), is one of our latest projects in the country and a great example of seismic engineering.

For the Carrasco substation, the client needed a genset with very specific needs, as the installation is located in a very sensitive area, which is quite vulnerable to earthquakes. With the objective of facing this possibility and avoiding a catastrophe, our engineering team carried out a thorough study after listening to the client and analyzing the site in which the genset would be installed.

Upon receiving all required information, Genesal Energy manufactured a very precise genset, with all the necessary special systems to protect the Carrasco electrical substation. The result is a unit which, amongst other features, has anti-seismic mounts, and spring mounts between the base frame and the floor. A vent for the channelling of the cooling air to the outside, and a 1.700 litre fuel tank -which in this case was reinforced to comply with anti-seismic regulations- are just a few examples of the features of this genset, whose goal is to avoid failures in the mains supply which provides power to millions of citizens, at all times.

Features

  • Anti-seismic mounts.
  • Spring mounts between the baseframe and the floor.
  • Vent for the channelling of the output cooling air to the outside.
  • Reinforced 1700 litre baseframe fuel to comply with anti-seismic regulations (without certificate).
  • IVECO NEF67 TE2A engine at 24V.
  • Mecc Alte ECO 38-2S alternator at a voltage of 380/220.
  • 3400×1350 mm soundproof canopy.
  • RAL 9002 genset colour.
  • IEC61850 communication.