We have supplied a generator set for the rental fleet of our dealer in Denmark

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We’ve supplied a 100/110 kVA John Deere genset for the rental fleet of our Danish distributor.

Incorporated on the unit is a socket panel adapted to the client’s requirements, with differential protection, installed on one of the front ends of the canopy.

Features – Rental generator sets available in Denmark

  • Stamford alternator with PMG system.
  • Control panel programmed for MRS function.
  • Extended fuel filling point to avoid fuel spillage during genset transport.
  • Socket panel adapted to the client’s needs, with differential protection.
  • Completely covered power cables to avoid access to live parts.
  • Breaker installed separate from the alternator on its own support frame.

Special generator set to operate in the extreme cold on a Norwegian vessel

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Low temperature emergency gensets must perform at full capacity in the harshest of conditions. A good example of this is the totally soundproof genset we manufactured for a vessel in Norway.

It was installed inside a 20’DV container and is prepared to operate at full capacity on the high seas. Along with the marine generators that provide electricity to the ship constantly, this GEN440FC is in charge of backing up these generators if ever the main equipment were to ever fail, as well as whenever the boat is in port. Furthermore, the maintenance tasks can be carried out with the Genesal Energy generator installed on the boat’s deck.

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Features

  • Air recirculation system to increase air temperature at startup.
  • Engine water preheating for genset startup.
  • Air preheating for genset startup.
  • Genset room internal heating system.
  • Motorized and heated louvers.
  • Superficial treatment according to ISO 12944 norm, in a C5M finish.
  • Alternator anti-condensation heating.
  • Alternator marine impregnation.

 

Supply of a generator set in the hotel sector

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Once again, GENESAL ENERGY is the chosen brand for the supply of a generator set in the hotel sector, specifically in such a tourist-dense destination as Santa Cruz de Tenerife.

This 440 kVA genset has been designed and prepared to guarantee the correct operation of the hotel should a mains failure ever occur on the island.

Features

  • 400 kVA PRP & 440 kVA STP generator set, with VOLVO engine and MECC ALTE alternator.

1,000-1,100 kVA generator set prepared to operate in low sound conditions

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At Genesal Energy we customize projects to make them special. Guaranteeing power supply 24/7, 365 to a residential area has been one of our latest projects in Great Britain, one of our markets in expansion.

We designed a 1,000/1,100 kVA soundproof unit to guarantee power supply in the area at all times. The client requested that, in the event of a mains failure, all emergency elements in the community, such as the lighting or ventilation systems, or the automated garages, all operate without fail. At Genesal Energy we continue working to give you the best energy!

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Features

  • High capacity spill tray to cover the whole generator set.
  • Automatic breaker accesible from the outside through a door, prepared for easy access and with connection of four screened cables per phase.
  • Control panel with outside access to be able to operate the genset without having to access the container.
  • Air outlet silencer for a higher attenuation, achieving a sound level of 85 dBA at 1m.

Generator set for one of the world’s leading companies in paper and packaging solutions in Austria

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Another accomplishment by our distributor in Austria has allowed us to supply a 550 kVA genset in a container, prepared to operate in permanent parallel with the mains, for one of the leading companies worldwide in paper and packaging solutions.

It’s a Volvo unit of 500/550 kVA, installed inside a 20’DV container with special fire-resistant components at the client’s request, as well as a special control system designed to manage not only the generator set, but two external automatic transfer swithes located at the client’s facilities.

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Features

  • Control cabinet including: 3 x Comap Intelivision 5, 1 x IG-NTC-BB to control the genset, 2 x IM-NTC-BB to control the external ATS’s, and 1 x IGS-PTM module to provide 10 free contacts; as well as separate chargers for start and control, MainsPro protection relay, and a 5 RJ45 port Ethernet switch.
  • Battery disconnect switch.
  • Double-walled 2500L fuel tank located in a separate comapartment in the container, separated by the genset with an F90 fire-resistant wall.
  • Fire-resistant doors with anti-panic fittings.
  • Leakage collection tray under the genset for the engine liquids.

Low temperature emergency diesel genset for a Norwegian ship

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Generator sets for low temperature conditions have to be very special, and at Genesal Energy we’re experts in designing specific systems to withstand thermometers below zero.

This is exactly the case of the genset we designed to perform at full capacity and to withstand marine conditions in an icy climate such as Norway’s.

It’s a diesel, soundproof genset, which has been installed on a vessel inside a 40’DV container. It’s prepared to operate on the high seas in perfect conditions, all whilst facing the most adverse circumstances. Along with the marine generators that provide electricity to the ship constantly when it’s at sea, the Genesal Energy unit, GEN1000PC, is in charge of backing up these generators if ever the main equipment were to fail and whenever the boat is in port. It’s also possible to carry out the maintenance tasks with the Genesal Energy generator installed on the boat’s deck.

  • External fuel filling point, on the outside of the container (stainless steel)

  • Heaters inside the container with operation via thermostat

  • Motorized and heated air inlet and outlet louvers

  • Motorized and heated air inlet and outlet louvers

  • Hot air recirculation system via temperature sensors which send the command to open/close the louvers so that the genset’s temperature can increase during the first moments of its startup

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Features

  • Thermal and acoustic insulation as required.
  • Air recirculation system to provide the correct air temperature for startup during winter.
  • Engine water preheating for genset startup.
  • Air preheating for genset startup.
  • Genset room internal air conditioning system.
  • Superficial treatment according to ISO 12944 norm, in a C5M finish.
  • Alternator anti-condensation heater and marine impregnation.

We supplied two customised generator sets for the Austrian market

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We continue rounding up references in Austria, where we’ve just supplied two special gensets of 650/715 kVA with Volvo engines for an important international multi-platform media firm.

They are two identical units, completely customised to fit the requirements of the client, who needed two generator sets prepared for parallel operation between eachother and with the mains, designed to withstand the load sequence of the coolers located at the facilities.

Each generator set has an oversized 1000L fuel tank installed in the base frame which includes a leakage collection tray, and is prepared for automatic fuel transfer from an external tank; as well as a special busbar adapted to the client’s power cables.

Features

  • 1000L fuel tank in the base frame with leakage tray to collect all genset liquids, prepared for automatic fuel transfer from an external fuel tank.
  • Parallel operation between gensets and with the mains.
  • Busbar adapted to the client’s power cables.
  • Fuel filter with heater.

 

Supply of generator sets to the Tres Mesas wind farm in Mexico

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Another achievement by one of our distributors.

We have supplied two 82 and 110 kVA units prepared to back-up the auxiliary services of the electrical substations of the Tres Mesas Wind Farm (Phase IV), guaranteeing the correct operation of the electrical systems in response to any eventual failure that may occur.

Features

  • Double-walled 600L fuel tank and automatic fuel transfer system for 48 hours autonomy at 60% load.

 

Toyota chooses a Genesal emergency genset for its factory in Guanajato (Mexico)

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Toyota has trusted in Genesal to deliver emergency power to its Mexican factory in Apaseo el Grande, Guanajato.

The client needed something very specific: a back-up genset for the auxiliary equipment of the switching substation which serves the factory, for which we designed and supplied a 220 kVA special set, capable of providing the necessary support to the factory in the event of a mains failure.

The factory is one of the biggest projects carried out in the Apaseo el Grande municipality and will cause a great economic impact in the area, generating employment for 1.100 people. Furthermore, the installation will complete the production that the Japanese multinational corporation carries out in Baja California, where it currently produces around 170.000 units a year, of which nine out of ten are exported to the United States.

Precision and maximum reliability

In its first stage, this factory will assemble an average of 100.000 units a year of one of their star models: the Tacoma truck. In its second phase, the factory is estimated to produce 200.000 vehicles, reaching 300.000 before the year 2025. According to the company’s estimations, the factory is set to be operational towards the end of this very year.

The design of special generator sets to provide emergency power to great factories has been one of Genesal Energy’s focuses from the very beginning. Likewise, all of our gensets are custom-made after listening to each unique client with the objective to comply with their specific needs. In this case, the unit manufactured for Toyota’s new factory in Mexico has, amongst others, the following features:

Main Features

  • Double-walled 1000L fuel tank for 12 hours autonomy at 100% load.
  • Start-up through external command.
  • Communication system with SCADA System through TCP/IP protocol.

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

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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?

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