Genesal Energy Electrical Generator, dual voltage and dual frequency

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500-550 KVA genset designed for industry leader in cold storage installations for the South American market.

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The client, an industry leading company in cold-storage facilities, had a special request: On the one hand, they needed and emergency backup power option for their manufacturing plant at 50Hz. However, they also need an alternative energy source to carry out testing on machinery (freezers, water recovery systems etc) at 60Hz for products which would be sold to Latin American markets. Because of the different voltage and frequency used in Central & South American countries the power grid in the client’s European base prevents them from testing products in authentic conditions. Hence the reason for an alternative power source to allow testing in the conditions found in Latin American markets. It was for these reasons that GENESAL ENERGY designed a “dual frequency” solution to meet all their needs.

GENESAL ENERGY developed a specific project to ensure a power supply with two power supply functions:

  • Emergency back up to provide electricity to the clients European manufacturing plant in case of a power grid failure.
  • Provide an electricity source for testing machinery built with different voltage and frequency.

Project summary

Design and manufacture of a 500-550 KVA genset to operate in emergencies, giving an independent power supply in case of a power grid failure to two workshops at 400/230 V 50Hz. At the same time, it will also give a power supply to a testing bench at 400/230V 50Hz or 460/266V 60Hz in manual mode.

Project goals

Was to design a genset with three operational modes:

  • Emergency power for workshop 1 at 400/230V 50Hz
  • Emergency power for workshop 2 at 400/230V 50Hz
  • Power supply for a testing bench at 400/230V 50Hz or 460/266V 60Hz

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Solution

We opted for a newly designed 4500mm long canopy, with a view to easy access for maintenance and mechanical operations, along with an 800l fuel tank integrated in the base frame, to ensure a constant power supply for extended periods before having to refuel.

Only one control panel was installed for the entire control of all operations required from the genset, and at twice the size of a standard genset control panel This was integrated in to the interior of the genset with a front access window panel for visual access, although for safety and security, access is only gained by the authorised key holder to the control panel

Features

  • Dual voltage and dual frequency
  • Modbus TCP-IP (IB-LITE) communication device
  • Oil extraction pump
  • Automatic start up in case of grid failure
  • 800L internal base frame integrated fuel tank with
  • connections for future link to external fuel tank
  • Up to 11 hours of autonomy at 80% load, or 18
  • hours at 50%.
  • Battery disconnector

Download project info here

We have been awarded with the AENOR Certification OHSAS18001

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Genesal Energy is delighted to share with you that we have been awarded with the AENOR Certification OHSAS18001 for Health & Safety at Work, as well as renewing currently held certificates in ISO 14001 Environmental Management, UNE 166002 R&D&I Management System and ISO9001 Quality Management System.

The official presentation took place in in our European headquarters in Northwest Spain

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Such recognition validates our ongoing efforts in the company with regard to the health and safety of our employees as well as reducing the risk of injury in the workplace.

Genesal Energy has obtained the OHSAS 18001:2007 certificate as accreditation for our management with relation to H&S at work. This rating, officially accredited in Spain by AENOR, is in addition to the other certifications held by the business and recently renewed: ISO9001:2015 Quality Management System, ISO 14001:2015 Environmental Management and UNE 166002 R&D&I Management System.

The OHSAS certification was finally awarded after an exhaustive process which involved a strict external audit consisting of an evaluation all the methods and protocols in place for managing work safety. The award itself reinforces Genesal’s commitment to the workforce and our dedication to ensuring we have the best materials in matters of health and safety, our priority being to provide the best possible working conditions

AENOR is the leading authorised certifier in Spain, ad amongst the top 10 globally. Their knowledge in the field of quality, environmental management, innovation and work safety are to the highest and strictest standards, giving the awarded companies such as ourselves added value, and a guarantee of excellence.

The OHSAS 18001:2007 Certificate is the latest in a long line of achievements here at Genesal Energy, and will be incorporated alongside our other afore mentioned and now renewed certificates for the next 3 years.

Leaders in securing the UNE166002 R&D&I Certificate

Amongst the list of renewed certificates, we should highlight our Certificate for Environmental Management (ISO 14001:2015), official recognition that at Genesal Energy we meet the most rigorous standards in terms of environmental protection. A special mention should also go to our UNE166002:2014 certificate in R&D&I management, as we were the first Galician company in our sector to achieve this standard.

Director General Fernando Cueto and other members of our workforce from a variety of departments were delighted to be presented with the newly acquired OHSAS18001 alongside the 3 renewed certificates, from AENOR’s Galician Director, Martin Pita. The ceremony itself took place onsite in our European headquarters in Northwest Spain.

Genesal Energy supplies emergency power to the Steinkjer fish-farm in Norway with gensets synchronised in parallel

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Precision pre-heating systems and a stable power supply to combat the very low temperatures found in Northern Europe were just some of the key characteristics of this customised project carried out by Genesal Energy for the Steinkjer fish factory (town pop. 21,000) in the Trondheim fjord in North Norway.

Fish factories are singular installation: containing water temperature, water flow and recirculation control systems, designed specifically to maintain and foment conditions as close as possible to the natural sea environment for ideal fish growth. They therefore require a constant and stable electricity supply due to the delicacy of the product. For this reason, back up emergency gensets that become operational if there is power grid cut are crucial, a power cut of just a few minutes can lead to large economic losses for the business.

In the case of the Steinjker fish factory there was an added difficulty – the climate; The town is in North Norway an area very prone to very low temperatures. For this project, an emergency backup system of 2600kVA was calculated in order to supply the load required for continued activity, and the overall design needed to fit in to a small area.

To meet the client’s needs, Genesal Energy came up with the idea of 4 gensets to run in parallel, each with a rating of 650kVA, ensuring that if there was a power grid failure, the four engines are sharing the entire load and guaranteeing normal functionality in the fish factory itself.

Designed to meet the client’s needs

Not only was it important that the genset emergency system could supply the load in the minimum time possible and with maximum reliability, it was actually considered a high priority. Using 3D technology Genesal also designed the entire installation project.

The project, aptly named “Fishfarm”, included aspects such as made to measure gensets, ventilation in the room they were to be located, and a connected fuel supply system. Once an exhaustive study of the client’s needs had been carried out the entire design and manufacturing process was carried out at GENESAL’s headquarters in northwest Spain, as follows:

  • Assembly of 4 synchronised gensets in parallel, built to fit perfectly in the end-users on site storage room, and to secure handle the loads that will be required
  • High quality engines and alternators were chosen for their reliability
  • Manufacture of auxiliary systems for start-up in very low temperatures (guaranteeing optimal functionality)

Features

  • Automatic fuel transfer system
  • Parallel synchronisation
  • Automatic motor protection thermal magnetic circuit breakers, with the outlet in the top of the genset, due to the complex characteristics of the installation onsite.
  • Modbus communication board
  • Manual oil extraction pump
  • Low temperature start up system
  • 400 litre internal mainframe fuel tank

The Fishfarm project is yet another example of Genesals focus on designing and participating in distinctive projects requiring a very distinctive touch. The integral service, along with constant innovation, in-house technology and the company’s ability to diversify, allows Genesal to take complex situations from the drawing board and make them a reality, just some of Genesals identifying marks.

Download project info here