Emergency back up power for the Machala General Hospital (Ecuador), a healthcare facility with 36 specialities and a catchment area of 350,000 people

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Genesal Energy has recently supplied 4 electrical generators as backup power for the Machala General Hospital in Ecuador.

A modern facility it’s healthcare options include 36 areas of specialisation for a region of 350,000 in the El Oro Province, one of the country’s most important administrative and financial centres.

Designed by Genesal Energy the emergency gensets form an essential part of the electrical installation within the complex, which covers 24,000 sq. metres and contains 200 patient beds.

The Genesal Energy solution is a guarantee of a continued power supply for the hospital in the event of a grid failure for national network, ensuring the hospital remains fully operational and that all vital healthcare continues. The Genesal Energy solution means the gensets have been prepared to operate in parallel two by two, supplying 1,254 kVA per genset pairing, as well as automatic start up if there is a g power cut in the external grid supply.

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The nature of these projects means that the any unexpected eventuality can be fatal. The gensets have therefore been designed with one clear objective, to immediately support the loads demanded should the normal external power supply stop functioning. Aside of their maximum operational precision, the gensets have been sound proofed for outdoor installation and to ensure that noise levels are kept to a minimum I the surrounding area.

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Features

  • Dimensions: 5,000 x 1,886 x 2,356mm
  • Weight: 5,680 kg

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

Foto AENOR

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 2,600 kVA 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 650 kVA, 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 L 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

Genesal Energy has participated in the construction of the first submerged tunnel to be built in Latin America

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Genesal Energy was responsible for designing the diésel generator responsible for ensuring power supply in emergency situations.

GENESAL ENERGY has recently administered a project to supply emergency electrical power in the Coaztacoalcos (México)tunnel, the first submerged tunnel of its kind in Latin America and one of the largest engineering projects ever undertaken on the American continent.

GENESAL’s responsibility was such that not only were they to supply the generator power unit, they were also in charge of the installation on site. The diésel genset itself (ERP 2407kVa at 13.2Kv) was designed at GENESAL’s European headquartes and manufacturing facility near La Coruna, and has since been installed and is fully operational in the tunnel.

Requiring an investment of $250 million dollars the 2,280-metre tunnel with 4 lanes for road traffic, runs below the riverbed of the River Coaztacoalcos, connecting the two neighbouring municipalities of Coaztacoalcos and Allende in Veracruz State. Further afield it has provided improved links to the states of Tabasco and Chiapas, and the tunnel services over 500,000 people as well as the numerous petro-chemical businesses in the area.

The fully submerged tunnel entered in to active use in April 2017, connecting Coaztacoalcos and Allende in little more than 3 minutes, a 40-minute reduction on the pre-tunnel journey time. The structure, consisting of 4 traffic lanes and almost 3KM long, communicates 2 urban areas in the Veracruz area with a population close to 500,000.

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Synchronized Genset

The structure of the tunnel in some parts reaches a depth of 35 metres, and was constructed using pre-tensed reinforced concrete, with a total weight of 135,000 tonnes, equivalent to 355 Boeing 747 jumbos. The same type of construction used in the tunnel section of the structure connecting Copenhagen in Denmark to Malmo in Sweden was applied here.

Should the tunnel for whatever reason suffer a power cut in the mains supply, or if there is a drop-in voltage, the GENESAL ENERGY generator will switch on automatically, ensuring continued power supply. When the mains power returns to its previously normal state, the genset will synchronize with the mains power and close off the breaker switch, smoothly returning all load power to the mains without any discernible change in the origin of the power supply.

Indie the tunnel a special room has been constructed and designed by GENESAL ENERGY, and the genset has been installed in here. GENESAL also designed a second room for storing the medium voltage cells and transfer measurement.

Fitted with the latest technologies, the genset underwent stringent testing at GENESAL’s main plant before being shipped to Mexico on the 13th February 2017. Due to its size, the radiator was specially designed to meet with cooling requirements in this environment. This also allowed the whole set up to be constructed on one supporting frame, which later reduced the difficulties in the installation process.

This entire project was done in conjunction with the Mexican branch of GENESAL ENERGY.

Download project info here

Genesal Energy supplies a fully operational Containerized Power Supply for a Mobile 3D Radar System

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The objective of this project was to supply fully operational power source for a Radar system.

The energy solution would supply independent electric power for the normal operation of a Tactical Radar System, with no requirement or dependence on other energy sources.

The Containerized Power Supply solution consisted of 2 gensets of the same type and model installed in a ISO-10’ container, each genset consists of an engine, alternator, fuel tank, switch panel, synchronisation and control panels, network monitoring and an Uninterruptible Power Supply (UPS).

In situations where the Radar System is deployed in places with a power supply, the Genesal System has been fitted with the capability to fully monitor the external power supply, and in case it should fail, switch to the emergency power supply or UPS. Should this situation occur it entails one of the gensets within the container initiating its operational sequence and consequentially ensuring a continued power supply to the Mobile Radar System. The Genset will operate for as long as the external power supply is off-grid.

OVIDIO ALDEGUNDE

Our commitment with R&D allow us to offer the best energy solutions for the military and defense application. We have the expertise needed to adapt each solution to every specific necessity of this field, always with the most strict confidentiality that this projects required.

Genesal Energy military gensets are compact, light, silent and easy to transport. They are ready to operate under the most extreme weather conditions, guaranteeing the power supply in all tactical situations.

Some features of our military generating sets are:

  • Super-silent, for shelters.
  • Trailer-mounted for easy transportation.
  • Water-cooled or air-cooled.
  • AC or DC generators.
  • Compact and lightweight.
  • Wide range of powers available.

Features

  • Two 180/200 KVA military-grade generator sets in 10-foot ISO 1D containers, forming what is known as the Power Plant.
  • This Power Plant supplies the energy required to operate a complete Radar System in standard operating mode, independently and without reliance on any other external power source.
  • Containers equipped with integrated levelling and lifting jacks, flush-mounted within the ISO-10 standard dimensions.
  • Each container was also fitted with a 70 kVA Uninterruptible Power Supply (UPS) system, incorporating its own climate control unit, ensuring a minimum autonomy of 10 minutes at full rated load (70 kVA).
  • The Power Plant could operate in two modes:
    • Using both containers in a 1+1 configuration (main + standby)
    • Using a single container operating with one generator set only
  • Automatic change-over system based on running hours between main and standby units in 1+1 configuration.
  • Each generator was equipped with a military-grade power and control connection box.
  • Stainless steel base frame with an integrated 1,000-litre fuel tank, providing over 24 hours of autonomy at 100% load [Under standard operating reference conditions for this class of equipment BS 2869:1998].
  • The engine–alternator assembly and UPS were removable to facilitate maintenance operations.
  • The engine was designed for continuous operation, compatible with TF-03 diesel, NATO F-54 diesel and JP8 (F-34) fuel types.
  • Electric cable reel for storing 50 metres of power connection cables.
  • The maximum total weight of each module comprising the system was 8,000 kg.

Download project info here.

Combined Cycle Power Plant Valle de Mexico II

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Genesal Energy has supplied an emergency power genset with a power rating of 2178 kVa which will be used as a back-up for the Combined Cycle Power Plant Valle de Mexico II in the municipality of Acolman (Mexico State).

Once finalised the plant itself will have an output power capacity of 615 MW and will operate with natural gas, at an approximate cost of 700 million $USD in construction investment.

The power plant itself will contribute to a 4 % increase in available energy to meet the growing energy needs in the centre of the country.

This particular project has been delivered in conjunction with our Genesal Energy Mexican branch, which has for many years contributed and supported the growth of the Mexican energy sector.

Download project info here

Emergency Gensets for substation Lastva in Montenegro

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Substation 400/110/35 KV

Genesal Energy supply to the Lastva substation in Montenegro, 2 gensets of special configuration to start at low temperatures, high capacity of autonomy and special programming for a perfect synchronizing with the substation’s own system.

Project background

Situated in Montenegro project SS 400/11-/35 KV consists of the construction of a sub-station with 2 x 300 MVA output and the expansion of the existing substation 400/220/110k Kv Pljevja 2.

The project is vital in terms of bettering the energy infrastructure in Montenegro as this project is an essential component to connect other substations within the country. This includes an underwater connection by cable to the Italian electricity supply network, leading to improved voltage and reactive conditions in the network leading to lower loss rated in the transmission grid.

Genesal’s involvement in this project was to construct and deliver 2 emergency generators as onsite back up for the construction of this project in Montenegro

Project development

In accordance with the clients’ specifications, Genesal Energy manufactured and supplied 2 emergency generators with 715 kVA ESP. This tailor made genset ensures a high level of autonomy (assisted by the integrated 1700 litre tank), as well as high reliability and a fail-safe system designed with sophisticated data readings and fault alarms.

The design was completed with the customers’ requirements at the forefront of our decision making, such as the location, the necessary soundproofing and the climatic conditions.

Features

  • Integrated Fuel tank of 1700 Litres (autonomy 12 hours +)
  • Maximum noise level at 1M : 85dB
  • Liquid retention basin.
  • Designed for ease of transport, loading and unloading.
  • Impregnated alternator for use in marine and corrosive environments.
  • Control panel for use in very low temperatures.
  • Sensors to measure temperature and exhaust gas pressure.
  • General thermomagnetic and differential protection
  • Monitoring of battery conditions as well as measurement of intensity, voltage and fault alarm for battery chargers.
  • Alternator alarm (voltage loss, low excitation, diode failure, bearings overheating, high/low frequency, and overload).
  • Temperature sensor for alternator windings.