We designed a mobile genset adapted to the needs of our client, to start up at low temperatures in Finland

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The close relationship we have with our distributors has lead us to supply a 130/142 kVA trailer-mounted genset, with weight limitations and prepared to be moved around in unfavourable meterological conditions.

Features

  • Mobile unit, mounted on a road-approved trailer, with M+S tires.
  • Compliance with emission standards for mobile gensets.
  • 250 litre fuel tank integrated into the base frame, specially designed to not excede the requested weight limits.
  • Cable drum to accommodate 15 metres of rubber cable of the H07RN-F 5G35 type located on the trailer’s tow bar.
  • Manual 4 pole breaker, with LS/I protection and minimum voltage coil.
  • 125 A external socket, with differential and thermal protection.
  • Power outlet busbar with access from the outside.
  • Average sound level of 74 dB(A) at 7 metres.

Supply of two generators to a fish farm in Norway

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We’ve supplied two 660 kVA gensets through our distributors in Norway, prepared to operate in parallel, which will guarantee the electricity supply of a fish farm.

Features

  • The engine has been painted with a special anti-corrosion treatment and the alternator contains anti-condensation heaters in its windings, to protect the gensets from the high levels of concentration of salt in their surroundings.
  • Both gensets are going to work in parallel, guaranteeing necessary power supply in the event of a mains failure.

 

Supply, delivery and installation of a 1,000 kVA generator set for a CPD in Barcelona

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Another client who trusts in Genesal Energy for their data center.

But not only in regards to supply – the whole logistics management was taken care of, including the cutting off of the street, the heavy-duty crane for the genset’s placement, verification of the power cable connection, connection of the alarm cabeling with the building’s centralized system, exhaust gas piping and load tests.

All carried out from midnight to 6 AM in order to not interfere with the centre’s day-to-day. And of course, we’ll carry out the required maintenance works with a 24 hour service and in a maximum intervention time on site of 3 hours from the call made to our Call Center.

Data Centres or Data Processing Centres (DPCs) are specially designed environments which house computer equipment, from computers to storage or network systems. They are facilities in which any electrical failure is a catastrophe as these types of instances can paralyze companies and risk the great amount of information they manage. For this reason, generator sets are vital in Data Centres as the service they provide must be continuous, without interruption.

At Genesal Energy, we’ve installed a 1.000 kVA emergency genset, model GEN1000TC, in a Data Centre in Barcelona. The client needed a new unit due to the building’s expansion, and we carried out a totally comprehensive turnkey project. At Genesal Energy, we studied the project and took care of the whole process. The unloading, installation, and commissioning took place in under six hours and in the early hours of the morning to not alter the area’s usual activity with the transport and installation works.

Special and made-to-measure

The generator set was especially designed with the ideal dimensions for its installation in the data centre. Furthermore, the client asked us to change the existing genset – the previous one was 12 years old and now obsolete – without bringing any part of the procedure to a halt and while avoiding any potential risk in the process, which also included the dismantling of the old genset and the set-up of the new one.

To achieve complete knowledge of the situation, Genesal Energy’s Technical Service Team travelled to the Data Centre to see the facilites on siteand plan the necessary works. Additionally, the team took care of all bureaucratic procedures (Municipal procedures, street cut-offs…), as well as all loading and unloading works, and the installation of a provisional rental genset for its use during the operation. The new generator set was installed and started-up in less than six hours.

Features

  • Genset prepared for parallel operation with another genset to be installed soon.
  • 1600A motorised genset breakers.
  • Level sensors in the genset’s fuel tank for the management of an external fuel transfer system.
  • Modbus RS-232/485 communication module.
  • Remote alarms in the form of dry contacts.
  • Engine cooling liquid recirculation and heating system to provide the correct temperature for start-up.
  • Spring type Silemblocks underneath the genset’s baseframe along with the engine-alternator assembly’s anti-vibration mounts to achieve a greater level of isolation.
  • – 40 db exhaust gas silencers to reduce noise.
  • Integrated control panel.

 

Two emergency gensets to guarantee reliability of an air traffic control tower in Cuba

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At Genesal Energy, we’ve supplied two 20kVA prime power gensets for a mobile air traffic control tower in Cuba.

They’re prepared to power the installation in the case of a public mains failure, protecting it at all times, as they have the capacity to power all of the tower’s systems as well as the vehicle’s electrohydraulic mechanisms.

The solution adds a special functionality: to change between one and the other automatically or to choose which of the both carries out the function of master and slave.

Both units were manufactured after studying the requirements of the client, who needed two compact gensets which would be easily integrated into the truck with the electrical panel and control panel separated and at a distance between one another.

Our group of engineers found a special solution and designed two two-phase gensets at a voltage of 220-110 V to adapt to the voltage of the Cuban grid. They’re very versatile units, with four different modes of operation which can be selected through the control panel. They’re located under the platform of a truck and have a remote control system located on the vehicle’s trailer.

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Why is it a special solution?

The main feature of these gensets is, above all, their redundant design, that is, the power supplied is done so by one of the gensets whenever there is a mains failure, meaning a second backup genset is left if the genset selected as the master were to fail or if the second genset itself were to be stopped due to maintenance.

Each genset has a remote control system through which the double switchover between both is managed as well as the switchover between each genset and the grid. Said system is installed inside the truck, communicating with both.

The solution adds a special functionality whose objective is to manage the redundancy of the gensets so that it’s possible to switch between one and the other automatically or choose which of the both carries out the function of master and slave manually through a selector in the control panel.

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Ultracompact

The gensets, on the other hand, are designed mechanically in an ultracompact format so that they occupy the least possible space, as they are installed under the platform of the truck’s semi-trailer where the control tower is located. Furthermore, the canopy that ensures the soundproofing of the gensets is completely removable in order to improve the accessibility of the genset for maintenance works due to the limited space available.

On the other hand, the engines used in these gensets are Deutz engines, cooled by oil, as they have to endure working temperatures of up to 30% higher than a standard engine cooled by antifreeze, thus maximizing the reliability of the system, especially considering the fact the gensets will be operating in especially harsh conditions. Reliability is a must in this type of units.

Energía de Hoy interviews Alexander Blanco López, head of the Operations Management department

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Operations Management is one of our most strategic departments. The magazine Energía de Hoy expressed interest in finding out how it works, its development and its operation. We’re sharing with you the interview that the magazine had with its Head of Department, Alexander Blanco López, in order to get a closer understanding of this area.

Alexander Blanco López is the Head of Operations Management at Genesal Energy. He studied Industrial Design in Ferrol and upon obtaining his post-graduate qualifications in the University of A Coruña he began working in Genesal Energy in January of 2007. Throughout these past 12 years, Blanco has grown professionally in the company. He is currently the Head of Operations Management, coordinating the interrelationship between the company’s different departments.

As you’ve made it known to the public, 2018 has been a very positive year for the company both in the international as well as the domestic market. What is Genesal Energy’s success based on?
From my point of view, our success is based on, above all, our versatility. In Genesal Energy we advise our customers, we assist them from the beginning because not only do we manufacture gensets, we also carry out “turnkey” projects which means we’re on top of everything during the whole process. We design and manufacture custom-made units, we take care of the installation, commissioning and subsequential maintenance works. I think that’s the key. While other big companies only manufacture, for us, the process starts when the client has an energy requirement and lets us know about it, and from that moment onwards we assist them, advising them and accompanying them at all times. Our link with the client doesn’t end in the factory. In reality, at Genesal Energy we’re really devoted to a comprehensive and highly personalised service. We don’t believe in the concept of mass production. Every sale the sales department closes we take on as a personalised project and a relationship of trust.

What perspective do you have for 2019?
We want to continue growing. 2018 was a very good year, the company took a great leap forward. For this reason our goals are centered around at least maintaining the levels achieved in the last fiscal year, where turnover grew 40% from 2017. The objective is to maintain these numbers, to consolidate them and to continue in the path of continuous and sustained growth.

This year you’ll be launching the new canopies by ranges. What will be their main features?
We’re finalizing the development of the first model of the new canopies so that the client, when they receive our gensets, perceive great quality. We’ve wanted to take it a step further and improve key aspects like utility and maintenance without them having an impact on the cost. The new canopies will adapt better to our our new production systems. In Genesal Energy we install different brands, both in the realm of engines and alternators and now, with this new generation of canopies, the sound attenuation of the gensets will improve and maintenance works will be simplified. This improvement has been promoted by the experience we’re acquiring not only in our own market, but also in other external markets where the requirement levels are higher, by taking note of this and trying to achieve excellence.

The development of products for the international market is without a doubt one of your strengths. Where does Genesal Energy operate exactly? Do you expect to expand this market short or medium term?
At Genesal Energy we carry out projects across the five continents and we have a magnificent relationship with big companies who develop projects worldwide and who we support. In this sense, the commercial department treats all our clients as if they were the only one, as they really are the ones who help to not only maintain us where we are, but also to improve and continue growing. It’s because of this that all throughout the month of January, a team of the Genesal Energy sales department travelled around the world to continue strengthening the relationships with clients and suppliers.

Offering a comprehensive service to your clients also contributes to the success of this company. What does this service entail?
We offer complete support to the client: telephone assistance, in situ, we visit their site, we take care of the set-up of the genset in any type of installation. We respond to any of their technical queries. On the other hand, once they’ve made a purchase order, we carry out a custom-made design, we manufacture the product, we carry out tests in our headquarters in Bergondo (100% of the manufactured units are tested before leaving the factory, at 110% of the load), we send over the genset, install it, and then we carry out another test in situ. We also offer our after-sales maintenance service throughout the whole lifespan of the genset.
At Genesal Energy, we don’t leave any part of the process on the sidelines. We’re aware of every detail, from the most basic elements to the genset’s maintenance works, both in the preventive and corrective sense. And if any fault should occur, we’re always there, implementing remote maintenance systems through which we know the status of the genset in real time and are made aware of any problems that could arise, carrying out the necessary preventive actions before a mains failure could occur and the genset is no longer working. We look for excellence for our customers, we know they make large investments in machinery that costs a lot of money, so we must guarantee their correct operation.

Source: Interempresas Media – Energía de hoy Magazine

Supply of two generator sets for a solar power plant

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Another achievement by our distributors.

We’ve supplied two gensets of 220 and 462 kVA, 220-127Vac at 60Hz, prepared to operate under CFE norms according to the degree of seismicity in Mexico as well as the area’s semitropical characteristics.

With a capacity of 170 MW, the Santiago photovoltaic power plant is located in the state of San Luis Potosí (México). It’s a large complex, whose construction began in 2017 with the participation of 1.000 workers. The power plant was built with the idea of supplying enough electricity to power 138.000 homes.  

Its 672.000 solar panels turn the Santiago power plant into one of the largest renewable energy installations in terms of investment (250 million dollars) and also one of the most spectacular, not only in regards to its size (it occupies 750 hectares), but also to the results its expected to achieve: it was built with the objective of preventing the emission of 340.000 tons of CO2 into the atmosphere each year.

The Galician company Genesal Energy participated in this megaproject through the design and supply of two generator sets of 220 and 462 kVA, 220-127 Vac at 60 Hz, prepared to operate in the area’s special conditions, such as the semitropical climate.

Both units were manufactured in Genesal Energy’s headquarters, located in the town of Bergondo, in A Coruña (Spain), with the goal of guaranteeing the correct operation of the booster and switching substations during emergency situations, providing the power necessary for the auxiliary services, emergency lighting, etc.

Genesal Generator in a solar power plant

High precision

Both gensets are high precision units, whose design has been thought out to the very last detail to comply with the client’s requests. They have the following features:

The first unit (GEN220FC) is soundproof type and has a 500 L fuel tank integrated in its baseframe, while the second (GEN462F) has a 1.000 L fuel tank. Both special gensets comply with all technical requirements established by CFE (Comisión Federal de Electricidad or Federal Electricity Commission) norms, the prestigious certification that the CFE awards and which elevates the company to the category of trusted supplier.

The CFE-LAPEM certification is granted by the LAPEM (Laboratory for Equipment and Materials Testing), an organization dependent on the CFE, and Genesal Energy received said distinction last year upon passing the audit process carried out by LAPEM in the company’s headquarters, thus becoming part of the select group of companies which have been awarded this certification, a true symbol of excellence.

Features

  • GEN220FC 500L fuel tank integrated into the base frame, Soundproof type, and with technical features following CFE (Federal Electricity Commission of Mexico) standards, painting with finish according to CFE norms.
  • GEN462F Approved 1000L double-wall fuel tank for external installation, with technical features following CFE (Federal Electricity Commission of Mexico) standards, painting with finish according to CFE norms.

 

We supplied two “turnkey” generator sets to the biggest combined-cycle power plant in Jamaica

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One of our latest projects in America has taken us to Jamaica.

We’ve had the pleasure of participating in one of the largest engineering projects in the island, the Old Harbour Bay combined-cycle power plant, the biggest in the country, for which we’ve designed and provided two special gensets.

Located in the fishing port of Old Harbour Bay, at almost 100 kilometres from Kingston, the 190 MW power plant is designed to operate with two fuels, gas and diesel, and uses a seawater cooling system. In this type of power plant there are special loads that must be fed permanently for the correct operation of the installation, for example, systems from the water treatment plant or the pumps from the lubrication units. These elements must continue operating so that, in an emergency situation such as a power outage, the whole system can be safely shut down. This is precisely the job of one of the gensets supplied by Genesal Energy.

The other is a Black Start unit, whose purpose is to power a motor in charge of the rotation of the main turbine, an element used for the cold start of the turbine after a programmed shut down. Furthermore, this genset has the particularity of supplying medium voltage directly (6600V).

Our client requested that both gensets be managed, controlled and monitorized completely from the genset’s control panel. The control philosophy consists in the diesel generator set being connected to the main power panel which is connected to the power busbars of the installation’s special loads -in the case of the emergency unit- or of the gas turbines – in the case of the Black Start unit.

Adapted to the client’s needs

For the implementation of this control system, a PLC was integrated in order to manage all of the elements of the generating installation, as well as a protection relay and a synchronizer for parallel with mains operation.

Both units were designed according to the client’s needs: special sets with a turnkey service. This way, each genset is soundproof and installed in a completely adapted container which includes all of the elements requested by our client (air conditioning, fans, motorized louvers, fire detection systems…).

Where we’ve had the pleasure of participating in one of the largest engineering projects in the island, the Old Harbour Bay combined-cycle power plant.

Features

  • Power panel integrated in the same soundproof container. In the case of the Black Start set, they’re Medium Voltage Switchgear.
  • Recirculation and heating system for the engine’s cooling liquid in order to provide the correct temperature during engine start-up.
  • Air conditioning system in the genset’s control.
  • Motorized louvers.
  • Fans in the engine room to keep the temperature under control.
  • Superficial treatment for the container according to the ISO 12944 standard, with a C5I coating.
  • Anti-condensation heater in the alternator.
  • NFPA fuel tank
  • Management of the genset control system and associated systems from the client’s installation through a PLC and a touch-screen.
  • Protection relays and mains analyzer for the generator.
  • Fire detection system integrated in the client’s installation’s detection loop.
  • Fire extinction system through water sprinklers.

Emergency Generator Set to provide power to a Data Center

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We already know that the presence of generator sets in data centres and communications companies is critical.

Our distributors are aware of this, and they’ve trusted GENESAL ENERGY to supply an emergency genset that will guarantee power supply in the main building of one of the most important telecommunications companies in Europe.

Features

  • Oversized fuel tank to provide over 24 hours of autonomy.
  • Leakage tray integrated into the fuel tank.
  • Easy connection cabinet for the unit’s power cables.

 

Emergency gensets for the railway sector

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We’ve supplied an emergency generator set to guarantee power supply to a tunnel in case of a main failure.

Allowing for continuous operation of the lights, emergency telephones and fans, as well as other critical services, thanks to the projects in the railway sector carried out by our distributors.

Features

  • Three-phase 230V voltage without neutral
  • Water-cooled genset through heat exchangers, both from the primary circuit as well as intercooler type, to cool the unit through the exchange of water originating from an existing tank in the tunnel in which the unit is installed, creating the secondary circuit necessary for that purpose.

We designed the gensets for two biomass power plants: the Viseu and Fundão power plants, in Portugal

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Genesal Energy has designed and supplied two special gensets for two biomass power plants in Portugal

The Viseu and Fundão power plants, two twin installations which, according to experts, will prevent the emission of 88.400 Tn of CO2 to the atmosphere. Both are a prime example of clean, renewable energy production.

Biomass power plants are thermoelectric power plants that use organic matter as fuel, whether it be of plant or animal origin, susceptible to being used for power purposes. These installations generate electricity through the combustion of the biomass to heat the steam in boilers. The steam, in turn, moves a turbine which spins a generator, which transforms the electric power into mechanical power.

As this process relies on combustion systems, great quantities of power are needed to cool the power plant’s systems to guarantee its operation.

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Slow combustion

In the event of a mains failure, the biomass power plants must be brought to a safe shut-down. To achieve this, it’s neccesary to maintain and power different cooling systems in order to avoid material or personal damages due to the overheating of the systems as, by its own nature, biomass combustion is a slow process.

In the event of a mains failure, this type of installation must be brought to a safe shut-down

If an electrical failure arises in this kind of power plant, the biomass inside its boilers will continue to burn, generating thermal power which won’t dissipate if the cooling systems aren’t operational. At Genesal Energy, we designed two units for these plants capable of starting up when a failure to power the essential services’ busbar is detected.

If the genset in question starts up and starts powering loads, the power plant will be in the process of shutting down and during this time it’s fundamental the cooling systems be active.

This way, when the genset is powering loads, even if mains returns, the power plant operator is the only one who can stop its operation and bring back mains power, guaranteeing that the shut-down process is always carried out in safe conditions.

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Maximum security

On the other hand, each of these units has different security systems which prevent the control over the breakers that power the essential systems’ busbar by other systems which aren’t the actual genset, in order to avoid short circuits due to errors in the operators’ handling.

The manifactured units are capable of starting up as soon as a failure to power the essential services

The only moment in which a system other than the genset can control the busbar’s mains breaker is during the power plant’s start-up, as in that moment the genset won’t be active.

Technical Features

  • Remote control panel in the installation’s electrical room
  • 1000 L base frame fuel tank
  • Fuel filler neck on the outside of the container
  • Installation in a 20” soundproof container with an air outlet silencer to achieve a sound level of 85dB at 1 metre
  • Communication via MODBUS TCP/IP with power plant control system
  • Integrated web server with access from the power plant’s control system
  • Genset load system in a sequence of up to 14 steps.