Emergency power for the Navantia San Fernando shipyard

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Avoiding issues in first-rate installations and infrastructures is one of our specialties thanks to our R&D department.

As such, with innovation as our banner, at Genesal Energy we can offer complete, personalized and cutting-edge solutions like the ones we designed for Navantia and its San Fernando shipyard, in Cádiz.

We supplied a 1650 kVA genset for the shipyard, prepared to operate at full power and guarantee power supply to all equipment located in the dry dock.

The main objective was specifically to supply emergency power for the dry dock’s bilge pumps, which must operate continuously as there can be no water in the area, due to the personnel always at work in it.

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Features

  • 1500L fuel tank integrated in the baseframe with collection bund of 110% the fuel tank’s own capacity.
  • Parallel to mains operation with dual circuit breakers: one of them motorized for parallel with mains and one manual for connection of the load bank to carry out load tests with the genset already installed.

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.