Essential sectors: Genesal Energy supplies emergency power to a large supermarket chain

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The food industry is an essential service whose quality depends largely on flawless logistics.

At Genesal Energy we are aware of the importance of the so-called food retailers, and we know that its facilities cannot afford power failures, especially due to the large amount of perishable products that are stored in these strategic locations.

In relation to the food sector, at Genesal Energy we have just supplied one of the main supermarket chains in Spain with emergency power to achieve the maximum precision and efficiency of the equipment. Specifically, our client needed an emergency system for one of its main logistics centers and after analyzing the place and the environmental conditions, our engineers designed a 2,045 kVA generator set.

The aim: guaranteeing the cold chain

The constant storage of perishable products requires very specific storage conditions, both in terms of temperature and time. A power outage can alter or break the cold chain, which would cause enormous material and economic losses. For this reason, our client needed a generator set including specific features that make it capable of facing the start-up of the entire system in the event of a mains voltage failure.

Thus, we manufactured a super soundproofed generator set, which was installed in a bespoke 40 HC container due to its location.

The control and automation of the generator was also tailor-made so that a PLC device can fully control the emergency system.

Characteristics

  • Integrated power panel inside container
  • Engine coolant heating system to provide the proper temperature when the genset starts.
  • Air inlet and air outlet attenuators to achieve a low noise level.
  • 1500 L double walled fuel tan installed inside an independent room within container.
  • Painted in the customer’s required color.

‘Black Start’ emergency power for a petrochemical plant in Tarragona

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At Genesal Energy we have supplied a 2,250 kVA black start generator set to a petrochemical plant in Tarragona (Spain).

The facility is equipped with a cogeneration plant that required tailor-made emergency power, that is, special equipment to guarantee the electricity supply at all times and in any situation. The project for this infrastructure was developed by our engineering team after analysing in detail the specific requirements our client had. Carrying out the black-start of the cogeneration plant in the face of a black-out of the external electricity supply was one of their main concerns.

Black Start equipment allows energy to be restored without depending on the external network, which is essential for the optimal maintenance of a power plant such as the one in Tarragona, since operation is guaranteed with no need of being linked to the power transmission network, allowing the servicing of the own turbines without any problem.

Likewise, the control and automation of each generator set for its integration into the other systems of the plant was also tailor-made so that a PLC panel can fully control the emergency system. Furthermore, in this case the generator is capable of operating in parallel with two mains.

The operator decides by means of a button on the corresponding control panel or remote order with which network it wishes to synchronize to restore the bar to normal situation. The system is equipped with a RS485-Modbus communication module to monitor all variables remotely.

Specialists in starting from scratch

Black Start technology is ideal for a project such as the petrochemical plant in Tarragona as it allows the power systems to be restarted without any problem in the event of any unforeseen event or collapse in the electricity network. The Autonomous Start or Black Start makes this possible and, therefore, reduces the threat of lack of supply, which is the greatest fear in this kind of plant. Start-up is guaranteed. At Genesal Energy we have the knowledge and experience to offer this kind of customer service. Always with a personalised attention.

Features

  • Fuel tank installed inside the container.
  • Attenuators inside the container.
  • Motorized breaker.
  • Neutral earthing switch.
  • Recirculation and engine coolant heating systems to reach the proper temperature when starting the genset.
  • Air inlet and air outlet motorized louvers.
  • Parallel operation between two networks.

Genesal Energy generator sets designed to run at full capacity in the Qatari desert

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When a Generator set is manufactured to work in places with unusual environmental conditions, it is essential that they are highly customized.

At Genesal Energy our equipment is designed in such a way that they are capable of operating in extreme conditions and at temperatures above 40 ºC. They are made-to-measure generator sets designed by our engineers after having carefully studied the environmental conditions in which they must operate.

One of our latest projects has taken place in a Middle Eastern country: Qatar. The Qatari authorities asked us to design several trailer mounted generators for a contingency energy fleet.

With a very hot climate and high humidity levels, Qatari summers easily exceed 45ºC. Therefore, the generating sets that have to operate in these circumstances must be custom designed. In this case, the client needed the equipment to have a great autonomy and that could easily transfer fuel from an external tank. They also needed them to be located in different areas by means of a trailer which must be suitable to drive along the desert sand.

Dust filters

In custom manufacturing, everything is designed in detail. Furthermore, the containers were manufactured considering the environmental conditions, including a customized tank, transfer system and external fuel connection point, as well as dust filters to prevent the entry of sand as they had to work in the middle of the desert.

Features

  • Engine and alternator sized to give the required power at the design temperature.
  • Sand filters.
  • Made-to-measure fuel tank.
  • Fuel transfer system and external fuel connection point.

We supplied emergency power to a maritime LPG terminal in Chile

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Emergency power to a new maritime liquefied petroleum gas in Chile.

At Genesal Energy we have just supplied emergency power to a new maritime LPG (liquefied petroleum gas) in Chile through a generator set designed to guarantee the continuity of the electricity supply in this facility.

Generator sets are essential in port infrastructures since continuity in the electrical supply is required for lighting the facility and for the uninterrupted operation of most the equipment and chargers. The lack of energy during the unloading of a ship can pose a great safety risk that is multiplied when we talk about this type of gas installations. Therefore, in these cases, it is essential to count on an alternative source of electrical energy in addition to prolonging discharge times.

What did our customer need?

The customer needed a solution with specific soundproofing conditions, special levels of interior lighting in accordance with port regulations, an interior fuel tank and a fuel transfer system for an external tank, as well as a controller for parallel operation with the mains and even another generator set if necessary.

The design of the generator also has a steel floor, with a liquid collection tray, exhaust system with built-in spark arrestor to avoid risks of explosion, PMG of the alternator and many other options that make this equipment a generator set fully adapted to the client’s specific needs.

Features

  • Power output panel integrated in the soundproof container.
  • Recirculation and engine cooling heating system to provide the proper temperature when the generator starts.
  • Exhaust system with spark arrestor integrated inside the container.
  • Anti-skid steel floor.
  • Marine impregnation in the alternator and PMG.
  • Surface treatment of the container according to ISO 12944, in C5 finish.

 

We supplied a generator set to a senior centre in Madrid.

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We have recently supplied a generator set to guarantee the electricity supply in the event of a mains failure in a senior centre located in Madrid.

In this case, it is a soundproofed unit of 550 kVA designed to face any unexpected event of accident.

This senior centre has 220 places available, 40 of which are destined to day care centres, as well as several rest and common areas. Needless to say that a power outage in this kind of centres may cause serious harm to residents since many are dependent persons who need continuing medical care, so it is fundamental to guarantee the electricity supply.

Medical care in these centres is a priority, and that what our customer emphasized. Thus, Genesal we looked for the most suitable solution considering the characteristics of the building and, especially, the residents’ needs.

110% load testing

Our engineering department’s solution focused on making the standard generator set fit like a glove to the place where it will be working inside the building. This genset included an upper air outlet, amongst other features.

Besides, all necessary tests were carried out, including a final test on our load bank up to 110% power aiming to verify that the equipment would work without any problem when needed.

This test is part of the exhaustive controls that Genesal Energy carries out not only customized, but also standard units, to meet the strict quality standards required by the company.

Emergency power to guarantee electrical supply in a hotel complex in Mexico

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We’ve recently supplied emergency power for a hotel complex in Mexico to guarantee continuous electrical supply in any situation.

This will be possible through the design and manufacture of two generator sets (GEN1250CA) prepared to cover the energy needs of these facilities should any failure or accident take place in the mains network.

The fact that the hotel is located in Mexico, with a climate which is subject to intense and harsh changes in weather such as cyclones or tropical storms, makes the installation of generator sets, which must be prepared to start up in the most difficult of circumstances, even more necessary.

Why is it so important for this type of facilities to possess generator sets?

This type of buildings, which are usually of great dimensions and feature numerous additional services, require their own power generation system for emergencies as they cannot leave anything to chance.

Halls, bedrooms, rest and restaurant areas, lighting, DHW, elevators… all areas, whether private or common, must always possess adequate power supply as a power outage would entail serious losses for both the clients and management of the hotel. At Genesal we’re specialists in this type of buildings -the first Hilton in Galicia is one of our latest projects-.

We offer a different, comprehensive service

Additionally, Genesal Energy’s broad experience in Mexico, a country in which it owns a branch office, makes the whole process with the client even easier. From the very beginning, the company provides the client with the knowledge of our engineers, a 360º service where all processes prove a lot easier despite their complexity, in important aspects such as genset commissioning or maintenance.

For this hotel complex, each generator set will supply power to a step-up transformer which changes the genset voltage to medium voltage and synchronizes both gensets and the mains in the event of an emergency.

This was the solution provided by Genesal’s engineers

From a mechanical point of view:

  • A base frame adapted to the assembly comprised of a Cummins KTA38 G14 engine and Stamford HCI634J1 alternator was developed, calculated and manfactured.
  • BRB AMC BRB 220 40 SH M24 anti vibration mounts were installed to prevent the transmission of unwanted vibrations to the hotel structure and a busbar of easy access and connection, but with adequate safety measures.
  • A control panel was designed to allow the taking of genset measurements from the medium voltage side, in such a way that, even if the group generated in low voltage, the startup and synchronization would be carried out in the medium voltage network.
  • To maintain the alternator protected if ever the step-up transformer fails, a specific protection relay for the low voltage part was added so that, if ever there were a short-circuit between the transformer and alternator, the genset could shut down and isolate the transformer to avoid greater damage.
  • Furthermore, a control panel for the management of the parallel operation between the island of gensets and the mains was supplied, so that the island would be capable of automatic startup following a mains failure, and synchronization upon mains return would be possible, so that the loads remain powered during the whole mains return process.
  • Finally, to ensure fuel economy of the gensets, between both gensets is a power management system which allows for one of the gensets to shut down if during a certain time the load dips below the configured value, starting up and synchronizing again if the consumption of the loads increases.

Characteristics of the generator sets

  • Alternator with PMG.
  • 600L base frame fuel tank.
  • Motorized breaker.

 

Genesal Energy guarantees emergency power to one of the UK’s major hospitals.

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At Genesal Energy, we have just supplied emergency power to one of the main hospitals in the Northwest of the UK through the design, manufacture and supply of a 1,100 kVA standby generator set ready to work in parallel with the mains.

The generator designed by our engineering team guarantees the continuous electricity supply and therefore, the uninterrupted operation of the hospital’s health services in the different areas.

Generator sets must be designed for a quick response – a few seconds – in the event of a mains failure or any other reason involving a power outage. This is the case of the equipment we designed for the abovementioned British hospital as its main goal is to ensure the electricity supply in all the medical care facilities, operating rooms, hospitalization plants and other health areas with the greatest precision. In addition, noise pollution has been reduced to the maximum considering the importance of peace and quiet for patients in this kind of buildings.

Our extensive experience in developing on-demand solutions for hospitals, regardless of their size and/or location, is one of Genesal Energy’s highlights both in Spain and internationally, as well as the best guarantee of the quality of our equipment.

There is a common denominator in hospitals: they treat convalescent people. This consequently implies a challenge for the company, as the safety and precision of Genesal’s equipment must reach their highest levels, especially in these buildings. “Our generator sets are designed under the premise that nothing can fail, and there cannot be any fissures in the process. It is fundamental for every unit that leaves the factory to be extremely reliable so that energy is provided quickly and with the necessary power”, our R+D+I department stated.

Features

  • Comap InteliGen NTC BaseBox controller with InteliVision 5 display unit.
  • Configuration:
    • Auto start in the event of a mains failure
    • Parallel operation with the mains
  • 1,600 L base frame integrated fuel tank including a collection tray with capacity to collect 110% the capacity of the actual fuel tank.
  • Generator mounted on a 20HC soundproof container with built-in air inlet and outlet silencers of -35 dBA to achieve a noise level of 75 dBA@1m. Acoustic panel of greater thickness inside the container and high-density soundproofing sheet have been included as well.
  • Double doors on both sides of the container for a greater accessibility and to facilitate maintenance works.
  • Customized external cable connection box for an easy connection of customer’s cables.
  • Control panel on the outside for quick access.
  • Motorized louvers.