Generator set for a hangar at Barajas airport with a surface area equivalent to three football pitches.

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Adolfo Suárez Madrid-Barajas airport leads the ranking of air traffic in Spain. It closed the 2023 financial year with a passenger volume of more than 60 million and more than 380,000 operations carried out.

The figures reflect the importance of this airfield which, due to its colossal dimensions, needs to have many hangars where aircraft can “rest”. Premises equipped to carry out repairs and maintenance operations inside.

They are normally designed to house more than one aircraft and emergency power is key to their operation. With a surface area of more than 22,400 square metres, the equivalent of almost three football pitches, one of these airport hangars needed a special generator. Genesal Energy has just supplied contingency power to prevent a significant loss of time and money with a special genset for airports.

Tailor-made: generator set for a hangar

“The client required the customised manufacture of hoppers and bellows for the generator’s cooling air outlet, as well as a gas duct with 90° bends to adapt to the layout of the hangar’s generator room“, explain the engineering staff which developed this project. 

Our engineering team’s solution consisted of a highly customised generator set, which was manufactured according to the customer’s requests, seeking the best options for a special site with such particular dimensions.

Technical Data

  • Power panel integrated in the alternator, allowing the intake of two cables per phase.
  • Calculation of the necessary cross-sections for the inlet and outlet of gases in the room, tailor-made hopper and bellows.
  • Oversized exhaust silencer model.
  • Multicolour control panel.
  • Heating system.
  • Integrated 350 L tank.

Genesal Energy provides emergency power for two sugar farms in Tanzania

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Africa is a continent with great natural resources. Market studies of the states in the eastern region, formed by 14 countries, reflect a 3% growth of the energy sector in the coming years.

In this favourable scenario, one country stands out: Tanzania.

With a population of more than 63 million people, Tanzania’s agriculture is an important source of income, representing 25% of GDP, and sugar cane is one of its most profitable crops. Within this sector, the Kilombero Sugar company is a heavyweight. Its projects to increase production in the medium and long term require solid infrastructures capable of withstanding any unforeseen power supply eventuality, the country having a very deficient electricity network.

Reliability: emergency energy gensets for sugar farms

Genesal Energy has just reinforced the safety of the energy supply in one of its factories of brown sugar for direct consumption.

The company owns and operates two farms close to each other, Msolwa K1 and Ruembe K2, located on both sides of the Great Ruaha River and linked by a bridge. Both farms are involved in brown sugar production and need a very reliable network to carry out their daily business.

The project developed by Genesal Energy for Kilombero Sugar focused on the design, manufacture and commissioning of two soundproof generator sets with three different rooms each: engine-alternator room, control room and storage room.

2xGEN2000YC features:

  • Two soundproofed generator sets were designed in 40 feet containers, guaranteeing an average sound pressure level of 85 dB at 1 m.
  • The container has 3 separate rooms: engine-alternator room, control room and storage room.
  • A Baudouin engine was fitted with a Mecc Alte alternator on an electro-welded steel base with anti-vibration blocks.
  • A 2000 L, double-walled, certified tank was installed inside the container.
  • A water spray fire detection and extinguishing system was installed in the group room and the storage room.
  • CO 2 extinguishers were installed in the control room.
  • Air-conditioned control room.
  • C5 paint surface treatment, in accordance with ISO12944

GEN1100YC features:

  • 40ft Container, guaranteeing an average sound pressure level of 85 dB at 1 metre.
  • Container with 3 separate rooms: engine-alternator room, control room and storage room.
  • Baudouin engine & Mecc Alte alternator on an electro-welded steel base with anti-vibration blocks.
  • 2000 L, double-walled, type-approved tank installed inside the container.
  • Water-spray fire detection and extinguishing system installed in the genset and the storage rooms.
  • CO2 extinguishers in the control room.
  • Air-conditioned control room.
  • C5 paint surface treatment, in accordance with ISO12944

Genesal Energy participates in Data Centre World London, Europe’s leading trade fair specialising in data centres.

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Visitors will have the opportunity to see the company’s most advanced generator sets, characterised by their cutting-edge technology.

Data Centre World

Bergondo (A Coruña). 2024, February

Genesal Energy will show its latest innovations in generator set solutions for data centres and critical facilities at the Data Centre World 2024 in London. This prestigious trade fair that will bring together the sector’s world elite in the capital of the United Kingdom on the 6th and 7th of March. A chance to exchange experiences, learn about the latest products on the market and showcase the most cutting-edge technologies.

Data Centre World (DCW London) is the leading forum for data centre professionals, held in London’s largest exhibition centre, the ExCel. Genesal Energy is going to showcase its latest advances in data centres, a market where the Galician company has been innovating for years to offer the most robust and reliable generator sets. The best service to these key facilities for the digital transformation.

The present and future of data centres, the latest trends, the importance of sustainability and the challenges & opportunities offered by a sector in constant transformation will be the topics to analyse and debate at the annual DCW. London will be the European capital of data centres for two days, both in terms of the number and prestige of exhibitors and attendees.

For Genesal Energy, the fair will also be a good opportunity to exchange experiences and to show its last-generation products adapted to the Uptime Institute standards. The company will have its own stand, D1282, where visitors will be able to exchange their views with professionals from the Spanish company, characterised by providing customised solutions tailor-made to the needs of the client.

About Genesal

Genesal Energy is a business group based in Northern Spain devoted to the distributed energy sector with a firm commitment to innovation, specialisation and sustainability. It takes pride in its strong R&D department and designs, manufactures, and services top-quality generator sets. Internationalisation is key to its business strategy – 70% of its production is exported – it has subsidiaries in Mexico and Peru and sells its products to more than 30 countries.

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We bring energy to the “Carlos Tartiere”, the largest football stadium in Asturias with a seating capacity of 30,500

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With 30,500 seating capacity, the “Carlos Tartiere” municipal football stadium, home to Real Oviedo, is also the largest sports venue in Asturias.

Genesal Energy has designed an open and customised generator set for stadium to guarantee the electricity supply in the event of a possible failure of the main grid. If it happens, the show must go on.

For facilities of this type, the availability of emergency generators has become compulsory by law. The reason is to prevent a simple blackout from forcing the cancellation of a match or competition, with the consequent inconvenience that this would cause the players, spectators and, above all, the club, as it would have serious economic and reputational consequences.

Emergency generator for stadium

“The installation of a generator set in a football stadium guarantees 100% of the electricity supply and that the events in the stadium can take place normally, without problems”, explained the Genesal Energy Engineering Department.

In this type of project, the generator sets must have highly reliable engines to assume the loads quickly in the event of a grid failure, maintaining not only the frequency but also the generation voltage.

Genesal Energy is perfectly aware of the importance of small details and precision in the manufacturing process of generating sets for sports venues and we have carried out numerous projects in this sector. Among our latest works we can highlight the emergency systems for the Mendizorroza stadium and for the municipal stadium of Anduva.

Which was our solution for Real Oviedo FC?

Our client needed to replace a generator in poor condition and reorientate the air inlet and gas outlet due to works being carried out at the sports facility. Based on this premise, the engineering department developed an open generator on a laminated ‘U’ with an independent 1,000 litre tank, switch on alternator and compact box of two batteries. The customer required the input to the group power with two cables per phase and the customised manufacture of the hopper and bellow for the air outlet of the radiator.

Features

  • Emergency unit with external start-up.
  • Open skid on laminated ‘U’.
  • 4-pole CB on alternator.
  • Dimensions adapted to customer’s room.
  • ComAp InteliLite4 AMF 25 controller.
  • Additional heating pump.
  • Additional tank 1,000 litres.

Emergency generating sets for the 4.0 conversion of a large shipyard in Spain

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Genesal Energy has designed three special shipyard generator sets to reinforce the security in the power supply of one of the main Galician shipyards, a benchmark in Spain.

The purpose of the works is to convert the shipyard into a ‘smart factory’ improving all the processes and tools of its value chain and production centres to incorporate them into the new digital ecosystem. A 4.0 Shipyard.

The equipment was manufactured to complement the renovation works on the facilities of the famous shipyard. This works cover four fields of action: machinery and products, applications, people and company. The customer required three generator sets for the supplementary power supply station with a production capacity of 4,5 MVA with an option to extend it by 2,2 MVA.

If there was a power failure at the substation supplying the shipyard, there would be a serious problem, hence the importance of back-up power: our generator sets would be up and running within seconds. Guaranteeing the safety and optimal operation of the facilities.

Shipyard generator: versatility, a plus

The tailor-made generator sets are adapted to work in a saline environment and are 100% versatile. The control system is adapted to operate in parallel with the grid, and an automatic diesel fuel transfer system was designed for refilling from a central tank.

“We took into account the loads that are going to feed the equipment and the type of control that the client is going to use in the installation”, explained Engineering. The containers were also customised according to the final location of the machinery with the colour and design requested by the client.

Features

Equipment for saline environment:

  • Stainless steel exhaust gas silencer.
  • Marinised alternator.
  • Alternator anti-condensation resistor.
  • PT100 probes in alternator windings.
  • Motorised air inlet and outlet louvres.
  • Stainless steel ventilation louvers.
  • Surface paint treatment according to ISO12944 – C5M.
  • Container design requested by the customer.
  • Motorised CBs.

We take part in the extension of Extresol, the solar thermal plant in Badajoz

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When it came into operation in 2010, Extresol-1 was the second plant of its kind in the world.

A budget of 300 million euros, 50 MW of installed power and the use of the most advanced technologies. Extresol uses cylindrical-parabolic collectors within a solar radiation concentration system equipped with a sun-tracking mechanism. The task of these plants is to direct solar radiation from the reflecting surfaces onto the receiver tube and concentrate it about eighty times.

A generator for a solar thermal plant

Built on 2,25 square kilometres of land in Badajoz, Southwest Spain, Extresol currently supplies electricity equivalent to the consumption of more than 30,000 homes and avoids the emission of 149,000 tonnes of CO2 per year. Genesal Energy takes part in the expansion works of this infrastructure doing what we do best: reinforcing the security system with a solid emergency network to avoid issues and shutdowns in the event of failure in the network.

Customer’s need

Our client needed to guarantee the emergency supply in the event of a failure in either of the two existing transformers and it had to be done independently. Genesal Energy installed a 935/1010 KVA open genset placed inside one of the plant buildings, with double switching mounted on the genset itself due to the existing space limitations, and also double mains detection, operating the equipment independently for each of the transformers.

Technical Data

  • 1000 litre specially designed fuel tank on the bedplate.
  • Switchboard integrated in the bedplate, equipped with two 1600A 4P 230V motorised ATS.
  • ATS Mains detection system.
Gas generator in natural environment

We bring our energy to the Montseny Natural Park, World Biosphere Reserve

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The southernmost fir forest in Europe is located in the Montseny Natural Park (Barcelona), declared a World Biosphere Reserve by UNESCO in 1978.

A privileged environment that extends over more than 30,000 hectares. There, in the heart of nature, you can find holiday camps & farmhouses where vulnerable families’ children can enjoy unforgettable summers in a film-like area.

The challenge: installing a generating set in a protected place

Genesal Energy has provided emergency power to guarantee the electricity supply in one of these holiday homes located in Sant Pere de Vilamajor. In such a special and protected place, from an environmental point of view, the care taken when developing the project was of the utmost importance.

Gas generator in natural environment

Genesal Energy’s engineering department paid utmost attention to the location of the generator set, which had to operate in a natural park protected by UNESCO. So, from the very beginning one of the objectives was to reduce the acoustic and visual impact of the generator set so as not to spoil the beauty of the site.

The project included the installation of a gas generator, which is more environmentally friendly in terms of CO2 emissions than a diesel generator. The generator set was manufactured in a soundproof cabin to lower the noise levels of the machine as much as possible.

Technical Data

These are its main features:

  • LPG gas engine.
  • Alternator with auxiliary winding.
  • No fuel tank on the base frame, which functions as a tray for liquid collection.
Containerized soundproof generator sets

Genesal Energy supplies 6 containerized soundproofed generator sets to a data centre in Norway

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The strategic importance of data centers

Data Centres are facilities that allow companies and users to quickly access data and, due to the function they perform, they have become essential in an increasingly digitalised world. Their electricity consumption is considerable and this high demand is not only used to run the IT equipment, but also to cool these rooms that house it.

Maintaining optimal temperatures in data centers

The optimum operation temperature in a data centre to ensure proper performance of the servers is between 18 and 20°C. To keep the temperature within these values, an uninterrupted power supply is vital. Any brief network outage could paralyse all the activities of a company and cause not only economic losses but also reputational damage that is difficult to recover from in most cases.

Generating sets: guarantee of continuity

For this purpose, redundant supply sources are used to ensure operational continuity in the event of any failure in the electricity grid, namely, electrical generators. An efficient and specialised solution to guarantee the constant availability of electrical energy.

Data Centre generator sets require cutting-edge engineering and experienced personnel. Genesal Energy provides both and for this reason the projects we develop are in great demand in this market.

One of our latest projects in this field has taken us to Norway, where we have supplied a total of six generator sets to power the emergency network of a data centre. The cold climate of this Nordic country was not an obstacle to the success of the project, as the six generator sets were designed to withstand the country’s low temperatures.

The engineering solution: 6 soundproofed generator sets in a container

Six 2250-2500 kVA soundproofed generator sets in a 40 feet HC container ready to work in permanent parallel with the grid. Two were designed with the power output on the right-hand side and four sets, symmetrical to the first two, with the power output on the left-hand side, which facilitated the installation of the power cabling.

Characteristics of containerized soundproof generator sets

  • 4.000 L Certified double-walled fuel tank which provides autonomy for more than 9 hours at 100% load.
  • Connections for fuel transfer from an external tank.
  • High-capacity fuel filtration system.
  • Container floor covered with checker plate.
  • Double starter motor.
  • Double set of batteries.
  • Motorised air inlet and outlet louvers.
  • Heat exchanger integrated in the base frame for heat recovery.
  • Customised power output busbars for easy connection.
  • C3 paint surface treatment, according to ISO12944, in RAL7016 colour.
  • Exhaust gas silencer installed on container, heat-insulated, with external aluminium coating.
  • The sound pressure level at a distance of 1 m is 85 dB.

Welcome 2024! We turn 30 full of positive energy

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Innovation, internationalisation and sustainability will guide our path in 2024. These are three foundations of Genesal Energy. The fourth, of course, is the customer.

Data Center World

Under this premise, we start a new year with renewed enthusiasm and with the aim of finding new green fuels that contribute reducing carbon footprint. We are developing increasingly sustainable solutions with the purpose of consolidating and seeking new markets. These will be our main challenge in a very special year because Genesal Energy is in its prime: We turn 30!

Over the next 12 months, our efforts will focus on continuing the path started three decades ago: bringing the best emergency power to every corner of the world. Now, also developing and prioritising more sustainable energy models. The planet demands advanced and efficient solutions, and we will spare no effort to achieve it.

Our business strategy for 2024 is focused on delivering cutting-edge projects, most of them one hundred percent customised, designed by and for the customer, taking into account their needs and criteria. Listening then producing.

We will also pay special attention to cultivating and promoting key aspects in the development of any company: training & education, seeking sustainability in each of our actions. In the latter case, we will do so through Greenesal, the energy transition plan that already identifies us in the energy sector as a benchmark in this area.

Genesal energy transition office in Madrid

Our passion, our projects

From Bolivia to Tajikistan: internationalisation as a flagship.

The development of efficient solutions will mark our production in 2024 thanks to our R&D department which is more committed than ever to the energy transition and renewable energies. The application of new technologies will be key to differentiate us in the generator set market, offering our customers the latest advances in a fast-changing and highly competitive sector.

The international character of the company, far from diminishing, will increase this year. Our short and medium-term forecasts show an upward trend of sustained growth.

Genesal Energy will celebrate its 30th anniversary with the maturity of a business group that does not forget its origins: Internationalisation without losing the essence of an SME. It is not in vain that we define ourselves as a micro-multinational. And it is with this spirit, an SME which thinks big, that we lead projects in all markets and sectors, from healthcare to transport, residential, military or data centres. Ten, a hundred or 10,000 kilometres away from our headquarters in Northern Spain you can find our engineering.

During 2023, our production line delivered at a good pace, both in Spain and in our subsidiaries in Mexico and Peru, without neglecting any sector and offering our after-sales services in all types of ranges and products.

Our recent projects include everything from the manufacture and supply of emergency power units for the Gastroenterology Hospital in La Paz, Bolivia – installed at an altitude of over 3,600 metres – to the reinforcement of security at the new 12 de Octubre Hospital in Madrid.

We also participated in the modernisation of a hydroelectric plant in Tajikistan to help fighting climate change. Tailor-made projects as those for numerous data centres (both in the Spanish market and in the rest of the European Union), for strategic military sectors or to shield the Railways operation in the Spanish capital. And we will continue walking the same path.

We are growing: A new Factory in Bergondo and OFITE in Madrid

New manufacturing plant for generating sets in Bergondo

The opening of our first Energy Transition Office (OFITE) in Madrid was added to the entry into service of a new industrial building in Bergondo, more than 10,000 square metres which will become one of the neural centres of our organisation.

The photovoltaic façade and OGGY project: benchmarks in sustainability

In 2024, finding new sustainable fuels will be a must. It is urgent as the challenges of decarbonisation are many and new energy solutions will arise. The implementation of transformative projects will therefore be another of the priorities for the new year. In this context, HVO is presented as a solid alternative for the future energy scenario. ‘What works today may no longer be useful tomorrow’. We need to innovate.

To adapt to this ever-changing scenario, we have been combining theory with practice for some time now. Continuous innovation and training are the first step before any action. We believe it is necessary to cultivate both fields.

The inauguration of our photovoltaic façade – the first integral industrial façade in Galicia and one of the few in Spain – in our premises in the Bergondo Industrial Estate was one of the milestones of 2023. It marked a turning point with the visit of the president of the Region, Alfonso Rueda, and with the recognition of the sector in the form of awards. The entry into service of its 126 photovoltaic panels became the best proof that we are very serious about sustainability and that we lead by example.

For the same reason, we have developed our own energy management system: OGGY (Off Grid Genesal Energy), which puts us on the right path to energy self-sufficiency and optimises our energy use at all times. We strive for excellence.
All these actions are part of Greenesal, the strategic plan designed to navigate the energy transition and designed to align our processes with the 2030 Agenda and the Sustainable Development Goals (SDGs).

Energy management system: OGGY (Off Grid Genesal Energy)

Genesal Energy Energy Transition Professorship. In the core of the University

We are a startup launcher: Velca is the first one

The events, awards and seminars organised under the umbrella of the Genesal Energy-USC Energy Transition Professorship will be another important chapter in 2024. Last year highlights as the ‘II Seminar on Corporate Carbon Footprint for SMEs’ or the ‘II Seminar on STEM Women and Energy Transition: moving towards a sustainable future’, put us in contact with the teaching world and with the new generations. An ideal way to search for talent, which we will continue to promote with new calls for the Genesal Energy Professorship awards.

In 2023, we also diversified by taking a stake in Velca, a young company with a great future ahead of it. They manufacture and market electric motorbikes and bicycles. It was the first startup to join our Genesal Energy startup launcher initiative and it brings together everything we look for: talent, innovation and sustainability.

Velca Shareholders

Public-private collaboration

On a different note, we bid farewell to the year with a commitment to public-private collaboration becoming part of ‘Recursos de Galicia’, a joint venture owned by the Xunta de Galicia (Region’s Government) and 32 other companies from different sectors. An exciting project we believe to be the starting point of a stronger and more solid Galician industrial network.

Innovation and sustainability are, once again, our hallmarks for the year ahead. They will guide us in this very special 30th year of the company. A new stage with solid experience acquired and many new, ambitious and exciting projects in the pipeline.