Genesal Energy equips a combined-cycle power plant in Brazil with two high-power, high-autonomy generator sets

Genesal Energy has designed and supplied a solution for a combined-cycle power plant located in Brazil, which uses gas from the Azulão field in the Amazon basin.

This project is based on the premise that thermal power plants require reliable energy sources at all times to maintain full coordination and operation of essential equipment in the event of any grid disturbance.

The project consisted of the installation of two GEN2750YC generator sets as contingency system.

Operational continuity under any circumstance

In power generation environments, incidents such as voltage fluctuations, supply interruptions or unscheduled maintenance shutdowns may occur. In such scenarios, generator sets are activated to keep essential systems running until the main supply is restored.

Tailored engineering for high power and autonomy

The Genesal Energy engineering team developed a solution based on two 2,750 kVA units installed in 40ft HC Containers. The engine-alternator assembly is mounted on a steel base frame with elastic coupling, contributing to improved stability and performance.

This project is based on the premise that thermal power plants require reliable energy sources at all times to maintain full coordination and operation of essential equipment in the event of any grid disturbance.

To ensure high autonomy, each unit is equipped with an integrated 1,500-litre fuel tank, complemented by an external 7,500-litre tank, enabling up to 17 hours of continuous operation at full load. The system is completed with 2.2 MW load banks housed in independent containers, one for each generator set.

As part of the project scope, key elements have been included to enhance system safety, operability and maintenance:

• Alternator terminal box with IP45 protection rating.
• Container with 120-minute fire resistance.
• Complete external fuel storage system of 7,500 litres.
• Piping for connection to the external tank using double-wall flexible piping.
• 2,200 kW resistive load banks in containers for outdoor installation.
• Spare parts list for 2 years of operation.
• Anchor bolts for container fixation.

The advanced control system is based on the ComAp InteliGen range of controllers with Siemens PLC, 15-inch HMI, battery charger and redundant power supplies, ensuring high operational reliability and integration into critical systems.

The units have also undergone specific testing, including 8-hour continuous operation at full load without exceeding thermal limits, open circuit characteristic (OCC) testing, and noise level verification.
The scope of supply includes factory acceptance tests (FAT) with client presence, project technical documentation in English, operation manuals in Portuguese, and delivery of the final Databook.

Commissioning services

The project was completed with on-site commissioning supervision services for 4 days, training in Portuguese, and technical support.

Features

• Construction type: Engine-alternator monoblock in 40-foot High Cube container.
• Integrated tank: 1,500 L double-wall approved steel.
• Day tank: 7,500 L double-wall approved steel (1 per unit).
• Silencer model: 2x MSR250 (- 30 dB) TYPE A STAINLESS STEEL.
• Generator and load bank circuit breakers SIEMENS 3WA1240-4CE01-1AA0.
• Control panel ComAp InteliGen 1000.