Backup Power for the Steel Industry: Maximum Reliability for Critical Processes

The continuity of the power supply is a key factor in industrial environments with continuous production processes and high energy demands.

In this context, Genesal Energy supplied a 1,250 kVA generator set to a steel manufacturing company in northern Spain, ensuring the operational continuity of its plant in the event of any disruption to the electrical grid.

A Demanding Environment Where Power Cannot Fail

Facilities of this kind require a constant electrical supply due to the uninterrupted nature of their processes and the high energy consumption of their equipment. An uncontrolled outage can result in anything from machinery damage to significant losses of in-process materials, while also compromising personnel safety.

In these environments, having a reliable backup power system is essential to keep critical assets such as furnaces, hydraulic systems, cranes and control equipment operational. Furthermore, sudden temperature fluctuations caused by an unexpected shutdown can severely affect the entire infrastructure, leading to substantial financial losses.

Continuity, Autonomy and Adaptability: The Engineering Challenge

The client required a solution capable of ensuring the continuous operation of critical systems, minimising risks while guaranteeing both plant safety and compliance with stringent operational requirements.

Genesal Energy’s engineering team designed a bespoke solution based on a generator set mounted on a 4,400mm base frame, featuring an engine-alternator assembly with a flexible direct coupling.

Unlike other configurations, the system did not incorporate an integrated fuel tank. Instead, it is fed from a certified 1,000-litre double-wall fuel tank complemented by an additional 1,500-litre tank equipped with a fuel transfer system and pumping panel, ensuring the autonomy required for continuous operation.

Advanced Safety and Total Control

One of the key aspects of the project was the incorporation of advanced safety features which are less commonly found in this type of application, including a lockable battery compartment with a padlock-operated isolator switch and a 2,000A motorised circuit breaker, also fitted with a locking system.

The control panel was fully customised to the client’s requirements, incorporating specific alarms, colour-coded wiring identification, and an audible and visual signalling tower to indicate the operating status of the generator set. Attention was also given to operational safety through the inclusion of guards on moving and hot components, as well as emergency stop systems.

Seamless Integration into the Facility

The project also included the design of the auxiliary systems required to ensure the correct integration of the generator set within the plant. Specific calculations were carried out for exhaust gas evacuation, leading to the supply of a double-wall stainless-steel modular chimney system.

In addition, components such as a discharge plenum, flexible connector and louvre grille were designed and installed to channel radiator airflow to the outside, optimising system performance and ensuring safe operating conditions.

Key Features

• Flexible coupling system between engine and alternator.
• Anti-vibration mounts specifically calculated according to the engine and alternator configuration.
• Oversized silent enclosure (-30 dB attenuation).
• 2,000A motorised circuit breaker with padlock locking system.
• Circuit breaker fitted with an undervoltage release coil to protect against overloads, short circuits and earth faults.
• 1,000W engine coolant heater.
• Certified 1,000-litre double-wall steel/polyethylene daily fuel tank.
• Certified 1,500-litre above-ground double-wall steel fuel tank.
• Fuel transfer pumping panel.
• Fuel transfer system with high-level and low-level float switches, pumps and solenoid valves.
• Exhaust system calculations for a double-wall stainless-steel modular chimney.
• Design and supply of discharge plenum, flexible connector and louvre grille for generator cooling air discharge.
• Surface coating treatment in accordance with ISO 12944 C5.
• Lockable battery isolator switch.