We supplied two “turnkey” generator sets to the biggest combined-cycle power plant in Jamaica

We designed the gensets for two biomass power plants: the Viseu and Fundão power plants, in Portugal

We designed 11 gensets for three combined-cycle power plants in Bolivia that will increase the electric power in the country by 50%

Genesal Energy has supplied an emergency genset for the combined cycle power plant (CCPP) known as Empalme II, a huge engineering project in the Sonora State of Mexico.

Gensets for a solar power plant in South Africa that will supply electricity to 150,000 homes

Kathu Solar Park in South Africa is a concentrated solar power system(CSP) up to 100MW. Building commenced in May 2016, and it is destined to be in service by the end of 2018. Genesal Energy contributed with the project design and supply of two emergency gensets.

The thermoelectric plant itselfwill be able to supply 4.5 hours of thermal energy thanks to cutting edge technology which allows supply to continue well after the sun has gone down. When fully operational Kathu Solar Park will supply power to 150,000 households. Also, according to the construction management team, the installation will contribute to sustainable development in the province of North Cape where the plant is situated. This will result in a C02 emissions saving of 6,000,000 tonnesover the next 20 years.

Genesal designed the emergency gensets in compliance with a series of requirements. The gensets had to be soundproofedand the control room needed to be maintained at an optimal working temperature. This was achieved by installing a split air conditioning system and a heat exchanger.

                       

Remote Control

Rock wool acoustic panels inside a metallic mesh cover were used for soundproofing, guaranteeing an excellent attenuation result, functionally, but also aesthetically. The interior of the generator set was split in to two clearly defined compartments: the engine room and the control room. The emergency gensets can be controlled either directly via the in-built control panels using buttons, switches and touch screen technology or it can be controlled remotely through a DCS (distributed control system) which is a method to centralize and controlthe entire power station.

Alongside the gensets two double walled certified fuel tanks were supplied for external installation, one at 7,500 litres full load, and the other at 10,000 litres, guaranteeing over 24 hours of autonomy if necessary.

TECHNICAL DATA

GENSET 1: GEN1586HC

  • PRP Power: 1,442kVA
  • Standby Power: 1,586kVA
  • Frequency: 50 HZ
  • RPM: 1,500rpm
  • Dimensions: 12,192mm x 2,438mm x 4,500mm
  • Weight: 17,500 Kg

GENSET 2: GEN2131HC

  • PRP Power: 1,938kVA
  • Standby Power: 2,131kVA
  • Frequency: 50 HZ
  • RPM: 1,500rpm
  • Dimensions: 12,192mm x 2,438mm x 4,500mm
  • Weight: 18,700 Kg

Made to measure energy solution for the Almaraz Nuclear Power Plant

Both the reactors at the Almaraz Nucelar Power Plant in Caceres (the oldest in Spain) supply 7% of the nations energy demands. The plant is located in an area know as Ribera del Rio Tajo, and they have recently placed their trust in GENESAL ENERGY to design an emergency back up generator set capable of dealing with any potential incident.ualidad.

The project consisted in designing, building, installing and commissioning a genset capable of supplying a 110kVA of power to supply energy to the Individual Temporary Storage (ITS), which alongside the fuel pools, allow for temporary storage of used combustibles from the reactors in the event of a power failure.

Genesal has designed a soundproofed genset inside a 20ft container with an interior control room configured for automatic start up. The bench frame incorporates a 700 litre fully bunded fuel tank, providing the genset with up to 25 hours autonomy. The genset has been specially designed to work at 45°C as well as resist seismic movements, in order to comply with security norms.

To meet with the client’s specific needs the genset was designed with an independent control room and power output with various local controls to manage the genset and other parts of the installation.

Load bank

In the switchgear output of the grid/genset, switches are fitted for each area of the ITS in the power plant. Each one can close or open via pushbuttons or using a pre-programmed sequence designed by the client.

For the correct functionality of the genset, a separate room within the container was built to hold a resistive load bank which is connected to the genset output always and when the load is less than 40% of its maximum capacity. This allows for fuel use optimization and prolongs the lifetime of the genset (normally a genset is recommended to work at 70/80% of its maximum).

The load bank can connect to the genset manually via pushbutton for maintenance work. It is also important to highlight the implementation of signals exchange in the Distributed Control System (DCS) of the power plant, for example the state of switchgear, of the genset and a measurement of zero return to detect grounding failure in the installation.

Technical Data

  • Power PRP: 100kVA
  • STP Power: 110kVA
  • Frequency: 50 Hz
  • Voltage: 400/230V
  • Fuel Tank: Fully bunded, bench frame integrated with 700 litre capacity
  • Pre-heating resistance
  • Seismic resistant genset, includes anti-shear dampers
  • Size: 6058mm x 2438mm x 2591mm
  • Resistive load bank
  • Manual pump for diesel filling
  • Control panel with automatic start-up in case of grid failure
  • Control of input of manual loads and automatic sequencing (as per client’s spec)

Combined Cycle Power Plant – Mexico

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PROJECT ID Combined Cycle Power Plant, Valle De Mexico II
OUTPUT 1980/2178 kVA
TYPE Soundproofed
SPECIALLY CONFIGURED Genset manufactured according to a range of specific conditions as determined by the engineering

 

GENESAL ENERGY has supplied an emergency power genset with a power rating of 2178 kVa which will be used as a back-up for the Combined Cycle Power Plant Valle de Mexico II in the municipality of Acolman (Mexico State). Once finalised the plant itself will have an output power capacity of 615 MW and will operate with natural gas, at an approximate cost of 700 million $USD in construction investment.

The power plant itself will contribute to a 4 % increase in available energy to meet the growing energy needs in the centre of the country.

This particular project has been delivered in conjunction with our GENESAL ENERGY Mexican branch, which has for many years contributed and supported the growth of the Mexican energy sector.

DOWNLOAD PROJECT INFO HERE

CO-GENERATOR POWER PLANT

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DOWNLOAD PROJECT INFO HERE

  • LOCATION: COATZACOALCOS – MEXICO 
  • INSTALLED POWER:  1563 kVA Prime Power; 1719 kVA Standby Power; 480/277V 60Hz with a power factor of 0.8.
  • SPECIAL CONFIGURATION: A sound-proofed genset which itself is split in to three separate compartments, one compartment being for the joint motor-alternator set up, a compartment which includes the main control and power panel, and finally a compartment containing a 100L fuel tank. The design should follow some engineering specific requirements, including a programmable control panel which features the ability to adapt to the required mode of operation.

PROJECT OBJETIVES

The underlying objectives in this project contained the design, documentation, parts and materials, manufacturing, testing, supply (packaging included), transport and start-up of one diésel genset and associated electrical components. The genset specific use is to give power to low voltage back up auxiliary equipment for the combined cycle generation plant Afranrent in Coatzacoalcos in Mexico. 

The combined cycle cogeneration plant in question is for electricity power generation, as well as the production of low pressure steam to power two absorption chillers, which themselves provide ice cold water for a cryogenic plant in the vicinity.

The electrical installation in the cogeneration plant is made up of step-up transformers, the power generation system at 13,8KV, and the auxiliary systems power of 4.16/0.48KV. Energy is generated in the power-plant using a Gas-Turbine with a synchronous generator (output = 135 MVA with a power factor of 0.9, voltage = 13.8 kV ± 10%) and a Steam-Turbine with its corresponding synchronous generator (output = 55,412 MVA with a power factor of 0.85, voltage = 13.8 kV ± 10%). Through the use of step-up transformers or unit-transformers it goes from the generated voltage (13.8KV) to the transmission voltage (115kV). Generated power is then fed in to the grid through a link up sub-station at 115kV

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PROJECT DESCRIPTION

The project was developed during the last quarter of 2015. Initial studies on the technical specifications and preliminary designs were done prior to this in the middle of the year. The final specs and design work was approved in September 2015 leading to the contract being awarded to GENESAL ENERGY.

The project was launched in September 2015 at our Genesal European head offices. It was during this meeting that all project decisions were made including planning schedule management, milestones, documentation, and the necessary steps to complete the project.

Following on from the launch of the project detailed planning commenced to set the documented standards in developing the project and ensuring it met the deadline. The documentation included electrical designs, mechanics, signals lists, required materials, testing and all the calculations necessary for the design of the genset in accordance with the specified guidelines set out by ENGINEERING.

Upon completion of the documentation it was sent to the client for their comment and subsequent approval. The next phase was to commence the production of the genset using the finalised and approved design specifications for both electrical and mechanical engineering. At Genesal, mechanical engineering design is done using specialised software with 3D, this guarantees a pre-production design that is 99% of the finished product.

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Our electrical engineering design uses a specific design program to complete the electrical plans, single line circuit diagrams, materials required as well as detailed power & control cabinet layout.

When the manufacturing phase commenced the approved designs were strictly followed so that upon entering the in-house testing stage in the presence of the client, they could see this was in line with the testing document as approved by the client

In December 2015 the actual testing phase commenced on-site in Genesal’s main assembly plant, done with client present in order to demonstrate that the mechanical and engineering solutions and accompanying documentation had been adhered to. Checks were also done to ensure that the dimensions of the manufactured genset corresponded to the 3D designs and that all electric circuitry was in accordance with the electrical plans. Additionally (and following a very rigorous protocol) testing of safety alarms, the requested operational functions by the client was carried out. Next and very crucially the genset itself was placed on a load-bank for resistive and inductive testing which fully simulated the eventual working conditions it will operate in. During this final test the motor-alternator operated at 110% of its capacity to ensure the genset could meet the most extreme conditions.

In January 2016 with all the testing successfully completed and along with all the approved documentation, the logistics operation was undertaken to send the genset from our European manufacturing and assembly plant to its final destination at the cogeneration plant of AFRANRENT in COATZACOALCOS, MEXICO. 

Upon arrival in Mexico the genset was then installed as per the customers’ requirements and the agreed solution. In June 2016 GENESAL ENERGY qualified technicians initiated the start-up process. This consisted of full on-site testing to ensure correct operational functionality, as well as ensuring all the parts and components were in perfect condition. Most importantly the on-site testing phase included the synchronization functions between the genset and the low voltage network which supplies power to the back-up auxiliary equipment. Upon completion of the start-up protocols the genset was finally operational and ready to provide the power when necessary for essential services within the cogeneration facility.

Additionally our technicians gave the operatives in the plant an exhaustive training course on the functions of the genset, its care and also safe working practices.

FEATURES

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In order to fall within noise level requirements, the genset was acoustically soundproofed on the inside using rockwool, encased in perforated sheet metal for maximum sound absorption. Also, silencers were fitted to air intake and outlet pipes. Also noise reducing filters for waste gas were actually installed within the container to facilitate easier on-site installation.

The container was divided into 3 separate compartments – motor-generator, electrics, fuel tank:

  • The engine compartment has two doors, one on each side for ease of access during maintenance operations, as well as normal lighting and emergency lighting.
  • The electrics control room contain an exterior access door, normal and emergency lighting as well as climate control. Situated within this compartment are the control panel (automaton, touch screen, protective relays, synchronization etc) and the power control panel (LSIG breakers for output and busbar connectors to power supply wires).
  • The fuel holding compartment has exterior door access and internal lighting. Inside is a cylindrical double walled fuel tank with a 1500L capacity.