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)

Emergency Power for Phosphates Treatment Plant in El Jadida, Morocco

Situated 80KM south of Casablanca and 17Km from El Jadida is the Jorf Lasar industrial complex, a phosphates treatment plant which Genesal Energy has supplied with 3 specially designed gensets for emergency back-up.

The plant whose installations cover an area of 1,700 hectares began its production in 1986 and its numbers are quite impressive: the recuperation of 2 million tonnes annually of P2Oin the form of phosphorus acid.

Genesal Energy has supplied this elaborate facility in Morocco with a genset island comprising of identical generators for outdoor use (3 units at 400V/50Hz containerised with a control system) designed to work in parallel or if necessary individually. Five circuit breakers make up the switchgear.

Meeting the clients’ specific needs was a key priority, as they wanted to power the facility in two different ways. GENESAL designed the following options:

  1. To power the entire plant using the genset island via an incoming power cabinet situated in the entry area of the plant.
  2. Separate the energy feed between incoming power cabinet in the plant.

This allows for the genset island to feed one incoming power cabinet with all the panels, however if the client prefers to feed both incoming power cabinets, then that is also possible.

IN DETAIL

As with every project undertaken by Genesal, the control system designed for this phosphate treatment plant was managed to the tiniest detail:

  • If the gensets are operational, they can be synchronised, either with the output switch of each genset or with the coupling point, therefore reducing the number of movements required by the switches in case of changes in the operational format.
  • If a generator is stopped, the circuit breaker is disabled to avoid damage from unwanted power inputs from external busbars
  • If the client has not indicated that a connection panel should receive an electrical feed, the incoming power cabinet circuit breaker will not be permitted to close (not even manually), in order to avoid short circuits caused by external voltage not from the actual genset island.

 

 

 

DATOS TÉCNICOS: 

  • Prime Power (PRP) 800 kVAS
  • Standby Power (STP) 880 kVAS
  • Voltage: 660V
  • Frequency: 50Hz
  • RPM: 1,500 rpm
  •  Mm x Dimensions: 6058mm X 2438mm X 2591mm
  • Weight: 9,091 Kg

Genesal Energy continues to consolidate its standing in central America with a specially designed genset for Panamanian television.

 

Panama National Television (TVN), one of central Americas most important, has put their trust in to GENESAL ENERGY by asking us to design a super-compact electrical generator, adapted to their energy demands.

Having the ability to transmit their signal problem free from anywhere within the country of Panama, led TVN to realise and understand the importance of a genset that can supply energy to all of their field equipment. Whether it is to ensure an interview goes off without interruption, or a live connection remains live, TVN have chosen Genesal Energy to help them reach their large central American audience.

A fundamental part of the project was the ability to attach and suspend the genset to their mobile transmission trailer. For this reason alone, it was clear that a highly robust, super compact genset was required to be able to resist various situations, such as poor roads, inclement weather, stone or mud spatter when travelling etc. This was a clear case of designing a personalised genset, a speciality of GENESAL ENERGY.

Small size, big power

Grupo TVN Panamá-2

A key part of the GENESAL ENERGY solution was to design a genset which was very compact (2286x758x752mm) to fit correctly to the chassis of the TV truck. A 50-litre fuel tank was integrated in to the solution, and removable panels have been added for ease of access for maintenance and servicing.

Additionally, inlet pipes and outlet pipes were designed to be compatible with the movement of the trailer, taking in to account the direction it is travelling, and ensuring the genset is not at risk of damage.

The genset control unit is remote, and has also been designed by Genesal Energy. It contains all the functions required, alarms and the necessary protections as requested by the client, for safe supply of electricity to their connected apparatus (cameras, microphones, lighting etc).

Another key area requiring a prioritised solution was related to the noise emitted by a genset in operation, which can cause interference when the TV crew are recording material. The solution; we designed a soundproofed canopy using noise absorbing material, capable of reducing noise emission from the genset to levels sufficiently within those that are required for TVN to produce their audio-visual requirements.

The project has been successfully completed and most importantly delivered. Installation and commissioning was also supervised by our on-site team, and TVN now has a TV truck with the freedom to operate where the news is happening.

Technical Data

  • Prime Power : 25 kVA
  • Standby power: 27 kVA
  • Frequency : 240/120 V
  • Frequency : 60 Hz
  • RPM: 1.800 rpm
  • Dimensions : 2236x758x752 mm
  • Weight: 770 kg
  • Communication card: RS 232

Designing and supplying efficient energy for a Spanish paradise: The island of Ons

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Genesal Energy has designed a diésel generator to supply green energy to the Island of Ons, one of the most beautiful tourist destinations in the region of Galicia in northwest Spain. The Island is a protected reserve within the National Park of the Illas Atlanticas, and due to its situation, it is completely isolated from the mainland power grid.

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It was for these reasons that our team of inhouse engineers along with our R&D department created a “different” type of electrical generator, focused on taking great care with the local environment. The tailormade end product entered into operation in the summer of 2017. The generator has been designed to supply energy for the camping site situated on the upper part of the island. The site occupies an area of 8,000sq metres with a capacity for 276 people.

Considered the first self-sustainable camping site in the Galician region, the site already incorporates a system of solar panels to provide electricity. Yet, due to the limited hours of sunshine in this part of the world and the characteristics of the camping site, it has been deemed essential to ensure a round the clock power supply, and for that supply to be sustainable.

The solution designed by Genesal Energy, and in collaboration with Magaral engineering, is made up of a 60-66 Kvas genset in a 2900mm long soundproofed cabin. The genset high attenuating silencer for the exhaust pipe, not to mention many more specifications that make this much more than a conventional electrical generator. In fact, the word unique would be the most appropriate in this case.

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The fitted engine for the genset was chosen according to the highest standards possible in relation to quality and established legal norms, ideal for a natural reserve as such is the Island of Ons. The genset supplies electricity, green energy and reduces by up to 50% atmospheric emissions. Also, the extra soundproofing qualities ensure a peaceful coexistence with the campers, especially at night time.

The real difference comes from the specialised system designed and incorporated in to the genset solution, which uses the heat and waste gases generated by the genset to provide sanitary hot water for the camping site kitchens, bathrooms and day to day activity on the campsite. It entails using a thermostatic controlled system to reuse waste gas for heating water. IN this case, unique really means unique.

Having to move the genset to an isolated island off the Galician coast meant overcoming two challenges:

  • Logistic: The movement of a 1000 Kilo genset and components, which was executed by boat.
  • A protected nature reserve with no mainland power supply:  As opposed to an emergency standby power generator it was important to provide a solution that covered needs continuously if necessary and fully respecting the surrounding environment. Mission accomplished!

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Energy with remote control modules for the French bank Credit Agricole, a leading European high street bank.

Cabina 5000 copia

Leading European banking institution Credit Agricole with their headquarters in France and a strong presence in Spain has put their trust in Genesal Energy to carry out a project from the design stages to execution in order to supply emergency power in one of their key branches in the famous Paseo de la Castellan in Madrid.

Not only are Credit Agricole a key credit supplier in France, they are also one of Europe’s biggest banks, and manage more active assets than any other bank on the continent. They are also Europe’s biggest insurer and financer of large projects.

The project undertaken by Genesal for CA consisted in supplying two emergency gensets, each with a rating of 630kVA. The gensets were to form part of the overall electrical set up within the building, and have been set up to start up automatically should the mains electricity supply cease to operate, and therefore guarantee the ongoing operational status if the bank.

In this particular case, as the end user is a major international bank, it is essential to have a back-up power system as the knock-on effect to the whole business in the event of a power loss can cause complex issues to arise. This particular site needs to be powered 24 hours a day, there is no margin for error.

Any time, any place

The gensets supplied by Genesal Energy have been designed to incorporate a remote-control communication module, permitting start up and switch-off of the gensets online at any time from any location on the planet.

This type of communication system also allows for preventative maintenance to be carried out. Using a communication card, Genesal’s technical service department can visualise all the different parameters of the gensets. This permits instant recognition of potential alarms or anomalies that may occur in the future. This type of real time instant detection means Genesal Energy can ensure the gensets never reach a critical point which may affect their ability to function correctly.

Additionally, the gensets have been soundproofed so that they could be installed on the rooftop, and as such minimising the acoustic contamination in the vicinity.

TECHNICAL DATA

  • Prime Power: 570Kva
  • Emergency Power Rating: 630Kva
  • Voltage: 400/230V
  • Frequency: 50Hz
  • RPM: 1,500rpm
  • Dimensions: 5000mm x 1886mm s 2356mm
  • Weight: 5,680 Kg
  • Modbus TCP/IP communication protocol
  • Electronically adjusted engine

Emergency back up power for the Machala General Hospital (Ecuador), a healthcare facility with 36 specialities and a catchment area of 350,000 people

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Genesal Energy has recently supplied 4 electrical generators as backup power for the Machala General Hospital in Ecuador. A modern facility it’s healthcare options include 36 areas of specialisation for a region of 350,000 in the El Oro Province, one of the country’s most important administrative and financial centres.

Designed by Genesal Energy the emergency gensets form an essential part of the electrical installation within the complex, which covers 24,000 sq. metres and contains 200 patient beds.

The Genesal Energy solution is a guarantee of a continued power supply for the hospital in the event of a grid failure for national network, ensuring the hospital remains fully operational and that all vital healthcare continues. The Genesal Energy solution means the gensets have been prepared to operate in parallel two by two, supplying 1254 kVA per genset pairing, as well as automatic start up if there is a g power cut in the external grid supply.

The nature of these projects means that the any unexpected eventuality can be fatal. The gensets have therefore been designed with one clear objective, to immediately support the loads demanded should the normal external power supply stop functioning. Aside of their maximum operational precision, the gensets have been sound proofed for outdoor installation and to ensure that noise levels are kept to a minimum I the surrounding area.

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TECHNICAL DATA

  • Prime Power: 570 Kva
  • Standby Power: 627 Kva
  • Voltage: 220 / 127 V
  • Frequency: 60 Hz
  • RPM: 1800 rpm
  • Dimensions: 5000 x 1886 x 2356mm
  • Weight: 5680 kg

Genesal Energy Electrical Generator, dual voltage and dual frequency

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500-550 KVA / designed for industry leader in cold storage installations for the South American market.

The client, an industry leading company in cold-storage facilities, had a special request: On the one hand, they needed and emergency backup power option for their manufacturing plant at 50Hz. However, they also need an alternative energy source to carry out testing on machinery (freezers, water recovery systems etc) at 60Hz for products which would be sold to Latin American markets. Because of the different voltage and frequency used in Central & South American countries the power grid in the client’s European base prevents them from testing products in authentic conditions. Hence the reason for an alternative power source to allow testing in the conditions found in Latin American markets. It was for these reasons that GENESAL ENERGY designed a “dual frequency” solution to meet all their needs.

GENESAL ENERGY developed a specific project to ensure a power supply with two power supply functions:

  • Emergency back up to provide electricity to the clients European manufacturing plant in case of a power grid failure.
  • Provide an electricity source for testing machinery built with different voltage and frequency.

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PROJECT SUMMARY

Design and manufacture of a 500-550 KVA genset to operate in emergencies, giving an independent power supply in case of a power grid failure to two workshops at 400/230 V 50Hz. At the same time, it will also give a power supply to a testing bench at 400/230V 50Hz or 460/266V 60Hz in manual mode.

PROJECT OBJECTIVES

Was to design a genset with three operational modes:

  • Emergency power for workshop 1 at 400/230V 50Hz
  • Emergency power for workshop 2 at 400/230V 50Hz
  • Power supply for a testing bench at 400/230V 50Hz or 460/266V 60Hz

SOLUTION

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We opted for a newly designed 4500mm long canopy, with a view to easy access for maintenance and mechanical operations, along with an 800l fuel tank integrated in the base frame, to ensure a constant power supply for extended periods before having to refuel.

Only one control panel was installed for the entire control of all operations required from the genset, and at twice the size of a standard genset control panel This was integrated in to the interior of the genset with a front access window panel for visual access, although for safety and security, access is only gained by the authorised key holder to the control panel

TECHNICAL SPECIFICATIONS

  • Prime Power: 500 KVA
  • Standby power: 550 KVA
  • Frequency : 50Hz/60Hz
  • RPM: 1500 /1800
  • Dimensions: Length 4515mm, width 1710mm,
  • height 2260mm
  • Weight: 4510 kg

SPECIAL CHARACTERISTICS

  • Dual voltage and dual frequency
  • Modbus TCP-IP (IB-LITE) communication device
  • Oil extraction pump
  • Automatic start up in case of grid failure
  • 800L internal base frame integrated fuel tank with
  • connections for future link to external fuel tank
  • Up to 11 hours of autonomy at 80% load, or 18
  • hours at 50%.
  • Battery disconnector

DSC_1323_RDOWNLOAD PROJECT INFO HERE

Genesal Energy supplies emergency power to the Steinkjer fish-farm in Norway with gensets synchronised in parallel

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Precision pre-heating systems and a stable power supply to combat the very low temperatures found in Northern Europe were just some of the key characteristics of this customised project carried out by Genesal Energy for the Steinkjer fish factory (town pop. 21,000) in the Trondheim fjord in North Norway.

Fish factories are singular installation: containing water temperature, water flow and recirculation control systems, designed specifically to maintain and foment conditions as close as possible to the natural sea environment for ideal fish growth. They therefore require a constant and stable electricity supply due to the delicacy of the product. For this reason, back up emergency gensets that become operational if there is power grid cut are crucial, a power cut of just a few minutes can lead to large economic losses for the business.

In the case of the Steinjker fish factory there was an added difficulty – the climate; The town is in North Norway an area very prone to very low temperatures. For this project, an emergency backup system of 2600kVA was calculated in order to supply the load required for continued activity, and the overall design needed to fit in to a small area.

To meet the client’s needs, Genesal Energy came up with the idea of 4 gensets to run in parallel, each with a rating of 650kVA, ensuring that if there was a power grid failure, the four engines are sharing the entire load and guaranteeing normal functionality in the fish factory itself.

Designed to meet the client’s needs

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Not only was it important that the genset emergency system could supply the load in the minimum time possible and with maximum reliability, it was actually considered a high priority. Using 3D technology Genesal also designed the entire installation project.

The project, aptly named “Fishfarm”, included aspects such as made to measure gensets, ventilation in the room they were to be located, and a connected fuel supply system. Once an exhaustive study of the client’s needs had been carried out the entire design and manufacturing process was carried out at GENESAL’s headquarters in northwest Spain, as follows:

  1. Assembly of 4 synchronised gensets in parallel, built to fit perfectly in the end-users on site storage room, and to secure handle the loads that will be required
  2. High quality engines and alternators were chosen for their reliability
  3. Manufacture of auxiliary systems for start-up in very low temperatures (guaranteeing optimal functionality)

Special characteristics of the emergency gensets

  • Automatic fuel transfer system
  • Parallel synchronisation
  • Automatic motor protection thermal magnetic circuit breakers, with the outlet in the top of the genset, due to the complex characteristics of the installation onsite.
  • Modbus communication board
  • Manual oil extraction pump
  • Low temperature start up system
  • 400 litre internal mainframe fuel tank

Technical data

  • Prime power: 590kVA
  • Standby power: 650KVA
  • RPM: 1500
  • Dimensions: 3560x1230x2075 mm
  • Weight: 3,600 KG

The Fishfarm project is yet another example of Genesals focus on designing and participating in distinctive projects requiring a very distinctive touch. The integral service, along with constant innovation, in-house technology and the company’s ability to diversify, allows Genesal to take complex situations from the drawing board and make them a reality, just some of Genesals identifying marks.

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GENESAL ENERGY has participated in the construction of the first submerged tunnel to be built in Latin America.

The structure, consisting of 4 traffic lanes and almost 3KM long, communicates 2 urban areas in the Veracruz area with a population close to 500,000.

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GENESAL was responsible for designing the diésel generator responsible for ensuring power supply in emergency situations.

GENESAL ENERGY has recently administered a project to supply emergency electrical power in the Coaztacoalcos (México)tunnel, the first submerged tunnel of its kind in Latin America and one of the largest engineering projects ever undertaken on the American continent.

GENESAL’s responsibility was such that not only were they to supply the generator power unit, they were also in charge of the installation on site. The diésel genset itself (ERP 2407kVa at 13.2Kv) was designed at GENESAL’s European headquartes and manufacturing facility near La Coruna, and has since been installed and is fully operational in the tunnel.

Requiring an investment of $250 million dollars the 2,280-metre tunnel with 4 lanes for road traffic, runs below the riverbed of the River Coaztacoalcos, connecting the two neighbouring municipalities of Coaztacoalcos and Allende in Veracruz State. Further afield it has provided improved links to the states of Tabasco and Chiapas, and the tunnel services over 500,000 people as well as the numerous petro-chemical businesses in the area.

The fully submerged tunnel entered in to active use in April 2017, connecting Coaztacoalcos and Allende in little more than 3 minutes, a 40-minute reduction on the pre-tunnel journey time.

Synchronized Genset

The structure of the tunnel in some parts reaches a depth of 35 metres, and was constructed using pre-tensed reinforced concrete, with a total weight of 135,000 tonnes, equivalent to 355 Boeing 747 jumbos. The same type of construction used in the tunnel section of the structure connecting Copenhagen in Denmark to Malmo in Sweden was applied here.

Should the tunnel for whatever reason suffer a power cut in the mains supply, or if there is a drop-in voltage, the GENESAL ENERGY generator will switch on automatically, ensuring continued power supply. When the mains power returns to its previously normal state, the genset will synchronize with the mains power and close off the breaker switch, smoothly returning all load power to the mains without any discernible change in the origin of the power supply.

Indie the tunnel a special room has been constructed and designed by GENESAL ENERGY, and the genset has been installed in here. GENESAL also designed a second room for storing the medium voltage cells and transfer measurement.

Fitted with the latest technologies, the genset underwent stringent testing at GENESAL’s main plant before being shipped to Mexico on the 13th February 2017. Due to its size, the radiator was specially designed to meet with cooling requirements in this environment. This also allowed the whole set up to be constructed on one supporting frame, which later reduced the difficulties in the installation process.

This entire project was done in conjunction with the Mexican branch of GENESAL ENERGY.

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