Genesal Energy, delivering energy in the most extreme climates

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Securing energy supply in climates with extreme conditions, be it cold, heat or humidity, is a challenge that Genesal Energy is familiar with. In this case, the challenge of the project was to provide a solution in the extremely cold environment of Finland.

Faced with the need for reliable equipment to ensure the uninterrupted operation of the installation in the event of a mains power failure, we designed a generator set fully integrated into a 20 feet HC container, adapted to the demands of the environment and prepared to guarantee the continuity of the power supply. In addition, it had to be able to operate in low temperature conditions, be compact for easy transport and have the greatest possible autonomy. A technical challenge that we solved with a customised design.

Another key aspect of the design was the optimisation of space to increase the autonomy of the equipment.

To guarantee the correct operation of the unit in these climatic conditions, we incorporated a system of motorised grilles between the unit and the air outlet. These louvres allow air inlets and outlets to be closed, while the opening of an intermediate louvre creates a flow of hot air inside the container until the right temperature is reached. It is equipped with a heating recirculation pump to guarantee start-up in extreme conditions. At the same time, customised soundproofing ensures that the noise level is extremely low.

Another key aspect of the design was the optimisation of space to increase the autonomy of the equipment, so we designed a customised fuel tank with a capacity of 2,000 litres, with a double steel wall and strategically located at the entrance of the container. Its rectangular format allowed us to make better use of space without compromising accessibility.

Our Engineering Solution

Our team designed a solution totally adapted to the customer’s needs and focused on solving two problems: on the one hand, withstanding low temperatures, and on the other hand, increasing the autonomy of the unit as much as possible.

Features

  • Large capacity tank. 2.000 litres double walled (Steel-steel).
  • Recirculating heating pump.
  • Integrated silencer in container, GSI 490 (-30 dB).
  • 630 A, 3-pole, LSI circuit breaker.
  • Battery protection box with ventilation.

Genesal Energy promotes sustainability in wind farms with a mobile generator set for the recycling of turbine blades.

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The energy transition and the fight against climate change have boosted the development of wind energy, making it one of the main renewable sources worldwide. However, this progress brings with it a significant challenge: the efficient recycling of wind turbine blades.

With an average lifespan of 20 years – extendable to 25 with proper maintenance – most components of a wind turbine are recyclable. However, blades present a unique challenge due to the composite materials used in their manufacture: glass & carbon fibre and resins. These materials are complex to separate, which raises costs and makes large-scale recycling difficult.

Genesal Energy has taken a step forward in search of sustainable solutions to this challenge. In collaboration with GDES Wind – a company specialised in the maintenance and inspection of blades in wind farms – we designed and installed a 45 kVA mobile generator set to power a machine specialised in the recycling of wind turbine blades. This equipment cuts the blades using diamond wire, offering an efficient and environmentally friendly alternative. The pieces are then efficiently treated as waste, generating mortar or useful pieces for new applications such as planters, canopies or pieces of furniture.

With this project, Genesal Energy reinforces its commitment to sustainability and the circular economy.

This genset – which complies with Stage V emissions standards – not only ensures a low environmental impact but also provides autonomy of up to 35 hours at 100% load thanks to its 350-litre tank. It is also equipped with a socket panel to power auxiliary tools, extending its functionality and operational efficiency.

A growing challenge in the wind power industry

Although most blades are currently reused in repowering processes or converted into architectural structures such as bridges or bicycle racks, this strategy will not be sufficient in the long term. According to WindEurope, up to 5,700 wind turbines per year will be dismantled in Europe from 2030 onwards, which means an increasing volume of retired blades that will require innovative solutions for recycling.

The equipment designed by Genesal Energy to power the GDES Wind solution represents a key step in this direction, aligning with the principles of the circular economy and offering the wind sector an indispensable tool to sustainably manage the dismantling of wind turbines.

With this project, Genesal Energy reinforces its commitment to sustainability and the circular economy. We continue working to make energy not only cleaner, but also more socially responsible.

Features

  • Supply: 2600mm soundproofed canopy on trailer.
  • Stage V emissions-compliant engine.
  • 350L base frame inserted fuel tank.
  • Control panel: ComAp AMF 25 InteliLite4.
  • Socket panel.

Generator sets for events: keep the fiesta going

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Spain is a country of events, recordings, fairs, concerts, festivals or travelling sporting events that bring together thousands of people around and which depend on a stable electricity supply for their correct development.

Otherwise, the absence of reliable power can lead to problems with safety, the operability of technical equipment or even affect the audience’s experience. Therefore, for the music, events or audiovisual industry, having generator sets specifically designed for these applications is key to guaranteeing the success of any celebration.

Genesal Energy has designed a lightweight generator set for vehicle mounting, not exceeding the permitted road weight limits and facilitating access to the fuel supply from the same side as the HGV.

Reliability and efficiency are key aspects in the provision of energy in dynamic and demanding environments such as mass events.

The mobility of the unit was a determining factor, so it was necessary to optimise its design without affecting its performance and autonomy. To meet the requested requirements, our team developed a soundproof generator set with an aluminium canopy, a key choice to reduce its weight and improve its manoeuvrability. In addition, we incorporated a horizontal opening system with shock absorbers, which facilitates access to the interior of the genset for maintenance and refuelling in a safe and efficient manner.

Mobile generator set for events with lightweight design.
Resistance to vibrations and impacts

It has a 200-litre tank for greater autonomy and an anti-shock system to absorb vibrations and prevent structural damage. In this way, the mobility of the generator set will not be a handicap as the design ensures its solid condition for a longer period. Genesal Energy adapts its solutions to the needs of each client and application. Reliability and efficiency are key aspects in the provision of energy in dynamic and demanding environments such as mass events. Ensuring a continuous and secure power supply is our priority, allowing each event to run smoothly and meet the expectations of organisers and attendees.

Our Engineering Solution

Faced with this challenge, our team designed a soundproofed unit with a canopy made of aluminium to significantly reduce the weight of the unit and meet the limitation set by the customer. Another aspect to highlight is that this canopy had horizontal opening doors with shock absorbers to regulate its opening and closing when refuelling.

Features

  • Aluminium made Canopy
  • ComAp control panel
  • Integrated fuel tank with a capacity of 200l
  • Adjustable opening door dampers
  • Anti-shock system to reinforce structural solidity as it is a mobile unit.
  • Upper air outlet.

Genesal Energy reinforces Poznan heat network with an emergency generator set

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Genesal Energy has designed an emergency diesel generator set for a cogeneration plant in Poznan, Poland.

A key facility in the supply of heat and electricity for the city. In the search for efficient and sustainable energy solutions, heat networks emerge as a key alternative for the transition to more responsible consumption patterns.

This power plant supplies approximately 60% of the inhabitants of the city, as well as providing energy to industries, public institutions, shopping centres and other services. The incorporation of our generator set for energy plant ensures supply in the event of a plant shutdown, including battery chargers and part of the lighting network.

These installations consist of a generating plant and a network of pipelines and supply homes, hospitals, schools, shops and offices in an efficient and sustainable manner.

Our engineering team designed a unit that ensures a low sound pressure level thanks to the interior lining and a space divided into three separate rooms: the engine-alternator room, the control room and the storage room. In addition, the system has a Baudouin engine coupled to a Mecc Alte medium voltage (6300 V) alternator, mounted on an electro-welded steel base with anti-vibration blocks to minimise vibrations and noise.

For fuel storage, a 3.000 litres double-walled steel tank has been installed, equipped with a leak detection system. Exhaust gases are managed by stainless steel silencers integrated into the container eliminating the need for external installations. Finally, the container has undergone a C4 paint surface treatment in accordance with the ISO12944 standard, providing additional protection against corrosion and environmental wear and tear.

Genesal Energy emergency generator set installed at a cogeneration plant in Poznan, key to strengthening the urban district heating network.

Heat networks: an alternative to the traditional model

Heat networks consist of a centralised infrastructure for the production and distribution of thermal energy. These installations consist of a generating plant and a network of pipelines and supply homes, hospitals, schools, shops and offices in an efficient and sustainable manner.

Details of the generator set at the Poznan cogeneration plant.

Features

  • 40feet HC container, guaranteeing an average sound pressure level of 85 dB at 1m.
  • The walls were lined with 100 mm thick acoustic panels, guaranteeing EI120 fire resistance.
  • The container had 3 separate rooms: the engine-alternator room, the control room and the storage room.
  • A Baudouin engine was fitted with a Mecc Alte medium voltage (6300 V) alternator on an electro-welded steel base with anti-vibration blocks.
  • The coupling between the engine and the alternator is by means of an elastic coupling.
  • 3.000 litre double-walled (steel-steel) tank inside the container.
  • Tank fitted with a leak detection system.
  • The fuel supply and return pipes were double-walled, with a leak detection system.
  • High-capacity fuel filtration system.
  • Locks with electric lock and position contact were installed on the access doors to the group room and control room.
  • Fire extinguishers were installed in the group room and control room.
  • The control room was air-conditioned.
  • The exhaust gas silencers were made of stainless steel. They were integrated into the container, avoiding on-site installation.
  • The unit was fitted with motorised louvers at the air inlet and outlet.
  • Surface treatment with C4 paint, according to ISO 12944.

Genesal Energy designs customised solutions key to industrial productivity for a chemical plant

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Genesal Energy knows that energy is the engine that drives industry, and we work to ensure that it never stops.

We believe that it is essential to design generating sets that provide solutions for different industrial sectors.

To guarantee operational continuity, energy security and the capacity to respond to any type of contingency, it is essential to have equipment that guarantees a constant supply of energy. We have designed and supplied a customised generator set for a chemical plant located in the Sabón Industrial Estate, Northern Spain, reinforcing its capacity to guarantee production and maintain its competitive advantage in a demanding market.

This chemical plant operates during all three shifts, making constant power availability a critical factor. Our engineering team designed a generator set that can work in parallel with the power grid, minimising the impact of possible power failures and eliminating the risk of the dreaded ‘zero-crossing’, which could stop the machines and cause time and productivity losses.

Considering that this factory is located in a marine environment, the equipment was designed with specific features to guarantee its durability and optimum performance, with a soundproofed canopy, a 700-litre tank for greater autonomy and C5M paint surface treatment in accordance with ISO12944 standards.

A marinised alternator has been also included, specially prepared for high salinity conditions, to which an advanced ComAp InteliGen4 200 control panel has been added, designed to manage operations in parallel with the grid.

A key service for competitiveness in the industrial sector

In a market where efficiency and operational continuity are crucial, having a backup generator set not only protects production processes, but is also a differentiating factor that ensures business competitiveness.

Power outages not only affect immediate production but can also compromise the ability to meet delivery deadlines, impact product quality and ultimately customer satisfaction.

Our engineering solution

A unit was designed that, firstly, could fulfil the function of working in parallel with the grid to guarantee the minimum downtime impact in the event of a failure of the factory’s main supply. Then the parts of this equipment were manufactured with a special surface treatment as it was exposed to a marine environment (marinised canopy and alternator).

Features

  • Supply: 3900mm Soundproofed Canopy.
  • Tank: 700L base frame integrated.
  • Control panel: ComAp InteliGen4 200 for parallel operation.
  • Surface paint treatment according to ISO12944 – C5M.
  • Marinised alternator.
  • Motorised Circuit Breaker.

Genesal Energy ensures operational continuity at a thermal power plant in Dominican Republic

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In the current context, where energy transition and sustainability are global priorities, thermoelectric power plants continue to play a fundamental role in the electricity supply.

These facilities not only guarantee a secure energy source, but also, by incorporating advanced technologies such as the combined cycle, they achieve greater energy efficiency and reduce environmental impact.

Within this framework, Genesal Energy has designed and manufactured a generator set for a Combined Cycle Thermal Power Plant located in San Pedro de Macorís, Dominican Republic, intended to work with an already operational set and reinforce the electricity supply to a key region for the country.

With more than 10 million inhabitants, the Dominican Republic is experiencing a steady growth in energy demand, driven by industrial development, tourism and urbanisation. Thermal power plants, such as the one in San Pedro de Macorís, play an essential role in ensuring the stability of the electricity system and complementing renewable generation.

Backup power for essential systems

The main purpose of the diesel generator set supplied is to act as a contingency system. In the event of failures in the general power grid, voltage variations or scheduled maintenance shutdowns, the equipment guarantees the supply to the plant’s key systems, maintaining the operability of the equipment and the continuity of the electrical service until the grid is re-established.

To meet these demands, our engineering team developed a customised solution, which included:

  • Design and manufacture of a generator set in a 40ft HC container, with engine-alternator coupled directly on a steel base frame.
  • 1500 litres fuel tank providing more than 4 hours of autonomy at full load.
  • 2x MSR250 (-30dB) Type A technology silencers, which considerably reduce noise emission.
  • CompAp InteliGen control panel for advanced equipment management.
  • Additional safety measures, such as anti-fire system, protections on moving and hot parts, and emergency stop mushrooms.

Combined cycle power plants make efficient use of resources, combining gas and steam turbines to maximise power generation and reduce emissions, guaranteeing the sustainable economic development of the region. Genesal Energy reaffirms its commitment to sustainability, energy efficiency and social progress.

Features

  • Supply: Monoblock engine-alternator in 40′ High Cube container.
  • Tank: 1500L steel-steel tank, double walled.
  • Silenvcer: 2x MSR250 (-30dB) TYPE A
  • Control panel: CompAp InteliGen

 

Technology and commitment, Genesal Energy’s answer to healthcare challenges.

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Genesal Energy knows perfectly well that continuity of power supply is essential, especially in places where every second counts, such as a hospital.

That is why we have developed a tailor-made solution for the UK’s NHS Northwest, installing two 550 kVA open gensets specifically designed to meet the needs of this premises.

From vital medical equipment to security systems and medicines cooling, every component relies on electricity to operate 24/7.

Generator sets not only ensure the continuity of critical operations protecting the most important thing: patients’ lives.

Our engineering team developed a customised system including an engine-alternator monoblocks on steel frames with a capacity of 350 litres of fuel each and liquid collection trays with a capacity of 110% of the tanks.

They are also equipped with a Deep Sea DSE8610 MKII control cabinet, programmed to operate in permanent parallel with the grid ensuring the best efficiency parameters. There is also a Victron battery system to optimise energy management, allowing recharging during off-peak hours and support during peak demand. Both units are equipped with 800 A motorised circuit breakers, advanced protection systems and designs that facilitate transport and installation.

Industrial emergency generator set installed in a technical room.

Present at the Healthcare Estates exhibition and conference – IHEEM

The innovation that characterises Genesal Energy took us this year to the Healthcare Estates exhibition and conference – IHEEM held in Manchester Central. We had the opportunity to present one of these two hospital generators together with our partner Ingram Installations Ltd.

This event allowed us to show not only the technology that makes these projects possible, but also our vision for the future in the field of energy generation.

Our engineering solution

Our engineering department developed two 550 kVA open gensets, with the engine-alternator monoblock assembly on a 2800 mm long steel base, with a 350-litre capacity tank and a liquid collection tray designed to hold all the fluids that can be poured (oil, coolant, diesel…) with a capacity of 110% of the fuel tank. The engine radiator protrudes outside the bed, so the tray was designed to be large enough to accommodate this section. The fluid collection tray is supported on two omegas which serve as legs, protecting the tray from any contact against the ground that could damage it and facilitating the transport of the unit. By means of ‘zeta’ angles, they are joined to the main bedplate forming a single unit, with the base frame supports resting on the omegas and supporting the weight of the unit.

Generator set and control system for emergency power supply.

Equipment features

  • Construction type: Monoblock engine-alternator on 2800mm base frame.
  • Bunded tank on base frame with a capacity of 350 litres.
  • Liquid collection tray with capacity to hold 110% of the tank.
  • Four Tudor TC1453 145 Ah batteries.
  • Double set of batteries with protection box.
  • Victron system and positive disconnector for Manual battery change.
  • Alternator anti-condensation resistor.
  • Deep Sea DSE7410 MKII control panel.
  • Fully enclosed power output cabinet with no access to voltage parts.
  • No exhaust silencers.
  • Motorised circuit breaker with trip coil and position contact.

We supply emergency power to a combined cycle power plant in Brazil providing 14 million people with electricity

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The port of Açu is one of the main industrial and energy generation projects in Brazil.

Located in the north of the State of Rio de Janeiro, it has quickly established itself as an oil and gas hub thanks to its colossal dimensions and its capacity to transport people and goods. A 1.7 GigaWatts combined cycle power plant is being built at this strategic location as part of a mega-project that includes a similar facility and an LNG regasification terminal based on an already operating floating storage regasification unit (FSRU).

The size of this project has much to do with its optimal geographical location as Açu is close to Brazil’s two main gas pipeline systems in the north-east and south-east of the country.

The plants will have a combined total capacity of 3 GigaWatts and will be able to meet the energy requirements of 14 million households in Espírito Santo, Minas Gerais and Rio de Janeiro. The entire project is valued at around 1 billion euros. Genesal Energy is providing two 1750 kVA generator sets.

It is a state-of-the-art combined cycle power plant with gas turbines that will inject 1,672 MW of energy into Brazil’s integrated electricity system, so having an emergency generator set adapted for a combined cycle power plant to its needs was essential to guarantee its operation.

Social responsibility

Located about 400 km from Sao Paulo, the combined cycle plant (three natural gas turbine generators and one steam turbine) will deliver 1672MW of power at 500 KV to a distribution power line. Its commissioning will supply power to millions of homes.

Equipment features

  • Control Panel integrated in the soundproofed container.
  • Fuel tank inside the container.
  • Double-walled piping with leak detection.
  • Motorised louvers.
  • Air inlet and outlet mufflers for noise-level reduction.

Genesal Energy equipment to guarantee vital energy at the Montecelo hospital in Northern Spain

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Our engineering team has completed a significant project: the installation of three generator sets in the new Gran Montecelo Hospital, located in Northwest of Spain.

This project not only reflects our technical capability, but also our commitment to safety and reliability in environments where people’s lives are at stake.

Three high-power units were installed: two 1900 kVA units and one 1415 kVA unit. The main objective of this installation is to provide a backup power source to ensure the continuous operation of medical services, even in emergency situations.

Hospital facilities are critical environments where power loss cannot be allowed. In emergency situations, every second counts and the lives of many patients depend on the availability of power. It is therefore vital to maximise the reliability of electrical systems. Hospital gensets ensure that essential operation – medical care, life support equipment and lighting – is maintained without interruption.

Tailor-made solution

Our client required a solution adapted to the particularities of the installation and Genesal Energy’s engineering team developed implementation plans and customised solutions addressing crucial aspects such as air inlets & outlets soundproofing or the integration of the equipment in the corresponding rooms.

Three completely bespoke generator sets have been carefully designed to ensure that they can power the essential loads that depend on them. Also, tank capacity, which in this case is 1000 litres. This capacity has been defined in accordance with engine consumption and required operating time, ensuring an adequate supply of fuel during critical situations.

The custom-designed engine bed is also adapted to the dimensions of the resulting monoblock, radiator and power unit. In addition, the maximum suitable dimensions have been considered to facilitate transport and installation on site.

Among the features of the installed system are the following:

  • Special made-to-measure base frame: Designed to support the monoblock and associated components.
  • Double-walled tank: Made of steel-polyethylene, with a capacity of 1000 L.
  • Independent power panel: Vibration-isolated for the unit’s main switch, with a connection point for the connection of the power cables.
  • Air inlet and outlet silencers: Designed to reduce engine noise outside the room, with an attenuation level of -30 dB(A).

These silencers are designed to ensure that the generator both can breathe properly and meet the noise attenuation requirements, all while adapting to the available space in the building.

The installation of generator sets in hospitals such as Gran Montecelo is a clear example of how Genesal Energy is committed to providing safe solutions. Our engineering team not only designs and executes, but also ensures that people’s lives are at the forefront.

Features

  • Special made-to-measure base frame.
  • Parallel operation Control panels.
  • 1000 litres double-walled fuel tank: steel-polyethylene.
  • Motorised circuit breaker, independent of the monoblock and vibration isolated, with busbar for connection of power cables at the bottom.
  • 30 dB(A) air intake silencer.
  • 30 dB(A) air outlet silencer.

Genesal Energy’s key role in ensuring power stability in Taiwan

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In the current context, where the stability of the power grid is more critical than ever, the engineering behind generator sets plays an essential role in ensuring a continuous and reliable power supply.

Genesal Energy has taken on the challenge of designing energy efficient solutions as part of a project developed in Yunlin County, Taiwan.

This project not only highlights the technical capability of our engineering team, but also the importance of generator sets in the smooth operation of power substations.

Taiwan, with a population of 23 million people and a geographically complex terrain, relies heavily on the grid. Power on the island comes mostly from traditional sources such as coal and natural gas while renewable energies such as solar and wind continue to gain ground. This context requires power substations to be equipped with advanced technologies, capable of responding quickly to any eventuality. Genesal Energy has developed specific generators for this type of installation, designed not only to provide energy at critical times, but also to be environmentally friendly.

There are about 2000 secondary substations on the island, many of them located next to residential neighbourhoods, some even right next to residential homes. To provide a stable power service locally Genesal Energy and our local partner, MACRO-e Technology, also considered environmental concerns.

A containerised soundproof generator was designed to take over in the event of a critical situation. The generator will also help the energy storage system to operate longer. Its aim is to stabilise power quality and reduce the possibility of grid collapse.

Advanced technology for Taiwan’s energy challenge

The customer needed a flexible solution tailored to local requirements. Genesal Energy offered a high degree of customisation, allowing MACRO-e Technology to optimise the installation of the generators according to the specific needs of each substation. This includes everything from the design of the containers to the implementation of soundproofing and gas after-treatment systems, ensuring that the highest quality standards are met.

The success of this project in Taiwan reflects Genesal Energy’s commitment to innovation and quality engineering. Our generator sets not only meet technical requirements but are also designed with the environment and safety in mind. Our team’s ability to adapt solutions to the specific challenges of each environment consolidates us as a benchmark in the energy sector, ensuring that each electrical substation is prepared for any contingency.

Our engineering solution

Our engineers designed 20ft containerised generators with Cummins engines and Stamford alternators, which operate with low noise and minimal emissions thanks to a 40 dBA silencer and a gas aftertreatment system.

The fuel transfer system, external access to the control panel and the corrosion protection with stainless steel grilles demonstrate the Genesal Energy team’s dedication to providing a comprehensive solution. In addition, all the necessary safety measures were taken, such as the integration of guards on moving and hot parts, as well as emergency mushrooms and other elements necessary to operate the unit safely.

Features

  • Construction type: Monoblock engine-alternator in 20′ Dry Van container.
  • Without integrated tank, unit prepared for a fuel transfer system
  • Silencer model: GSI 650 (-30dB)
  • Deep Sea DSE7320 MKII control panel
  • 2 x Varta M18 180Ah batteries