Genesal Energy takes part in the construction of the world’s longest underwater tunnel

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Linking Northern and Southern Europe through new communication routes is one of the major engineering goals currently being realised.

Strong investments are being made in the development of infrastructures designed to reduce travel times and facilitate the movement of goods between countries.

One of them is the Fehmarnbelt tunnel, a mega construction that is pushing the boundaries of engineering. This unique $8 billion project will transform travel between Central Europe and the Scandinavian countries. Once completed, it will become the longest combined road and rail immersed tunnel in the world, spanning almost 20 km, crossing the Fehmarn Strait in the Baltic Sea and providing a direct connection between Northern Germany and the Danish island of Lolland.

It is a key component of the Scan-Med corridor, a transport network of more than 5,000 km, stretching from Malta in the south to Finland in the north.

A project of this scale demands the most reliable equipment to ensure its successful completion on time. To provide back-up power for the machinery involved in the tunnel’s construction, Genesal Energy’s engineering team designed and manufactured 16 generator sets, delivered in two phases.

These soundproofed units were customised with canopies of 3,800 mm and 2,900 mm, and fitted with fuel tanks of 630 and 350 litres, offering an autonomy of more than 17 hours at 100% load.

Due to the harsh environmental conditions, and in order to protect the alternators, a special marinisation treatment was applied to increase their resistance to highly corrosive atmospheres.

The generator sets were designed to operate in AMF mode, and are equipped with 3-way double valves to allow manual selection between the integrated tank or an external one for fuel supply.
This ensures a reliable energy supply throughout the construction phase, helping to keep the project on schedule.

Commitment and rigour

At Genesal Energy, we have built a solid reputation in the generator set sector, offering our customers products that stand out for their reliability, performance and quality.

We design and manufacture custom-made solutions tailored to each project’s technical requirements, delivering turnkey systems in which we take care of every stage.

This commitment has allowed us to take part in high-demand projects such as the Fehmarnbelt tunnel, where a reliable power supply is key to the project’s success.

Features

  • 16 soundproofed canopied generator sets: 16 with 3,800 mm length and 2 with 2,900 mm length
  • Integrated fuel tanks of 630 and 350 litres, providing more than 17 hours of autonomy at 100% load
  • Fuel tanks fitted with liquid retention trays and leak detection systems
  • Exhaust gas silencers installed inside the canopy, achieving a -30 dB reduction
  • Cyclonic filters for engine air intake
  • Motorised louvres at air inlet and outlet, which open only during operation
  • 3-way double valves to manually switch between integrated and external fuel tanks
  • Quick external connectors for fuel supply and return
  • C5-scheme paint surface treatment, compliant with ISO 12944:2018
  • ComAp InteliLite AMF 25 IL4 control panel
  • Alternators with anti-condensation resistors and special marinisation treatment
  • Powerlock switchboards for power output

 

Genesal Energy takes part in the undersea Greenlink highway project that will bring green energy to Great Britain and Ireland

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Greenlink: A huge HVDC interconnector will link Ireland and Great Britain to bring electricity to 350,000 homes.

Greenlink, the colossal engineering project designed to bring clean energy to thousands of people.

The Greenlink HVDC interconnector is an immense undersea highway which features are as spectacular as its construction. The interconnector will have a capacity of 500 MW and a length of 160 kilometres, the distance separating the counties of Wexford in Ireland and Pembrokeshire in Wales. Its entry into service, scheduled for this year, will enable the supply of clean electricity pursuing the aim of achieving zero emissions. This project has been declared a Project of Common Interest by the EU).

Our involvement in the project

For this mega project, delivered by Siemens Energy and Sumitomo Electric, Genesal Energy designed three generator sets to provide emergency power at both ends of the giant interconnector. Three special units developed at our HQ in Northern Spain to guarantee the supply of the two vital facilities in the connection of the electricity grid of Great Britain and Ireland.
“If for any reason there were to be a lack of supply, it would cause a major grid failure”, explains our engineering team, highlighting the importance of having precise, robust and extremely reliable contingency gensets.

Making a difference

For the Greenlink project, our client Siemens Energy requested the generators to be fully operated, controlled and monitored from the genset control panel. The solution we provided consisted of bespoke generators including the following features:

  • Bespoke soundproofing.
  • Great Britain and Ireland Regulations compliant in terms of air conditioning, motorised grilles or liquid retention systems. These latter trays fitted with sensors monitored from the control panel.
  • Integrated into the container Load-Banks so that the generator sets are always in the optimum working load range.

 

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Smart Grids

The Greenlink subsea interconnector project is perfectly in line with our policy of putting innovation at the service of sustainability and the environment. It is also a clear example of a Smart grid or intelligent electrical network that has been conceived to facilitate the transport and distribution of green energy.

2xGEN1100YC Features

  • Power output panel integrated in the same soundproofed container as the genset.
  • Engine coolant recirculation and heating system to provide the right temperature when starting the unit.
  • Air conditioning system in the genset control room.
  • Motorised louvers.
  • Liquids collection tray.
  • Integrated load bank.
  • Surface treatment of the container according to ISO 12944 standard, in C5I finish.

GEN175YI Features

  • 160/175 kVA soundproofed unit. 730 litres tank (17 hours autonomy at 100% load) and liquid collection tray integrated in the canopy.
  • Canopy adapted to the customer’s room.
  • Reduced dimensions due to space limitations.
  • Canopy designed to be attached to the wall. The doors on the side were sized to open accordingly.
  • -30 dB(A) Exhaust gas silencer.
  • 80 kW Resistor Load Bank, with 4 automatic steps of 20 kW each, integrated in the Canopy.
  • Interior Space Lighting.
  • C5M Surface treatment in accordance with the ISO12944 standard.

Emergency lighting in the Austrian highways

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We continue to work hard to give you the best energy. We take it to you.

Europe is, along with Asia and America, one of our greatest markets. In the European continent, more specifically, in Austria, we’ve manufactured, supplied and installed an Emergency lighting genset for one of the maintenance centres of the country’s highways. The generator set is prepared to supply power to offices and workshops, to ensure that the maintenance works always have the necessary power.

Features

  • Double fuel transfer system, so that the genset’s integrated fuel tank (500 L) can be fed either from the double-walled 4,000 L fuel tank integrated in the container or from an external fuel tank supplied by the client.
  • Genset prepared to operate in parallel with the mains.
  • Power cabinet with motorized breakers and two power outlets through isolators with fuses geared towards the client’s distribution cabinets.
  • Independent batteries for control and start-up.
  • Motorized louvers.

Emergency power for a fish factory in Norway

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Fish factories are special, extremely delicate installations, where a small power supply failure can turn into a massive catastrophe.

At Genesal Energy, we’re experts in avoiding setbacks, in designing, supplying, and installing generator sets capable of guaranteeing the species’ life in the event of any incidence, avoiding the loss of millions for the owner.

In Norway we’ve just supplied four 650 kVA emergency units prepared for parallel operation. In the event of a supply failure, the generator sets will take on the essential loads to ensure the operation of the fish factory. We continue to innovate to guarantee our clients’ peace of mind.

Features

  • Control panel for the parallel operation of the three supplied gensets.
  • Motorised louvers, and a dry contact for their operation.
  • IB-lite module for Modbus communication.
  • 400 L fuel tank with two maximum level sensors and one 50% level sensor, which will dictate the automatic fuel transfer system’s start-up. The valves in the fuel tank are 1 and a half inches, following the client’s requests. A 4-20mA connection for a fuel level indicator is also included.
  • Manual oil extraction pump.

The Saudi Embassy in Chad is powered by Genesal Energy

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Four generator sets designed and manufactured made-to-measure.

The Saudi Arabian Embassy in Chad is powered by Genesal Energy, through four generator sets designed and manufactured made-to-measure, in two sets of two different power ratings: 1,000-1,100 kVA and 1,500-1,650 kVA respectively, prepared for parallel operation.

The four gensets are designed to guarantee a constant and failure-free power supply, 24/7, 365. If ever there were to be a failure in the mains power supply, both gensets would start up; as long as loads don’t exceed 80% power of one of the gensets, one of them will stay in operation, powering the loads, and the other will stop; but if the load reaches 80%, the other genset would operate in parallel with the other, powering the loads.

In parallel

Likewise, in the event of the failure of one of the gensets operating on its own, the other will start up, providing redundant operation.

As well as its parallel, redundant, power-managing system, the units manufactured by Genesal Energy for the Saudi Arabian Embassy have the particularity of including a power outlet adapted to the client’s needs, constructed with a bus bar capable of holding up to four cables per phase of 630 mm2 at the genset breaker’s outlet.

Features

  • Special bus bar at the the genset breaker’s outlet to hold up to four cables per phase of 630 mm2.
  • Parallel and redundant operation between the gensets.
  • 1,000 L. Schütz fuel tank with Inpro fuel transfer system.
  • Recirculation and heating system for the engine’s coolant in order to provide the correct temperature for start up.
  • Control panel integrated in the base frame.

Supply of two generators to a fish farm in Norway

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We’ve supplied two 660 kVA gensets through our distributors in Norway, prepared to operate in parallel, which will guarantee the electricity supply of a fish farm.

Features

  • The engine has been painted with a special anti-corrosion treatment and the alternator contains anti-condensation heaters in its windings, to protect the gensets from the high levels of concentration of salt in their surroundings.
  • Both gensets are going to work in parallel, guaranteeing necessary power supply in the event of a mains failure.

 

Emergency Power for the Saudi Arabian embassies in Ghana, Cameroon, Niger and Zambia

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Design and manufacture of emergency back-up gensets for the Saudi Arabian embassies situated in Ghana, Cameroon, Niger and Zambia, ensuring they will continue to have electricity in the event of a power cut in the mains grid supply.

The first stage in partnership with the construction firm responsible for building the embassies was a rethink to ensure that the gensets were adequately installed according to their characteristics.

The final design was completed, followed by the acquisition of the required materials to ensure the production deadline was met. Finally, the gensets (both mechanical and electrical parts) were built, culminating in testing for approved standards certificates in conjunction with the consultant responsible for design approval and signing off on the delivery.

Energía de emergencia para las embajadas de Arabia Saudí

A total of 20 gensets have successfully been installed: four in Ghana, five each in Niger and Cameroon, and a total of six gensets in Zambia. Although the gensets appear to be very similar, they were configured differently in each room where they have been installed, depending on the position of the fuel tank as well as the accompanying cables.

This also included the need for adequate busbars for the fitting of the power cables to the gensets. Each embassy now has a set of gensets giving back up support to the main on-site buildings. Regarding the genset operational setting, depending on the embassy, this could entail running in parallel between the gensets. It also permits added power output or redundancy, useful where if one genset fails, the others or another will take up the load demand. The project was completed with individual gensets installed in to the underground bunker found in each compound.

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

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:

  • 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
  • High quality engines and alternators were chosen for their reliability
  • Manufacture of auxiliary systems for start-up in very low temperatures (guaranteeing optimal functionality)

Features

  • 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

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.

Download project info here