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

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Linking Northern and Southern Europe by means of communication routes facilitates the transit of goods between countries.

CStrong investments are being made in creating new infrastructures to reduce travel times.

One of these is the mega-construction that is defying the laws of engineering, the Fehmarnbelt tunnel, a unique $8 billion project that will change travel between Central Europe and the Scandinavian countries forever. Once completed, it will become the longest combined road and submerged rail tunnel in the world with almost 20 km, crossing the Fehmarn Strait in the Baltic Sea and providing a direct link between Northern Germany and the Danish city of Lolland.

It is a key element in the development of the Scan-Med corridor, a transport network spanning more than 5,000 km from Malta in the South to Finland in the North.

A project this size needs the best elements to ensure its timely completion. To provide back-up power to the machinery involved in the world’s longest underwater tunnel construction, Genesal Energy’s engineering team has designed and installed 7 generator sets.

These soundproofed generator sets are fitted in a 3,800 mm long cabin and have 910 litre fuel tanks that guarantee an autonomy of more than 21 hours at 100% load.

Due to the harsh environment conditions and to protect the alternators, a special marinisation treatment was applied to give them greater resistance to highly corrosive ambient conditions.

The gensets were designed for AMF mode of operation with 3-way double valves so that it is possible to manually select whether the genset is supplied from the integrated tank or from an external tank.

Commitment and rigour

Genesal Energy has been constantly enhancing its reputation in the generator set sector, offering our customers products that stand out for their exceptional quality. Custom-designed and manufactured sets, with very precise characteristics. Turnkey projects where we take care of all the steps. Guaranteed electricity supply in the most complicated situations.

Features

  • 7 x 3800mm Soundproofed Canopied Sets.
  • 910 litres integrated fuel tank. Autonomy of 21.6 hours at 100% load.
  • Tank fitted with a liquids’ retention tray and a leak detection system.
  • An exhaust gas silencer installed inside the canopy itself, which ensures a reduction of -30 dB.
  • Air Cyclonic filters for the engine intake air.
  • The air inlet and outlet fit motorised louvres.
  • 3-way double valves to allow manual selection of whether the genset is fed from the integrated tank or from an external tank.
  • External quick connectors for fuel supply and return.
  • C5-scheme paint surface treatment, according to ISO12944:2018.
  • AMF mode of operation. ComAp AMF25 InteliLite4 Control panel.
  • Special marinising treatment & Anti-condensation resistor in the alternator to provide increased resistance to highly corrosive environments.
  • Powerlocks switchboard.

 

Generator set for a hangar at Barajas airport with a surface area equivalent to three football pitches.

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Adolfo Suárez Madrid-Barajas airport leads the ranking of air traffic in Spain. It closed the 2023 financial year with a passenger volume of more than 60 million and more than 380,000 operations carried out.

The figures reflect the importance of this airfield which, due to its colossal dimensions, needs to have many hangars where aircraft can “rest”. Premises equipped to carry out repairs and maintenance operations inside.

They are normally designed to house more than one aircraft and emergency power is key to their operation. With a surface area of more than 22,400 square metres, the equivalent of almost three football pitches, one of these airport hangars needed a special generator. Genesal Energy has just supplied contingency power to prevent a significant loss of time and money with a special genset for airports.

Tailor-made: generator set for a hangar

“The client required the customised manufacture of hoppers and bellows for the generator’s cooling air outlet, as well as a gas duct with 90° bends to adapt to the layout of the hangar’s generator room“, explain the engineering staff which developed this project. 

Our engineering team’s solution consisted of a highly customised generator set, which was manufactured according to the customer’s requests, seeking the best options for a special site with such particular dimensions.

Technical Data

  • Power panel integrated in the alternator, allowing the intake of two cables per phase.
  • Calculation of the necessary cross-sections for the inlet and outlet of gases in the room, tailor-made hopper and bellows.
  • Oversized exhaust silencer model.
  • Multicolour control panel.
  • Heating system.
  • Integrated 350 L tank.

Made-to-measure power for the demanding Finnish market

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Flexibility and adaptability are two fundamental aspects when it comes to offering customised and optimal energy solutions.

The production of bespoke generator sets is one of the areas in which we’re specialised here at Genesal Energy. It is without a doubt one of our distinguishing characteristics, and it’s made us strong and competitive in a market as demanding as Northern Europe.

At Genesal Energy we’ve just manufactured a 200 kVA contingency generator set for this market, specifically for a client in Finland. Amongst its features are its ability to start up in the event of a mains failure and its 450L bunded fuel tank integrated into the base frame.

Client color

With a soundproof canopy and designed by our engineering department to operate at full performance when facing a temporary failure in electricity supply, our client also required a specific colour for the generator set. Following their indications, the genset’s canopy, a turnkey model, was painted in a very concrete tone of black, chosen amongst 200 alternatives in the RAL code colour palette.

Made-to-measure design of the structure and cooling system of one of our generator sets

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At Genesal, we design each generator set with diverse elements; elements which have been thought out and tailor-made according to the client’s specific needs.

This generator set is a prime example of the made-to-measure structure and cooling design of a genset with particular space requirements. The design allows for the assembly and removal of the genset in its installation area in a simple and practical way.

Features

  • Engine cooled via air intercooler in order to optimize space and avoid the need of great air flow.
  • Baseframe separated into 3 bodies for an easy installation and disassembly, in order to pass the generator set through a tight space.
  • Easily emptied engine and battery liquid collection bund.

We supplied two customised generator sets for the Austrian market

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We continue rounding up references in Austria, where we’ve just supplied two special gensets of 650/715 kVA with Volvo engines for an important international multi-platform media firm.

They are two identical units, completely customised to fit the requirements of the client, who needed two generator sets prepared for parallel operation between eachother and with the mains, designed to withstand the load sequence of the coolers located at the facilities.

Each generator set has an oversized 1000L fuel tank installed in the base frame which includes a leakage collection tray, and is prepared for automatic fuel transfer from an external tank; as well as a special busbar adapted to the client’s power cables.

Features

  • 1000L fuel tank in the base frame with leakage tray to collect all genset liquids, prepared for automatic fuel transfer from an external fuel tank.
  • Parallel operation between gensets and with the mains.
  • Busbar adapted to the client’s power cables.
  • Fuel filter with heater.

 

We’ve reinforced our presence in Asia through a new market: Taiwan, the ever-expanding Asian Tiger

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At Genesal Energy we’ve opened up a new market in Taiwan through the supply of a 500 kVA generator set designed to supply power in mains failure situations.

Our arrival to the Taiwanese market marks a turning point in Genesal’s internationalization plan in South East Asia. Taiwan is a strategic market, due both to its economic importance as the 28th wealthiest country worldwide and the 6th wealthiest in Asia, and to its potential for companies in the energy industry.

With a GDP that grows at a dizzying rate year by year, the power distribution sector is in constant evolution and with an increasingly strong focus on sustainability. As such, the first project we’ve carried out in the country, a stationary genset of 450-500 kVA, complies with Tier III emission standards. We delivered a genset which was completely adapted to the client’s requirements, providing the adaptability and flexibility needed for a correct integration of all components, with the following features:

  • Stationary, open type genset of 450-500 kVA at 60Hz, 380/220V.
  • DSE 7320 MKII control panel for automatic start at mains failure, with an Ethernet communication module to monitor the genset’s status remotely from a linked-up computer.

12 gensets for the Administration

Furthermore, our entry into the Taiwanese energy market has been consolidated through the supply of 12 gensets of 200/220 kVA for the Taiwanese Administration. The units, all customised, are designed to enter into operation should a mains failure ever occur. The gensets are stationary and were personalized according to the client’s requirements to be adapted to the modifications that would be carried out at a later date in their facilities. All of them comply with Tier III emission standards.

Main features

  • Open type stationary units of 200/220 kVA at 60Hz, 220/127 V.
  • DSE 7320 MKII control panel for start-up upon mains failure.
  • Engine with EGR valve for exhaust gas recirculation.
  • Alternator anti-condensation heaters.

Finland, a market in expansion

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In the European market, the Nordic countries are one of our main focuses, which is why Finland is key in Genesal Energy’s international strategy.

One of our latest projects has taken us to Finland’s west coast. Our client needed a 60/66 kVA genset to shield a church of great historical value against fire.

The result is an emergency unit which, in the event of a mains failure, will provide the power necessary so that the fire extinguishing system doesn’t fail.

Features

  • 110A Automatic Transfer System integrated in the genset’s control panel.
  • 200 litre fuel tank integrated in the base-frame with a leakage tray for oil, coolant and fuel.
  • Manual oil extraction pump.
  • 4-pole manual breaker, with LS/I protection and trip contact wired to the panel.

We supplied 24 gensets to guarantee the power supply in the Balearic Islands

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We’ve supplied 24 gensets in Mallorca, Menorca, Ibiza and Formentera.

At Genesal Energy we’ve supplied 24 gensets to guarantee the correct operation of the power grid in the Balearic Islands, either during a mains failure or when facing scheduled outages during maintenance.

The units sent to the islands of Mallorca, Menorca, Ibiza and Formentera are tailor-made solutions adapted to the needs of the client, who requested that the groups, of three different power ratings, be prepared to be moved anywhere by road. Following these requests, Genesal Energy developed robust gensets, capable of facing the inconveniences that inevitably arise due to the rattle of road transportation as well as the occasional complicated access points.

Although the 24 gensets are operated manually, they can also start-up automatically in the event of a mains failure for instance, or remotely through a dry contact or through SMS thanks to the GSM/GPS module incorporated inside. This communication module allows the following functions:

  • Control of the unit through SMS in order to start-up and stop the genset remotely, alarm reset, change of operation mode and visualization of the status of the genset in real-time.
  • Automatic SMS and e-mail delivery to the user regarding alarms and events pertaining to the genset.
  • Monitoring and control of one or more of the units through the web.
  • GPS Geolocation to know the location of the generator set at all times and to avoid the possible theft of the genset, which incorporates an alarm to alert whenever the genset moves out of the coordinates defined by the client in the control panel.
  • Fuel theft alarm.

Different soundproof systems

On the other hand, each genset has conditional permission to operate which is reliant on an external relay that will allow it to or not, as appropriate, when the genset in question is used to power a section of the medium-voltage network in island mode.

Following the client’s requests, all of the units are soundproofed, due to the fact that they are mobile gensets that must comply with the noise emission norms of the different places in which they could operate (residential zones, urban areas, hospitals…).

Genesal’s solution consisted in designing different soundproof systems in the canopies that ended up reaching noise emission levels which were far below the average for standard gensets of the same power rating.

The 24 gensets also contain fuel tanks with great autonomy (more than eight hours at 100% load in all of the units) and a leakage tray for all of the unit’s liquids.