Genesal Energy designs a generator set for the Paine Data Centre in Chile

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Genesal Energy has a line of work specialised in designing and manufacturing generator sets for data centres.

In an increasingly digital world, where most day-to-day and business activities depend on technology, having robust and secure facilities to handle data is essential.

The importance of data centres has grown significantly in recent years as they are a key element for the storage, processing and management of large volumes of data generated by companies and users.

On this occasion, our team of engineers has designed a data center generator for the expansion of more than 2MW in the Paine Data Centre, Chile.

This country has recently positioned itself as a digital hub in Latin America thanks to its political and economic stability, advanced infrastructure and commitment to technological innovation.

The presence of large technology companies such as Google and Amazon in the country not only supports this position, but also boosts economic development and job creation, improving connectivity, access speedand efficiency in the provision of digital services.

Genesal Energy worked with the objective of extending the emergency power supply, synchronising the generator sets with 4 other existing units.

For this purpose, a 2600 kVA soundproof generator was designed in a 40ft HC container with an engine from our Partner BAUDUOIN prepared to be installed on top of a belly tank.

The mandatory noise level and the need for a higher air outlet, required a tailor-made air outlet hopper for the container and large engine cooling-air attenuators.

Compatibility between the unit and the existing system in the data centre was also considered, so a control system was designed to improve compatibility between the equipment.

Ensuring uninterrupted operation

Continuous, uninterrupted operation need a backup power source in the event of power outages, protecting against data loss and system failures that can be a catastrophe for the large amount of information stored.

In addition, generators reduce downtime, comply with data security regulations, allow for scheduled maintenance without interruption and ensure operability in emergency situations.

Features

  • Soundproofed group with specific attenuation level: max. 85dB(A) at 1 metre:
    • Insulation in walls and ceiling by means of high thickness rock wool and acoustic membrane.
    • Large engine cooling air attenuators.
    • Hopper with top air outlet.
    • 40dB(A) exhaust silencer.
  • TIER II emissions compliant engine.
  • Elastic coupling between engine – alternator.
  • Alternator equipped with: PT100 probes in windings (2 per phase), 1 PT100 probe per bearing, current transformers and anti-condensation resistor.
  • Power output M/V switch cubicle and flyback cubicle.
  • Neutral grounding resistor (NGR).
  • AGM type batteries in protection box with disconnector.
  • Lacquered sheet metal on the container floor.
  • Surface paint treatment in accordance with ISO12944 – C4.
  • 34000 litre fuel BELLY TANK.
  • Integration with external control system (DEIF / GE).

An engineering feat to ensure power supply to a data center in Northern Europe

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We design five unique gensets capable of providing a DCP output of 3000 kVA each.

In an innovative and technological implementation, our engineering team has designed five generator sets that have been installed in a Data Center in Northern Europe. These are ad hoc machines designed to provide a DCP power of 3000 kVA and meet the stringent technical and regulatory requirements of the project.
We have reached this milestone hand in hand with manufacturers Baudouin, ComAp and Friga-Bohn. The generators were designed to ensure continuous uptime and data security in one of the world’s most critical and demanding environments, protecting the infrastructure against grid outages.
The integration of advanced technologies, customisation to detail and compliance with the highest standards of security and efficiency, consolidate this installation as a model to follow in the industry.

The importance of investing in emergency power generators

The installation of these generators responds to the critical need to ensure operational continuity in data centres, essential for the IT infrastructures of global companies. The benefits include:

  • Data Loss Protection: They provide an alternative power source to protect unsaved data and prevent damage to storage systems.
  • Cooling Maintenance: Enable continuous operation of cooling systems, preventing equipment from overheating.
  • Prevention of Costly Downtime: Minimise downtime that can result in significant financial loss.
  • Regulatory Compliance: Help companies comply with regulations that require robust contingency plans.

Innovation and security in every detail

This completely customised solution exceeded the customer’s most demanding specifications. The design of the container – with special dimensions of 13.5 x 3 x 3 m – includes a structurally reinforced base with pipes running underneath to facilitate connections to the fuel tank and a liquid collection tray that guarantees total containment in case of spills.
In addition, the container was given a C5 type surface treatment in accordance with UNE-EN ISO 12944-2:2018 – ideal for marine environments – guaranteeing exceptional durability and resistance.
To ensure that noise requirements were met the exhaust system was optimised including a thermally insulated (rock wool and aluminium) -30 dB silencer, maximising safety and minimising environmental impact.
In terms of equipment protection, 5000 A circuit breakers and Power locks were installed, as well as an oversized busbar, specially designed to facilitate the customer’s electrical connection of the system.
Our engineering team also developed an independent cooling system with motorised louvres and a fully integrated & automated fire suppression system to ensure a fast and efficient response in case of an emergency. The incorporation of wide accesses, advanced control systems, fire protection and adverse environment features completed this project and made it a benchmark in the industry.

Requirements and Customised Solutions

  • Non-full-flow: In terms of the cooling system, V-arranged Friga-Bohn air-coolers were installed in a room separated from the generator room. They were sized for a maximum ambient temperature of 38ºC at 100% load. This configuration allowed outside operation of a full flow system, significantly reducing air interference in the operating area.
  • Low noise level: The generators were required to operate at a sound pressure level of no more than 85 dB at 1 metre, at 100% load.
  • Fire protection: A Novec fire detection and gas extinguishing system and sectorisation panels were integrated, ensuring EI60 fire resistance standards.
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Business collaboration

After a thorough analysis of the customer’s specific power requirements, generator set models and capacities were selected based on a detailed list of electrical loads. The choice of Baudouin’s 3000 kVA DCP engines was not a gamble; these engines have been specially designed for critical applications and meet the highest standards of reliability and performance.
Regarding the control system – and as it was essential to ensure the highest availability of the equipment – redundant systems were installed. Namely, a redundant battery rack of eight units in total, separated into two groups of four. Also, a redundant two-stage starting system. First stage fitting two starter motors and managed by the engine ECU and a second stage with one starter motor managed by an ComAp controller. This particular control centre allows, in addition to real-time management and monitoring of the status of the generators, a flexibility that traditional control systems do not provide.

Features

  • V-arranged air-coolers were installed in a room separated from the generator room. They were sized for a maximum ambient temperature of 38ºC at 100% load. This configuration allowed outside operation of a full flow system, significantly reducing air interference in the operating area.
  • The generators were required to operate at a sound pressure level of no more than 85 dB at 1 metre, at 100% load.
  • A Novec fire detection and gas extinguishing system and sectorisation panels were integrated, ensuring EI60 fire resistance standards.
Containerized soundproof generator sets

Genesal Energy supplies 6 containerized soundproofed generator sets to a data centre in Norway

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The strategic importance of data centers

Data Centres are facilities that allow companies and users to quickly access data and, due to the function they perform, they have become essential in an increasingly digitalised world. Their electricity consumption is considerable and this high demand is not only used to run the IT equipment, but also to cool these rooms that house it.

Maintaining optimal temperatures in data centers

The optimum operation temperature in a data centre to ensure proper performance of the servers is between 18 and 20°C. To keep the temperature within these values, an uninterrupted power supply is vital. Any brief network outage could paralyse all the activities of a company and cause not only economic losses but also reputational damage that is difficult to recover from in most cases.

Generating sets: guarantee of continuity

For this purpose, redundant supply sources are used to ensure operational continuity in the event of any failure in the electricity grid, namely, electrical generators. An efficient and specialised solution to guarantee the constant availability of electrical energy.

Data Centre generator sets require cutting-edge engineering and experienced personnel. Genesal Energy provides both and for this reason the projects we develop are in great demand in this market.

One of our latest projects in this field has taken us to Norway, where we have supplied a total of six generator sets to power the emergency network of a data centre. The cold climate of this Nordic country was not an obstacle to the success of the project, as the six generator sets were designed to withstand the country’s low temperatures.

The engineering solution: 6 soundproofed generator sets in a container

Six 2250-2500 kVA soundproofed generator sets in a 40 feet HC container ready to work in permanent parallel with the grid. Two were designed with the power output on the right-hand side and four sets, symmetrical to the first two, with the power output on the left-hand side, which facilitated the installation of the power cabling.

Characteristics of containerized soundproof generator sets

  • 4.000 L Certified double-walled fuel tank which provides autonomy for more than 9 hours at 100% load.
  • Connections for fuel transfer from an external tank.
  • High-capacity fuel filtration system.
  • Container floor covered with checker plate.
  • Double starter motor.
  • Double set of batteries.
  • Motorised air inlet and outlet louvers.
  • Heat exchanger integrated in the base frame for heat recovery.
  • Customised power output busbars for easy connection.
  • C3 paint surface treatment, according to ISO12944, in RAL7016 colour.
  • Exhaust gas silencer installed on container, heat-insulated, with external aluminium coating.
  • The sound pressure level at a distance of 1 m is 85 dB.

We continue to grow in the data centre sector

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According to the experts, few sectors have such a promising future as data centres.

Their evolution goes hand in hand with that of the internet and the online world is unstoppable. Therefore, the need for companies, organisations and institutions to store a huge amount of data is growing and that is precisely the function of data centres or DPCs.

In a world that is becoming increasingly digitalised and where Artificial Intelligence has come to revolutionise everything, security is becoming more of a priority than ever. In this respect, our sector has also evolved a great deal because digital transformation and digitisation processes must be accompanied by ironclad security.

Distributed energy is vital here because if there is a failure in the network, even for a few seconds, a disaster may occur. To avoid this, generators are a fundamental piece of the puzzle. Reliability and sensitivity are two compulsory characteristics of generator sets for data centres, which need to be certified by a very demanding legislation from ‘The Uptime Institute’ that classifies equipment into four levels: Tier I, II, III and IV.

Always made to measure

Genesal Energy has spent years positioning in the data centre sector, offering our customers products that stand out for their exceptional quality. Turnkey projects custom-designed and manufactured with very precise characteristics. Because the road we travel with the customer does not end with the delivery of the equipment, it continues with maintenance so that there are no surprises, so that everything is under control.

One of our latest Data Centre projects was a built-in switching and special soundproofing for 65 dB(A) at 7 metres generator set.

Features

  • Engine Speed Electronic Governor
  • Special soundproofed canopy providing65 dB(A) at 7 metres
  • Integrated ATS with independent Control panel
  • 1350 L fuel tank with a 110% Leak tray
  • Fuel heater avoding ATEX atmospheres while functioning
  • Fuel transfer system
  • Fire detection system

Fail safe energy for a railroad network Data Centre

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The railway sector, highly digitalised in Spain, manages a huge amount of information, data stored in Data Centres.

Generator sets play a vital role in these facilities as they provide emergency power supply to operate with absolute tranquillity.

Trace convoy’s location, control arrival and departure times, manage tickets, detect delays or any type of event in real time is the bread-and-butter of nowadays train traffic systems. Failures, even the smallest ones, are critical because they can dramatically affect the network and passengers’ security.

Genesal Energy is an expert designing, manufacturing and supplying backup power for such complex Data Centres where the hundreds of hosted servers must be safe from any unexpected event. If power supply fails for just seconds, if there is a blackout… electricity must keep flowing. Errors are not an option.

Two high-capacity sets

Our customer needed to ensure power supply to an important data processing centre of the railway sector.

After carefully listening to the client’s needs and analysing the situation, we designed two high-capacity generator sets to cover the energy demands of the two installation’s grids and guarantee optimal redundant operation.

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This was the engineering solution

We designed and manufactured two 2750 kVA generator sets integrated in a 40 feet HC marine container, fitted with container-top mounted dry coolers and vertical exhaust system.

The control room is integrated and soundproofed to comply with the noise regulations.

Features

  • 40 feet HC Container
  • Dry coolers
  • Vertical exhaust system [-40 dB]
  • Integrated Control Room
  • Busway connection
  • Automatic 4000A integrated switch

Genesal Energy power for one of the largest telecommunication companies in Spain

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At Genesal Energy we have reinforced the emergency supply of a data processing center (Data Center, or DPC) owned by one of the main telecommunications companies in Spain.

The project took place at one of their buildings located in León, and consisted of designing, manufacturing and supplying two identical 300/330 kVA generator sets with a common 3000 L fuel tank.

We are specialists in the supply of emergency power for this kind of installations, where precision and customization are essential features, and our experience backs us up.

Data Centers are doubtless to say the brains of telecommunications companies. They handle millions of data from thousands of customers and store very sensitive information so that a power outage may cause serious losses, and thus fatal consequences for the company.

Turnkey Service

After a meeting with the client to find out their specific requirements, we decided to offer a turnkey service where we assumed the designed, manufacturing, transport, installation and maintenance of the generator set delivered to the León Data Center. Thus, to ensure a stable supply and guarantee the best service, the Genesal Energy team studied the conditions of the building, as knowing the room where the equipment will be located is essential to achieve the best results.

The client needed to guarantee energy at all times so that in the event of a breakdown or interruption of the electrical network, the equipment would start operating in record time. The generator sets designed by our engineering team are not only prepared to act in the event of a breakdown, but also to provide energy in adverse situations such as a storm or any other meteorological phenomenon that causes failures in the network. If this happens, the emergency system will allow the installation’s capacity to be increased in those production peaks in which the conventional network is not enough.

Apart from sharing a common fuel tank, these generator sets included an upper air outlet to fit like a glove to the room where they are located, as well as heated chimneys for greater safety – among other customized features.

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Features

  • Upper air outlet
  • Fuel transfer system.
  • 600 L base frame integrated fuel tank + 3000 L double walled fuel tank, connections and y legalization of the installation
  • Parallel operation
  • Signals and operation mode according to customer requirements
  • Chimney supply and installation

We maximize security: special generator sets to protect data in A Coruña and Bilbao Data Centers

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Do you know where companies keep their data?

In a world which is increasingly connected, storing data in a safe manner isn’t a luxury, but a necessity.

Data Processing Centers (DPCs) or Data Centers are spaces which house great computer equipment, and are key pieces in business infrastructure. These infrastructures tend to be proportional in size to that of the company they are storing data for: the higher the volume of data the company manages the more complex the Data Center and the safer its power supply system must be. The motive? A lengthy power outage can provoke a major catastrophe and millions in losses.

Most medium-sized companies – and of course all large companies – feature evermore modern and complex DPCs. Many occupy great rooms and even whole buildings where all of its computer components, necessary for the storage of information, are located. The correct maintenance of these spaces is vital for their optimal operation and here is where an essential factor comes into play: security.

Each second comes at a cost

These installations must not face a single risk and that’s why it’s so important to guarantee continuous supply under any circumstance. An accident which in other cases may not be too significant, such as a blackout, would cause great damage in a DPC. What would happen if a bank or administration entity lost millions of confidential pieces of data in mere seconds? And this is where, in the security system of a Data Center, emergency generator sets play a crucial role.

Emergency generator sets for DPCs have to be extremely relibale and powerful, two vital conditions to guarantee power supply under any circumstance, such as a fire, mains failure or any kind of accident, as a DPC cannot stop for a single instant. Each second, comes at a cost.

The distributed energy sector, in constant evolution, has provided answers to the particular requirements of DPCs, placing products and services in the market which are also very particular in the sense that they must comply with very specific norms regulated by Uptime Institute, an international organization which certifies exactly how these installations must be designed and classifies them in four levels: Tier I, II, III and IV according to their infrastructure.

Germany, a fulfilled challenge

At Genesal Energy we’re experts in manufacturing such special generator sets and their sucess in projects in which we’ve participated has turned us into references at a national and international level. In Spain for instance, we’ve reinforced the security of numerous DPCs in the peninsula, such as in Barcelona, and also in the Canary Islands, specifically on the island of Tenerife. Internationally, we’ve consolidated our presence in this field through other great projects. An example is the supply of two emergency generator sets for a DPC in Germany, one of the most important Data Centers in Europe.

At a national level, two of our latest projects have taken us to two cities in the North of Spain: A Coruña & Bilbao. In both, we’ve supplied emergency power for two important Data Centers, where a simple power outage can mean the failure of thousands of operations worldwide. The objective of our generator sets is to supply instant power in the event of a mains failure.

Emergency power for two great Data Centers in A Coruña and Bilbao

In the Basque Country we’ve recently participated in the construction of a new and important DPC in Bilbao through two 1250 KVA gensets with a parallel operation system. Our engineers’ solution consisted in two twin gensets with a special base frame adjusted to the client’s spatial requirements.

Additionally, a power outlet cabinet was designed with a specific Cu 50×10 busbar so that the client could connect their power cables. This cabinet, like the control cabinet, was installed according to the client’s needs in order to be able to adapt the units ergonomically to the existing infrastructure.

In the case of the DPC in A Coruña, the generator set we designed needed to be especially silent. To achieve this objective, the genset was installed inside a 20 foot container with external air inlet and outlet baffles, in order to reduce the level of decibels. This was the chosen solution to eliminate acoustic impact on the buildings surrounding the Data Center, which belongs to an important bank operator and is located in an urban area containing numerous offices. In this case, the client needed to increase the capacity and quality of the Data Center with another state-of-the-art genset.

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Bilbao Data Center Features

  • Engine-alternator assembly painted in the colour required by the client (RAL 7040)
  • Motorized breaker
  • Adapted power cabinet
  • Synchronization system
  • Exhaust gas silencer sleeve
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La Coruña Data Center Features

  • Power cabinet integrated in the soundproof container of the generator set.
  • Motorized louvers.
  • 1.500L integrated fuel tank.
  • Automatic fuel transfer system, connected to the existing installation.
  • External colour according to the client’s specifications.
  • Air inlet and outlet attenuators of -40Db. Turnkey solution including a great tonnage crane for the installation of the container, as well as fuel installation and night-time commissioning.

Genesal energy for a data centre. Always at the forefront of critical centres’ protection.

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A simple power outage, even if its duration is not too long, may be an eternity in a Data Centre. For this reason, generator sets must be extremely efficient and robust in terms of frequency/voltage stability and single step load acceptance.

Custom design and personalization make more sense in this market than ever as the greater number of data is stored, the more emergency power must be supplied to the Data Processing Centre (DPC).

At Genesal Energy we know the importance of details very well. We analyse the client’s needs based on the characteristics of the data centre and then we design the equipment adapting both to the client’s demands and the strict regulations affecting these facilities (the Uptime Institute, as responsible for making such certifications, establishes four levels: Tier I, II, III and IV).

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Engine and alternator at the highest level

One of our latest notable projects is a Data Centre in Valencia. The customer needed a diesel generator set to replace the existing one, which was obsoleted.

It was necessary to replace the genset with the data centre in operation, taking all the necessary measures to guarantee the supply in the event of a mains failure, which implied the need of counting on a rental generator set in order to ensure the power supply in the face of any contingency.

The solution provided by Genesal Energy consisted of replacing the old generator with a higher power equipment: a 400 kVA unit mounted on a 4500mm soundproof canopy with a top-level engine and alternator in order to guarantee a constant and uniform supply since it had to resemble the ideal conditions as much as possible.

Within the usual service that we provide to our clients, in this case we carried out the works including the crane for removal of the existing generator and positioning of the new equipment, as well as the electrical connection of the existing lines and fuel storage system with the new generator.