‘Black Start’ emergency power for a petrochemical plant in Tarragona

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At Genesal Energy we have supplied a 2,250 kVA black start generator set to a petrochemical plant in Tarragona (Spain).

The facility is equipped with a cogeneration plant that required tailor-made emergency power, that is, special equipment to guarantee the electricity supply at all times and in any situation. The project for this infrastructure was developed by our engineering team after analysing in detail the specific requirements our client had. Carrying out the black-start of the cogeneration plant in the face of a black-out of the external electricity supply was one of their main concerns.

Black Start equipment allows energy to be restored without depending on the external network, which is essential for the optimal maintenance of a power plant such as the one in Tarragona, since operation is guaranteed with no need of being linked to the power transmission network, allowing the servicing of the own turbines without any problem.

Likewise, the control and automation of each generator set for its integration into the other systems of the plant was also tailor-made so that a PLC panel can fully control the emergency system. Furthermore, in this case the generator is capable of operating in parallel with two mains.

The operator decides by means of a button on the corresponding control panel or remote order with which network it wishes to synchronize to restore the bar to normal situation. The system is equipped with a RS485-Modbus communication module to monitor all variables remotely.

Specialists in starting from scratch

Black Start technology is ideal for a project such as the petrochemical plant in Tarragona as it allows the power systems to be restarted without any problem in the event of any unforeseen event or collapse in the electricity network. The Autonomous Start or Black Start makes this possible and, therefore, reduces the threat of lack of supply, which is the greatest fear in this kind of plant. Start-up is guaranteed. At Genesal Energy we have the knowledge and experience to offer this kind of customer service. Always with a personalised attention.

Features

  • Fuel tank installed inside the container.
  • Attenuators inside the container.
  • Motorized breaker.
  • Neutral earthing switch.
  • Recirculation and engine coolant heating systems to reach the proper temperature when starting the genset.
  • Air inlet and air outlet motorized louvers.
  • Parallel operation between two networks.

Genesal Energy generator sets designed to run at full capacity in the Qatari desert

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When a Generator set is manufactured to work in places with unusual environmental conditions, it is essential that they are highly customized.

At Genesal Energy our equipment is designed in such a way that they are capable of operating in extreme conditions and at temperatures above 40 ºC. They are made-to-measure generator sets designed by our engineers after having carefully studied the environmental conditions in which they must operate.

One of our latest projects has taken place in a Middle Eastern country: Qatar. The Qatari authorities asked us to design several trailer mounted generators for a contingency energy fleet.

With a very hot climate and high humidity levels, Qatari summers easily exceed 45ºC. Therefore, the generating sets that have to operate in these circumstances must be custom designed. In this case, the client needed the equipment to have a great autonomy and that could easily transfer fuel from an external tank. They also needed them to be located in different areas by means of a trailer which must be suitable to drive along the desert sand.

Dust filters

In custom manufacturing, everything is designed in detail. Furthermore, the containers were manufactured considering the environmental conditions, including a customized tank, transfer system and external fuel connection point, as well as dust filters to prevent the entry of sand as they had to work in the middle of the desert.

Features

  • Engine and alternator sized to give the required power at the design temperature.
  • Sand filters.
  • Made-to-measure fuel tank.
  • Fuel transfer system and external fuel connection point.

We supplied emergency power to a maritime LPG terminal in Chile

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Emergency power to a new maritime liquefied petroleum gas in Chile.

At Genesal Energy we have just supplied emergency power to a new maritime LPG (liquefied petroleum gas) in Chile through a generator set designed to guarantee the continuity of the electricity supply in this facility.

Generator sets are essential in port infrastructures since continuity in the electrical supply is required for lighting the facility and for the uninterrupted operation of most the equipment and chargers. The lack of energy during the unloading of a ship can pose a great safety risk that is multiplied when we talk about this type of gas installations. Therefore, in these cases, it is essential to count on an alternative source of electrical energy in addition to prolonging discharge times.

What did our customer need?

The customer needed a solution with specific soundproofing conditions, special levels of interior lighting in accordance with port regulations, an interior fuel tank and a fuel transfer system for an external tank, as well as a controller for parallel operation with the mains and even another generator set if necessary.

The design of the generator also has a steel floor, with a liquid collection tray, exhaust system with built-in spark arrestor to avoid risks of explosion, PMG of the alternator and many other options that make this equipment a generator set fully adapted to the client’s specific needs.

Features

  • Power output panel integrated in the soundproof container.
  • Recirculation and engine cooling heating system to provide the proper temperature when the generator starts.
  • Exhaust system with spark arrestor integrated inside the container.
  • Anti-skid steel floor.
  • Marine impregnation in the alternator and PMG.
  • Surface treatment of the container according to ISO 12944, in C5 finish.

 

We supplied a generator set to a senior centre in Madrid.

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We have recently supplied a generator set to guarantee the electricity supply in the event of a mains failure in a senior centre located in Madrid.

In this case, it is a soundproofed unit of 550 kVA designed to face any unexpected event of accident.

This senior centre has 220 places available, 40 of which are destined to day care centres, as well as several rest and common areas. Needless to say that a power outage in this kind of centres may cause serious harm to residents since many are dependent persons who need continuing medical care, so it is fundamental to guarantee the electricity supply.

Medical care in these centres is a priority, and that what our customer emphasized. Thus, Genesal we looked for the most suitable solution considering the characteristics of the building and, especially, the residents’ needs.

110% load testing

Our engineering department’s solution focused on making the standard generator set fit like a glove to the place where it will be working inside the building. This genset included an upper air outlet, amongst other features.

Besides, all necessary tests were carried out, including a final test on our load bank up to 110% power aiming to verify that the equipment would work without any problem when needed.

This test is part of the exhaustive controls that Genesal Energy carries out not only customized, but also standard units, to meet the strict quality standards required by the company.

Emergency power to guarantee electrical supply in a hotel complex in Mexico

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We’ve recently supplied emergency power for a hotel complex in Mexico to guarantee continuous electrical supply in any situation.

This will be possible through the design and manufacture of two generator sets (GEN1250CA) prepared to cover the energy needs of these facilities should any failure or accident take place in the mains network.

The fact that the hotel is located in Mexico, with a climate which is subject to intense and harsh changes in weather such as cyclones or tropical storms, makes the installation of generator sets, which must be prepared to start up in the most difficult of circumstances, even more necessary.

Why is it so important for this type of facilities to possess generator sets?

This type of buildings, which are usually of great dimensions and feature numerous additional services, require their own power generation system for emergencies as they cannot leave anything to chance.

Halls, bedrooms, rest and restaurant areas, lighting, DHW, elevators… all areas, whether private or common, must always possess adequate power supply as a power outage would entail serious losses for both the clients and management of the hotel. At Genesal we’re specialists in this type of buildings -the first Hilton in Galicia is one of our latest projects-.

We offer a different, comprehensive service

Additionally, Genesal Energy’s broad experience in Mexico, a country in which it owns a branch office, makes the whole process with the client even easier. From the very beginning, the company provides the client with the knowledge of our engineers, a 360º service where all processes prove a lot easier despite their complexity, in important aspects such as genset commissioning or maintenance.

For this hotel complex, each generator set will supply power to a step-up transformer which changes the genset voltage to medium voltage and synchronizes both gensets and the mains in the event of an emergency.

This was the solution provided by Genesal’s engineers

From a mechanical point of view:

  • A base frame adapted to the assembly comprised of a Cummins KTA38 G14 engine and Stamford HCI634J1 alternator was developed, calculated and manfactured.
  • BRB AMC BRB 220 40 SH M24 anti vibration mounts were installed to prevent the transmission of unwanted vibrations to the hotel structure and a busbar of easy access and connection, but with adequate safety measures.
  • A control panel was designed to allow the taking of genset measurements from the medium voltage side, in such a way that, even if the group generated in low voltage, the startup and synchronization would be carried out in the medium voltage network.
  • To maintain the alternator protected if ever the step-up transformer fails, a specific protection relay for the low voltage part was added so that, if ever there were a short-circuit between the transformer and alternator, the genset could shut down and isolate the transformer to avoid greater damage.
  • Furthermore, a control panel for the management of the parallel operation between the island of gensets and the mains was supplied, so that the island would be capable of automatic startup following a mains failure, and synchronization upon mains return would be possible, so that the loads remain powered during the whole mains return process.
  • Finally, to ensure fuel economy of the gensets, between both gensets is a power management system which allows for one of the gensets to shut down if during a certain time the load dips below the configured value, starting up and synchronizing again if the consumption of the loads increases.

Characteristics of the generator sets

  • Alternator with PMG.
  • 600L base frame fuel tank.
  • Motorized breaker.

 

Genesal Energy guarantees emergency power to one of the UK’s major hospitals.

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At Genesal Energy, we have just supplied emergency power to one of the main hospitals in the Northwest of the UK through the design, manufacture and supply of a 1,100 kVA standby generator set ready to work in parallel with the mains.

The generator designed by our engineering team guarantees the continuous electricity supply and therefore, the uninterrupted operation of the hospital’s health services in the different areas.

Generator sets must be designed for a quick response – a few seconds – in the event of a mains failure or any other reason involving a power outage. This is the case of the equipment we designed for the abovementioned British hospital as its main goal is to ensure the electricity supply in all the medical care facilities, operating rooms, hospitalization plants and other health areas with the greatest precision. In addition, noise pollution has been reduced to the maximum considering the importance of peace and quiet for patients in this kind of buildings.

Our extensive experience in developing on-demand solutions for hospitals, regardless of their size and/or location, is one of Genesal Energy’s highlights both in Spain and internationally, as well as the best guarantee of the quality of our equipment.

There is a common denominator in hospitals: they treat convalescent people. This consequently implies a challenge for the company, as the safety and precision of Genesal’s equipment must reach their highest levels, especially in these buildings. “Our generator sets are designed under the premise that nothing can fail, and there cannot be any fissures in the process. It is fundamental for every unit that leaves the factory to be extremely reliable so that energy is provided quickly and with the necessary power”, our R+D+I department stated.

Features

  • Comap InteliGen NTC BaseBox controller with InteliVision 5 display unit.
  • Configuration:
    • Auto start in the event of a mains failure
    • Parallel operation with the mains
  • 1,600 L base frame integrated fuel tank including a collection tray with capacity to collect 110% the capacity of the actual fuel tank.
  • Generator mounted on a 20HC soundproof container with built-in air inlet and outlet silencers of -35 dBA to achieve a noise level of 75 dBA@1m. Acoustic panel of greater thickness inside the container and high-density soundproofing sheet have been included as well.
  • Double doors on both sides of the container for a greater accessibility and to facilitate maintenance works.
  • Customized external cable connection box for an easy connection of customer’s cables.
  • Control panel on the outside for quick access.
  • Motorized louvers.

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.

 

Genesal Energy will guarantee power supply to Vialia, the biggest shopping center in Vigo

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Vialia will open its doors in 2021 and will do so with Genesal Energy emergency power. We supplied two generator sets of great power, 600/660 kVA (GEN660YA) & 910/1,000 kVA (GEN1000YI) each, designed to guarantee power supply for the building, which shall become Vigo’s biggest shopping center.

Located in the center of the city -between Gran Vía and Urzaiz- the great complex will have a total surface of 43,080 m² and will combine its commercial use with the AVE’s new railway services and the bus terminal. Vialia will also feature a public plaza of 23,000 m².

Generator sets are essential for spaces of this nature. Just like with office buildings, shopping centers can’t risk a power outage: they feature multiple services, in this case, linked with leisure and restaurants, and as such the bustle of people is constant, and the planning facing any unforeseen setbacks is vital, as any accident or mains failure would cause great losses.

In the case of Vialia, at Genesal Energy we looked for a bespoke solution for the client, and opted for extremely reliable gensets adapted to the project’s requirements. These are the main features of both units.

GEN660YA Features

  • Genset with external fuel tank of great capacity.
  • Special baseframe for gensets of this size.
  • RS485 module.

GEN1000YI Features

  • New 6 meter canopy: for a soundproof genset of this power rating and characteristics, a new 6m canopy has been developed as an alternative to the 20 foot container to reduce size, lead time and costs.
  • The design of the canopy is characterized by being Heavy Duty. It’s modular, allowing for the installation inside it of engine-alternator assemblies of up to 1,250 kVA.
  • Allows an easy access to the control panel and circuit breaker, both located in their own cabinets with their own access door to the outside. It simplifies maintenance tasks due to its numerous doors on both sides.
  • External fuel fill connector, machinable cover for the control cable outlet and power cable outlet with rubber cover for improved isolation, and lifting lugs.
  • RS485 module.

We have increased our presence in Africa with the supply of three generator sets to the largest hydroelectric power plant in Cameroon

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The largest hydroelectric power plant in Cameroon will be powered by Genesal Energy. We participated in the project through the supply of emergency power to the electrical construction, which will allow the country to increase its installed electrical capacity by 30%.

The power plant is undoubtedly a key infrastructure in the development of Cameroon, where the electricity supply network, together with the transmission network, are the great pending issues of a country that spires to become the greatest emerging economy of Central Africa in the next 5 or 20 years.

The Cameroonian government’s mid-term goal is to provide sufficient energy capacity to meet the needs of its citizens.

Guaranteeing access for all countries to affordable and non-polluting energy is a commitment made by the United Nations in the 2030 Agenda through the achievement of the Sustainable Development Goal (SDG) 7, which at Genesal Energy we have incorporated into our Plan of Social Responsibility.

The project involves the design of three customized generator sets: two of 1000/1100 kVA to power the plant’s facilities, and one of 100/110 kVA to be used at site during the construction process. Once the plant is finished, this smaller unit will become back up power for the facilities too.
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¿Why is this a special solution?

In facilities of this kind, there are essential loads that must be powered permanently for the correct operation of the plant, as for instance, water treatment systems or lubrication pumps that need to run continuously so that a safe shutdown can be guaranteed in the event of an emergency situation, (e.g., a power outage). This is precisely the role played by one of the supplied generators.

The client required the generator sets to be fully managed, controlled and monitored from the generator’s own control panel. The control philosophy is that the diesel generator is connected to a main board and this in turn to the feeding busbars of the installation’s essential loads. In this case, at Genesal Energy we designed a generator set system to work either in parallel or alternatively, depending on the client’s loads needs (it is the case of the emergency genset).

In these gensets, it is possible to indicate a preferential start of Generator 1 or Generator 2, depending on which one is required to start fist. We also manufactured a fuel system consisting of four tanks: two daily tanks of 1000 L and two nurse tanks of 10 000 L in order to ensure long periods without refuelling the generator.

Difficult location

The difficult conditions of the location where the hydroelectric power plant is built forced our engineers to take additional steps to avoid any risk and guarantee the gensets’ operation at any time and in any situation. Thus, a fuel transfer system has been designed allowing the fuel to be pumped or transferred in such a way that, if any part of the system is out of service, the other can be used without problem, ensuring the control unit’s continuous power supply.

Our participation in the construction of this plant reinforces Genesal Energy’s presence in Africa and specifically Cameroon, a key state in our international expansion strategy due to its great energy opportunities. In this sense, our company has already participated in several projects related to the modernization of its infrastructure aimed at improving the living conditions of Cameroonians.

One of the latest projects carried out in this African country has been the design and installation of the electricity supply to a water treatment plant, which is a fundamental installation to bring drinking water to populations of the country that still don’t have a proper supply.

Features

  • Two units of 1000-1100kVAs, open type
  • One unit of 100-110kVAs, soundproof type, off-road trailer
  • Custom fuel transfer system, both automatic and manual, for 4 fuel tanks, 2 of 1000L and two of 10 000L capacity.