The Fenicias wind farm, in Mexico, our latest project in our quest for the wellbeing of our planet

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Electricity demand in Mexico grows at a rythm of 3% a year and in the solar power sector, the development of solar plants in the country increases year by year, generating investments of millions and thousands of jobs.

It’s no surprise that Mexico is one of the ten countries with the largest investment in clean energy of the whole planet and when it comes to power efficiency, it’s amongst the leading countries in Latin America.

The photovoltaic plant is a modern facility with capacity to generate 200 MW, which contains a booster substation, of medium voltage network, and two high voltage evacuation lines, both of 230 kVA.

We participated in the project through the manufacture and supply of three special generator sets, one of 250 kVA and two of 100 kVA. Each one of them was developed following state specifications and norms, an official certification which grants only few foreign companies the possibility to work on great governmental projects in Mexico.

The generator sets were designed in order to guarantee power supply if ever a mains failure were to happen and to operate as a back up for the booster and switching substations, in compliance with the client’s specifications.

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Features

Gensets complying with CFE W4700-10 specifications, featuring:

  • GEN110FC: Dual Voltage 240/120V.
  • GEN220F: Dual Voltage 220/127V.
  • Soundproof canopy.

Genesal emergency power for the largest combined cycle power plant in Latin America

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As part of our expansion plans in Latin America, at Genesal Energy we have designed, manufactured and supplied three generating sets of 1705 kVA, 300 kVA and 110 kVA, aiming to reinforce safety in the largest combined cycle plant in Latin America, which is located in Mexico.

The three units have been manufactured after studying the specific requirements and terrain conditions, and their function will consist of guaranteeing the energy supply in phase II of this huge electricity generation plant, which has a capacity of 1,187 MW and is composed of two generation modules, two gas turbines and a steam one.

This kind of installation always requires special loads that must be supplied permanently for the correct operation of the plant. Based on this premise, the main mission of the three Genesal generator sets will be to support the construction works of this second phase, strictly complying with the current regulations and client’s specifications.

Tailor-made solution

The solution provided by Genesal Energy consisted in equipping the plant with bespoke generators. In addition to the 300 kVA and 110 kVA gensets, the third unit (1705 kVA) has been designed to carry out a safe shutdown of the entire system in the event of an emergency.

In this sense, the client requested that the generator set was fully managed, controlled and monitored from the control panel itself, and that it was also able to start up in the event of the failure of two supply networks that the essential busbars could supply.

Thus, if the essential bus is de-energized and the external ATS system cannot recover it, the generator set starts up and takes control of the transfer system to supply the essential loads in less than ten seconds. Upon mains return, and provided that the operator validates it, the loads are returned to the network without zero crossing, guaranteeing the continuity of power supply of the loads during the process of returning from the network. Likewise, the automation of the generator allows the necessary integration with the external ATS and with the various switches that the generator set has to operate, so the starting and stopping sequence provided by the customer is followed at all times.

Like the other two gensets, this 1705 kVA unit – which has been designed to start without the need for any type of external voltage and without the need for safe voltage for the voltage circuit – has been mounted on a bespoke soundproof container with specially designed air conditioning system, motorized louvers and fans, amongst others.

On the other hand, given the space limitations of the generator set, a 4,000 liters double walled fuel tank was integrated into the container, guaranteeing a continuous operation for more than ten hours at 100% load.

Respect for the environment

Since the project was launched in 2005, the construction of the combined cycle plant generated more than 1,500 direct and indirect jobs, which has contributed to the economic development of the area as most of the jobs are local.

Combined cycle power plants generate electricity through the coexistence of two thermodynamic cycles: one uses water vapor and the other uses flue gases. In addition, combined cycle plants are considered clean energies and very low polluting, as the discarded gases are reused to produce more energy from water vapor.

We participated in the biggest photovoltaic plant in Andalusia: Cabrera Solar

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Four solar power plants, each of 50 megawatts, shape Cabrera Solar, the biggest photovoltaic project in Andalusia and one of the largest in Europe.

It’s located in Alcalá de Guadaíra (Seville), and we participated in the proyect through the supply of emergency power to ensure everything runs smoothly in the event of a mains power failure.

The project, which has obtained the Declaration of Public Utility by the Regional Government of Andalusia, will produce enough power for 145.000 homes and the plant’s activity will prevent the emission of 300 equivalent kilotons of CO2.

Our client needed a tailor-made generator set, designed to provide power to the substation’s emergency components. The solution provided by our team consisted in designing a generator set with very special features, capable of ensuring the normal operation of the whole power plant at all times, just as the client required.

The Cabrera Solar project has been praised for ensuring sustainability, and the power plant’s construction works are almost finalized. Since the start of the project, more than 350 direct jobs have been created, and it has the backing of the European Fund for Strategic Investments (EFSI) as well as an investment of over 43 million euros from the European Investment Bank (EIB).

Features

  • 100/110 kVA generator set with Baudouin engine and Leroy Somer alternator
  • Soundproof in 2.600 mm canopy
  • 160A ATS
  • Low coolant level sensor
  • High oil temperature sensor
  • BIO 8 signal expansion module, allowing the configuration of up to 8 digital inputs or outputs according to the client’s requirements.

Emergency power to guarantee supply to a new photovoltaic plant in Mexico

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Electricity demand in Mexico grows at a rythm of 3% a year and in the solar power sector, the development of solar plants in the country increases year by year, generating investments of millions and thousands of jobs.

It’s no surprise that Mexico is one of the ten countries with the largest investment in clean energy of the whole planet and when it comes to power efficiency, it’s amongst the leading countries in Latin America.

The photovoltaic plant is a modern facility with capacity to generate 200 MW, which contains a booster substation, of medium voltage network, and two high voltage evacuation lines, both of 230 kVA.

We participated in the project through the manufacture and supply of three special generator sets, one of 250 kVA and two of 100 kVA. Each one of them was developed following state specifications and norms, an official certification which grants only few foreign companies the possibility to work on great governmental projects in Mexico.

The generator sets were designed in order to guarantee power supply if ever a mains failure were to happen and to operate as a back up for the booster and switching substations, in compliance with the client’s specifications.

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Features

  • Baseframe fuel tank for 12 hours autonomy at full load.
  • PTC´s in control panel.
  • Double-walled (steel – polyethylene) 600L external fuel tank pared for 8 hours autonomy at full load.
  • DNP 3.0 communication protocol for connection with SCADA system.
  • Inspection of FAT procedure by third party (BV).
  • Spare parts according to CFE specifications.
  • Electronic speed regulator.
  • 24V starting system.
  • Paint and painting procedure according to CFE specifications.
  • Canopy interior lighting.
  • Panel space heaters and thermostat.
  • Prepared for external start-up command.
  • Heating resistors in windings.
  • Analog excitation voltmeter and ammeter.

RTVE trusts in Genesal Energy to guarantee their connections in Mesón do Vento, one of their main strategic broadcast centers

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The RTVE Corporation has 32 Medium Wave (MW) broadcast centers, that is, the band of the electromagnetic spectrum destined to, in the case of this particular public television service, the broadcasting of Radio 1 and Radio 5 Todo Noticias.

Six of these centers are considered strategic by the company, due to their broadcasting power as well as the population they cover, and thus, they are also the most important within the Medium Wave network. These are the Majadahonda center in Madrid, Las Mesas (Las Palmas de Gran Canaria), Los Palacios (Seville), Palau de Plegamans (Barcelona), Torre Cotillas (Murcia) and Mesón do Vento in Galicia. For this last center, we designed a generator set with a clear objective: to guarantee the safety of the 24 hour broadcasts.

In fact, security systems are absolutely vital in this type of installations as they have to be connected to the RTVE Corporation’s security system permanently. In this case, the Mesón do Vento broadcasting center was left without emergency power due to a breakdown of the existing equipment.

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Features

  • MTU engine and Leroy Somer LSA alternator, especially selected for telecoms due to their voltage and frequency stability, thanks to their optimal fuel injection and AVR card.
  • The scope of supply included two approved 1500 litre fuel tanks in order to increase autonomy to 24 hours.
  • Redundant startup system with double starting motor and double set of batteries.
  • Fuel cut-off valve.
  • Modbus TCP/IP communication system.
  • Made-to-measure exhaust gas outlet ducts to coincide with what the client required. They incorporated spark extinguishing systems as the center is located in a natural environment, in order to avoid a fire if ever a flame were to be expelled through the exhaust gas silencer.
  • FAT procedure for 40 continuous hours at 75% load.

 

Emergency power for a photovoltaic plant in the Chilean region of Atacama

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Our extensive experience in the manufacture of customised generator sets is a guarantee for our clients.

In Chile, a country in which we’ve already participated in the construction of a thermosolar power plant and a photovoltaic power plant in Cerro Dominador, high up in the Atacama desert, we’ve just supplied an emergency generator set for a very special project: to power the alternating current auxiliary services of a photovotaic solar plant’s substation in Region III, Atacama.

With 28 megawatts in power and an investment of 78 million dollars, the plant is one of the country’s greatest power projects, and has the approval of Chile’s Environmental Impact Assessment (EIA). It’s composed of 13 blocks of two megawatts each and two blocks of one megawatt respectively, and features 114.000 crystalline solar modules and tracking systems.

In order to provide the best service, our engineering team carried out an in-depth analysis and examined the area’s special conditions, an essential step in providing the most adequate solution.

And so, both the startup and the shutdown of the genset will occur through external commands and will be able to operate in parallel to mains. With this solution, the brief power cut-off experienced upon mains return which would have been generated in the client’s substation and sectioning centre auxiliary service panels, is avoided.

Features

  • Genset in parallel with mains, for non-zero crossing upon mains return.
  • Special canopy with double-walled base frame fuel tank.
  • Reinforced genset for 0,3g seismic compliance.

Emergency power for Moroccan Chemical Plant: optimal performance in the most extreme climates

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Elevated areas, high or low temperatures, all create hostile environments for generator sets as they directly impact their operation and essential functions such as startup capability and speed.

That’s why when a client asks us for generator sets to operate in locations with especially adverse climatic conditions, at Genesal Energy we analyze each detail of the territory before designing a generator set which without a doubt calls for a set of characteristics which are more special than usual.

An example of this is a project we carried out in Morocco, for which our engineering team designe dan emergency generator set for a chemical plant in a desert with extremely high temperatures.

For this project, aspects such as the sand, a natural adversary which is hard for this type of equipment to beat, were taken into account. The generator set had to operate in a desert area, with a great amount of sand and suspended dust, as well as extreme temperatures, and so it was fit with dust filters in the air inlet and alternator, which was IP45. Furthermore, a system was designed to pressurize the container, in turn avoiding the entrance of dust. A fuel tank of great autonomy was also installed.

A record time frame

In summary, the generator set was designed to guarantee power supply for the facility’s auxiliary and essential services in the face of a mains failure. Apart from being a bespoke generator set, the whole process was accelerated in order to comply with the tight deadline. This was a great challenge for Genesal Energy as the usual time allowed for development and production for this type of projects was cut in half.

Our experience in the manufacture of gensets for high temperatures has made us a reference brand in countries such as Chile, where we’ve supplied high capacity emergency power in areas as inhospitable as the Atacama desert.

Features

  • 20´DV container with C5 coating.
  • Inlet dust filters for cooling air and alternator.
  • Air conditioned control room.
  • Mains synchronization control panel.
  • Earthing switch.
  • Independent battery and battery charger for control.
  • Integrated automatic transfer switch.
  • IP45 alternator with special treatment prepared for aggresive environments.
  • Double PT100 sensors in alternator windings.
  • PT100 sensor in alternator bearing.
  • 2000l fuel tank in dedicated room with redundant fans to guarantee adequate room cooling.
  • Motorized louvers.

Delivering emergency power to the Poland-Lithuanian connection, one of the biggest electrical challenges in the Baltic countries

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The construction of the electrical interconnection lines between Poland and Lithuania is key in the creation of a common European energy market.

In this great project, the LitPol Link substation is an important part of the chain for which Genesal Energy has supplied bespoke emergency power for the essential services of the installation facing any possible failure.

The weather conditions that the Lithuanian substation -which represents the electrical link between the Baltic electricity transmission system and the European synchronous network, with a total distance of 341 kilometres- must face, were crucial in the production of the generator set for LitPol Link. Our engineers designed a generator set capable of operating at peak performance at the lowest of temperatures and through extremely adverse situations such as great storms and strong snowfall.

Adapted to the extreme cold

Our vast experience in the design of systems to combat the extreme cold was of huge backing to us when it came to facing this project. With good reason, Genesal Energy is a reference brand in Scandinavian countries and in the North of Europe with our low temperature range.

In the case of the LitPol Link substation, the result was a special generator set which was completely adapted to the harsh environment. Upon analyzing the client’s needs, the R&D department opted for a made-to-measure solution: a 200/220 kVA generator set with heaters installed inside the canopy, an anticondensation heater in the power cabinet and heater in the fuel tank. Likewise, all necessary measures were taken to avoid setbacks in vital processes such as the startup of the generator set in an emergency situation. Finally, at the client’s request, a fire (heat and smoke) detection system was installed. The generator set includes a control panel prepared for parallel operation.

Features

  • Genset designed to operate in the extreme cold, including engine air intake heating, oversized batteries, motorized louvers, heaters inside the canopy, anticondensation heaters in the power cabinet and heater in the fuel tank. These elements guarantee perfect startup and operation at low temperatures.
  • Soundproof canopy with IP44 protection, preventing the entrance of dust and water, Furthermore, it’s been given anti-corrosion C4 treatment.
  • At the client’s request, a fire (smoke and heat) detection system was installed.
  • The genset features a control panel prepared for parallel operation, as well as a signal expansion module for the specific alarms requested by the client.
  • Charger failure alarm.
  • External fuel filling points, including fuel transfer supply through a gauge and maximum level safety sensor.
  • Digital low oil level sensor.
  • The genset component nameplates were designed in Lithuanian language at the client’s request, according to the project’s specific requirements.

Emergency power for a pharmaceutical center to guarantee the robotic management of 20.000 products

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Pharmaceutical warehouses or distribution centers store and supply medication to the different pharmacies.

In these facilities, keeping strict control of the temperature (between 15 and 25ºC) and humidity is key in the correct care of their goods. For this reason, this type of facilities needs to have emergency generator sets to face any potential mains failure which would result in a catastrophe and the loss of goods.

At Genesal Energy we’ve designed, manufactured and supplied a generator set for an important robotic pharmaceutical distribution center, with the goal of providing power in mains failure situations for its warehouse in Spain which has just been expanded and fit with a robotic plant for the preparation of orders.

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Bespoke solution

After its construction phase, the distribution center will manage a volume of 20.000 pharmaceutical product references in a warehouse with a surface of 5.000 square metres.

In the face of the inability to transport the assembled generator set to its definitive location -due to its weight and dimensions- our team of technicians opted for dividing the base frame in two parts and putting together the engine-alternator assembly in the genset room.

In order to channel the air and exhaust outlets, we developed a vent and the exhaust piping accordingly and assembled them on-site. The base frame fuel tank was also eliminated due to the dimensions of the room in which the genset was to operate, opting for a double-walled external fuel tank instead which would also increase the its autonomy.

Features

  • 400-440 KVA
  • Split base frame.
  • Approved double wall fuel tank of great capacity.
  • The genset powers two supply sources.

 

We supplied emergency generator sets to ten rural schools in Argentina

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Ten rural schools in Argentina now have our power.

It’s an ambitious project for which we’ve sent our most precise and innovative technology with the objective of guaranteeing educational activities and avoiding a failure in the electricity supply or any other accident which could hinder the continuation of classes.

Precision and reliability are the common denominator in the gensets supplied to our client, who in this case, is a great company with numerous awards and who was chosen for the construction projects of over thirty educational centers across Argentina.

High reliability

The client needed generator sets to supply power to the ten biggest schools built by the company, educational centers which, in the event of a mains failure would have greater issues continuing with the development of classes than those smaller buildings, where the number of students and staff is considerably smaller. As they are schools located in rural areas with bad infrastructure, the need for emergency backup power was that much greater.

Thus, the company needed a compacy and highly reliable genset, adapted perfectly to the location and especially silent, in order to allow for the normal rythm of the classes if ever there were to be a power cut.

Features

  • Compact soundproof genset.
  • Capability of viewing the control panel from outside.
  • 200L fuel tank.
  • Startup upon mains failure.
  • ATS.