We designed 11 gensets for three combined-cycle power plants in Bolivia that will increase the electric power in the country by 50%

We designed a generator set for one of multinational company DSV’s centres in Sweden, prepared to operate in the extreme cold

We installed generator sets in the Quito Sur Hospital in Ecuador

Ecuador’s Government installs Genesal Energy generator sets in the Quito Sur Hospital, the largest and most modern hospital in the country

Covering almost 90,000 sq./m, costing 226 Million US dollars, and fully operational since December 2017, Ecuador’s largest and most up to date hospital has been built in South Quito, the capital.

Covering almost 90,000 sq./m, costing 226 Million US dollars, and fully operational since December 2017, Ecuador’s largest and most up to date hospital has been built in South Quito, the capital.

The project commissioned by the Ecuadorian national health service (IESS), is today a reality, and benefitting the residents of south Quito, in the El Recreo district. This publicly owned hospital with over 400 beds and 50 consultation areas, employs 1800 people. Each one of the 5 buildings within the complex contains a Genesal Energy emergency power genset.

Power cuts in hospitals can lead to critical situations for patients and the doctors and nurses that care for them. It is obviously vital that these types of buildings can continue to function and must not be brought to a standstill.

The high consequences of a power cut mean it is essential to install back up systems that will continue to supply electricity to all the systems, ensuring the medical teams and doctors can continue their work ensuring that patients continue to receive healthcare.

PROJECT AIMS

Due to the risks presented by a power cut the client required a solution that would incorporate gensets with automatic start-up (AMF). GENESAL ENERGY designed six generator sets with different voltages and power ratings, to meet the clients needs in relation to the different load requirements for each building. The objective; a guaranteed power supply in the event of a mains failure permitting the hospital to carry on as normal.

DESIGNED FOR HIGH ALTITUDE

The gensets supplied can give the necessary power at an altitude of 2,800M above sea level, bearing in mind that at this altitude there is less oxygen in the air, meaning the gensets mist work harder.

Additionally the solution had to account for the need to install gensets that would not cause noise contamination, and for this reason soundproofed gensets were supplied with the exhaust system at the top of the canopy.

TECHNICAL DATA

Characteristics common to all the gensets:

• Top canopy exhaust system

• Automatic fuel transfer from external fuel tanks

• Pre-heating resistance included

• Automatic start-up due to mains failure

• Ethernet connection

• PMG excitation system

Genesal Energy has supplied an emergency genset for the combined cycle power plant (CCPP) known as Empalme II, a huge engineering project in the Sonora State of Mexico.

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

PROJECT SUMMARY

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.

PROJECT DESCRIPTION

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.

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.

 

TECHNICAL SPECIFICATIONS

  • Emergency Power: 7 x 1100kVA / 2 x 2200 kVA / 8 x 27 kVA / 3 x 1400 kVA
  • Voltage: 400/230V
  • Frequency: 50 Hz
  • RPM: 1500

Gensets for a solar power plant in South Africa that will supply electricity to 150,000 homes

Kathu Solar Park in South Africa is a concentrated solar power system(CSP) up to 100MW. Building commenced in May 2016, and it is destined to be in service by the end of 2018. Genesal Energy contributed with the project design and supply of two emergency gensets.

The thermoelectric plant itselfwill be able to supply 4.5 hours of thermal energy thanks to cutting edge technology which allows supply to continue well after the sun has gone down. When fully operational Kathu Solar Park will supply power to 150,000 households. Also, according to the construction management team, the installation will contribute to sustainable development in the province of North Cape where the plant is situated. This will result in a C02 emissions saving of 6,000,000 tonnesover the next 20 years.

Genesal designed the emergency gensets in compliance with a series of requirements. The gensets had to be soundproofedand the control room needed to be maintained at an optimal working temperature. This was achieved by installing a split air conditioning system and a heat exchanger.

                       

Remote Control

Rock wool acoustic panels inside a metallic mesh cover were used for soundproofing, guaranteeing an excellent attenuation result, functionally, but also aesthetically. The interior of the generator set was split in to two clearly defined compartments: the engine room and the control room. The emergency gensets can be controlled either directly via the in-built control panels using buttons, switches and touch screen technology or it can be controlled remotely through a DCS (distributed control system) which is a method to centralize and controlthe entire power station.

Alongside the gensets two double walled certified fuel tanks were supplied for external installation, one at 7,500 litres full load, and the other at 10,000 litres, guaranteeing over 24 hours of autonomy if necessary.

TECHNICAL DATA

GENSET 1: GEN1586HC

  • PRP Power: 1,442kVA
  • Standby Power: 1,586kVA
  • Frequency: 50 HZ
  • RPM: 1,500rpm
  • Dimensions: 12,192mm x 2,438mm x 4,500mm
  • Weight: 17,500 Kg

GENSET 2: GEN2131HC

  • PRP Power: 1,938kVA
  • Standby Power: 2,131kVA
  • Frequency: 50 HZ
  • RPM: 1,500rpm
  • Dimensions: 12,192mm x 2,438mm x 4,500mm
  • Weight: 18,700 Kg

Made to measure energy solution for the Almaraz Nuclear Power Plant

Both the reactors at the Almaraz Nucelar Power Plant in Caceres (the oldest in Spain) supply 7% of the nations energy demands. The plant is located in an area know as Ribera del Rio Tajo, and they have recently placed their trust in GENESAL ENERGY to design an emergency back up generator set capable of dealing with any potential incident.ualidad.

The project consisted in designing, building, installing and commissioning a genset capable of supplying a 110kVA of power to supply energy to the Individual Temporary Storage (ITS), which alongside the fuel pools, allow for temporary storage of used combustibles from the reactors in the event of a power failure.

Genesal has designed a soundproofed genset inside a 20ft container with an interior control room configured for automatic start up. The bench frame incorporates a 700 litre fully bunded fuel tank, providing the genset with up to 25 hours autonomy. The genset has been specially designed to work at 45°C as well as resist seismic movements, in order to comply with security norms.

To meet with the client’s specific needs the genset was designed with an independent control room and power output with various local controls to manage the genset and other parts of the installation.

Load bank

In the switchgear output of the grid/genset, switches are fitted for each area of the ITS in the power plant. Each one can close or open via pushbuttons or using a pre-programmed sequence designed by the client.

For the correct functionality of the genset, a separate room within the container was built to hold a resistive load bank which is connected to the genset output always and when the load is less than 40% of its maximum capacity. This allows for fuel use optimization and prolongs the lifetime of the genset (normally a genset is recommended to work at 70/80% of its maximum).

The load bank can connect to the genset manually via pushbutton for maintenance work. It is also important to highlight the implementation of signals exchange in the Distributed Control System (DCS) of the power plant, for example the state of switchgear, of the genset and a measurement of zero return to detect grounding failure in the installation.

Technical Data

  • Power PRP: 100kVA
  • STP Power: 110kVA
  • Frequency: 50 Hz
  • Voltage: 400/230V
  • Fuel Tank: Fully bunded, bench frame integrated with 700 litre capacity
  • Pre-heating resistance
  • Seismic resistant genset, includes anti-shear dampers
  • Size: 6058mm x 2438mm x 2591mm
  • Resistive load bank
  • Manual pump for diesel filling
  • Control panel with automatic start-up in case of grid failure
  • Control of input of manual loads and automatic sequencing (as per client’s spec)