Two emergency gensets to guarantee reliability of an air traffic control tower in Cuba

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At Genesal Energy, we’ve supplied two 20kVA prime power gensets for a mobile air traffic control tower in Cuba.

They’re prepared to power the installation in the case of a public mains failure, protecting it at all times, as they have the capacity to power all of the tower’s systems as well as the vehicle’s electrohydraulic mechanisms.

The solution adds a special functionality: to change between one and the other automatically or to choose which of the both carries out the function of master and slave.

Both units were manufactured after studying the requirements of the client, who needed two compact gensets which would be easily integrated into the truck with the electrical panel and control panel separated and at a distance between one another.

Our group of engineers found a special solution and designed two two-phase gensets at a voltage of 220-110 V to adapt to the voltage of the Cuban grid. They’re very versatile units, with four different modes of operation which can be selected through the control panel. They’re located under the platform of a truck and have a remote control system located on the vehicle’s trailer.

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Why is it a special solution?

The main feature of these gensets is, above all, their redundant design, that is, the power supplied is done so by one of the gensets whenever there is a mains failure, meaning a second backup genset is left if the genset selected as the master were to fail or if the second genset itself were to be stopped due to maintenance.

Each genset has a remote control system through which the double switchover between both is managed as well as the switchover between each genset and the grid. Said system is installed inside the truck, communicating with both.

The solution adds a special functionality whose objective is to manage the redundancy of the gensets so that it’s possible to switch between one and the other automatically or choose which of the both carries out the function of master and slave manually through a selector in the control panel.

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Ultracompact

The gensets, on the other hand, are designed mechanically in an ultracompact format so that they occupy the least possible space, as they are installed under the platform of the truck’s semi-trailer where the control tower is located. Furthermore, the canopy that ensures the soundproofing of the gensets is completely removable in order to improve the accessibility of the genset for maintenance works due to the limited space available.

On the other hand, the engines used in these gensets are Deutz engines, cooled by oil, as they have to endure working temperatures of up to 30% higher than a standard engine cooled by antifreeze, thus maximizing the reliability of the system, especially considering the fact the gensets will be operating in especially harsh conditions. Reliability is a must in this type of units.

Supply of two generator sets for a solar power plant

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Another achievement by our distributors.

We’ve supplied two gensets of 220 and 462 kVA, 220-127Vac at 60Hz, prepared to operate under CFE norms according to the degree of seismicity in Mexico as well as the area’s semitropical characteristics.

With a capacity of 170 MW, the Santiago photovoltaic power plant is located in the state of San Luis Potosí (México). It’s a large complex, whose construction began in 2017 with the participation of 1.000 workers. The power plant was built with the idea of supplying enough electricity to power 138.000 homes.  

Its 672.000 solar panels turn the Santiago power plant into one of the largest renewable energy installations in terms of investment (250 million dollars) and also one of the most spectacular, not only in regards to its size (it occupies 750 hectares), but also to the results its expected to achieve: it was built with the objective of preventing the emission of 340.000 tons of CO2 into the atmosphere each year.

The Galician company Genesal Energy participated in this megaproject through the design and supply of two generator sets of 220 and 462 kVA, 220-127 Vac at 60 Hz, prepared to operate in the area’s special conditions, such as the semitropical climate.

Both units were manufactured in Genesal Energy’s headquarters, located in the town of Bergondo, in A Coruña (Spain), with the goal of guaranteeing the correct operation of the booster and switching substations during emergency situations, providing the power necessary for the auxiliary services, emergency lighting, etc.

Genesal Generator in a solar power plant

High precision

Both gensets are high precision units, whose design has been thought out to the very last detail to comply with the client’s requests. They have the following features:

The first unit (GEN220FC) is soundproof type and has a 500 L fuel tank integrated in its baseframe, while the second (GEN462F) has a 1.000 L fuel tank. Both special gensets comply with all technical requirements established by CFE (Comisión Federal de Electricidad or Federal Electricity Commission) norms, the prestigious certification that the CFE awards and which elevates the company to the category of trusted supplier.

The CFE-LAPEM certification is granted by the LAPEM (Laboratory for Equipment and Materials Testing), an organization dependent on the CFE, and Genesal Energy received said distinction last year upon passing the audit process carried out by LAPEM in the company’s headquarters, thus becoming part of the select group of companies which have been awarded this certification, a true symbol of excellence.

Features

  • GEN220FC 500L fuel tank integrated into the base frame, Soundproof type, and with technical features following CFE (Federal Electricity Commission of Mexico) standards, painting with finish according to CFE norms.
  • GEN462F Approved 1000L double-wall fuel tank for external installation, with technical features following CFE (Federal Electricity Commission of Mexico) standards, painting with finish according to CFE norms.

 

We supplied two “turnkey” generator sets to the biggest combined-cycle power plant in Jamaica

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One of our latest projects in America has taken us to Jamaica.

We’ve had the pleasure of participating in one of the largest engineering projects in the island, the Old Harbour Bay combined-cycle power plant, the biggest in the country, for which we’ve designed and provided two special gensets.

Located in the fishing port of Old Harbour Bay, at almost 100 kilometres from Kingston, the 190 MW power plant is designed to operate with two fuels, gas and diesel, and uses a seawater cooling system. In this type of power plant there are special loads that must be fed permanently for the correct operation of the installation, for example, systems from the water treatment plant or the pumps from the lubrication units. These elements must continue operating so that, in an emergency situation such as a power outage, the whole system can be safely shut down. This is precisely the job of one of the gensets supplied by Genesal Energy.

The other is a Black Start unit, whose purpose is to power a motor in charge of the rotation of the main turbine, an element used for the cold start of the turbine after a programmed shut down. Furthermore, this genset has the particularity of supplying medium voltage directly (6600V).

Our client requested that both gensets be managed, controlled and monitorized completely from the genset’s control panel. The control philosophy consists in the diesel generator set being connected to the main power panel which is connected to the power busbars of the installation’s special loads -in the case of the emergency unit- or of the gas turbines – in the case of the Black Start unit.

Adapted to the client’s needs

For the implementation of this control system, a PLC was integrated in order to manage all of the elements of the generating installation, as well as a protection relay and a synchronizer for parallel with mains operation.

Both units were designed according to the client’s needs: special sets with a turnkey service. This way, each genset is soundproof and installed in a completely adapted container which includes all of the elements requested by our client (air conditioning, fans, motorized louvers, fire detection systems…).

Where we’ve had the pleasure of participating in one of the largest engineering projects in the island, the Old Harbour Bay combined-cycle power plant.

Features

  • Power panel integrated in the same soundproof container. In the case of the Black Start set, they’re Medium Voltage Switchgear.
  • Recirculation and heating system for the engine’s cooling liquid in order to provide the correct temperature during engine start-up.
  • Air conditioning system in the genset’s control.
  • Motorized louvers.
  • Fans in the engine room to keep the temperature under control.
  • Superficial treatment for the container according to the ISO 12944 standard, with a C5I coating.
  • Anti-condensation heater in the alternator.
  • NFPA fuel tank
  • Management of the genset control system and associated systems from the client’s installation through a PLC and a touch-screen.
  • Protection relays and mains analyzer for the generator.
  • Fire detection system integrated in the client’s installation’s detection loop.
  • Fire extinction system through water sprinklers.

Emergency Generator Set to provide power to a Data Center

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We already know that the presence of generator sets in data centres and communications companies is critical.

Our distributors are aware of this, and they’ve trusted GENESAL ENERGY to supply an emergency genset that will guarantee power supply in the main building of one of the most important telecommunications companies in Europe.

Features

  • Oversized fuel tank to provide over 24 hours of autonomy.
  • Leakage tray integrated into the fuel tank.
  • Easy connection cabinet for the unit’s power cables.

 

Emergency gensets for the railway sector

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We’ve supplied an emergency generator set to guarantee power supply to a tunnel in case of a main failure.

Allowing for continuous operation of the lights, emergency telephones and fans, as well as other critical services, thanks to the projects in the railway sector carried out by our distributors.

Features

  • Three-phase 230V voltage without neutral
  • Water-cooled genset through heat exchangers, both from the primary circuit as well as intercooler type, to cool the unit through the exchange of water originating from an existing tank in the tunnel in which the unit is installed, creating the secondary circuit necessary for that purpose.

We designed the gensets for two biomass power plants: the Viseu and Fundão power plants, in Portugal

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Genesal Energy has designed and supplied two special gensets for two biomass power plants in Portugal

The Viseu and Fundão power plants, two twin installations which, according to experts, will prevent the emission of 88.400 Tn of CO2 to the atmosphere. Both are a prime example of clean, renewable energy production.

Biomass power plants are thermoelectric power plants that use organic matter as fuel, whether it be of plant or animal origin, susceptible to being used for power purposes. These installations generate electricity through the combustion of the biomass to heat the steam in boilers. The steam, in turn, moves a turbine which spins a generator, which transforms the electric power into mechanical power.

As this process relies on combustion systems, great quantities of power are needed to cool the power plant’s systems to guarantee its operation.

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Slow combustion

In the event of a mains failure, the biomass power plants must be brought to a safe shut-down. To achieve this, it’s neccesary to maintain and power different cooling systems in order to avoid material or personal damages due to the overheating of the systems as, by its own nature, biomass combustion is a slow process.

In the event of a mains failure, this type of installation must be brought to a safe shut-down

If an electrical failure arises in this kind of power plant, the biomass inside its boilers will continue to burn, generating thermal power which won’t dissipate if the cooling systems aren’t operational. At Genesal Energy, we designed two units for these plants capable of starting up when a failure to power the essential services’ busbar is detected.

If the genset in question starts up and starts powering loads, the power plant will be in the process of shutting down and during this time it’s fundamental the cooling systems be active.

This way, when the genset is powering loads, even if mains returns, the power plant operator is the only one who can stop its operation and bring back mains power, guaranteeing that the shut-down process is always carried out in safe conditions.

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Maximum security

On the other hand, each of these units has different security systems which prevent the control over the breakers that power the essential systems’ busbar by other systems which aren’t the actual genset, in order to avoid short circuits due to errors in the operators’ handling.

The manifactured units are capable of starting up as soon as a failure to power the essential services

The only moment in which a system other than the genset can control the busbar’s mains breaker is during the power plant’s start-up, as in that moment the genset won’t be active.

Technical Features

  • Remote control panel in the installation’s electrical room
  • 1000 L base frame fuel tank
  • Fuel filler neck on the outside of the container
  • Installation in a 20” soundproof container with an air outlet silencer to achieve a sound level of 85dB at 1 metre
  • Communication via MODBUS TCP/IP with power plant control system
  • Integrated web server with access from the power plant’s control system
  • Genset load system in a sequence of up to 14 steps.

Dual frequency and dual voltage gensets for an international construction company

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Design process thought out and revised to the very last detail.

Gensets that operate at different frequencies as well as different voltages are special units whose design process has been thought out and revised all the way down to the very last detail. One of our latest orders comes from an international building company who needed gensets capable of being moved from one place to another and of operating at different frequencies and voltages, as the client has construction projects in different countries around the world.

Features

  • 730-800 kVA units prepared to operate by manual and automatic start in the event of a mains failure, at 480/277 Vaz 60 Hz and 400/230 Vac 50 Hz.
  • The change of voltage and frequency is carried out from the control panel with a switch for the adjustment of frequency and a potentiometer for the adjustment of voltage.
  • At the same time as the frequency is selected, the control panel is reprogrammed with the values corresponding to the selected voltage and frequency.

Gensets designed to supply power for military telecommunications

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Features

  • Sound proofed to 65Dba AT 7m the generators have been installed in a specially designed cabin to comply with the exceptional dimensions and weight limits as requested by the client.
  • They are redundant gensets with 2 engines and 2 alternators installed in each canopy.
  • The gensets are mobile and have been installed on single or double axel trailers depending on their power. They have been designed to circulate either on public roads or complex terrain.
  • They can work in adverse climatic conditions (from -32ºC to 49 ºC, heavy rainfall, icy conditions, solar radiation, sand, fog etc)
  • These gensets were designed to be transportable by sea, air or railway.
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They have to had to overcome a wide range of critical tests:

  • Operate in elevated temperatures, up to +49 ºC.
  • Operate in very low temperatures, as low as -32 ºC.
  • Absorb sudden temperature changes of 13.4 ºC/min.
  • Withstand solar radiation without any deterioration at up to 1120W/ m2.
  • Operate in heavy rainfall a t up to 2,500l/ m2.
  • Withstand up to 37mm thickness of ice formation.
  • Resistant to sand and dust penetration.
  • Work to 100% load at up to 3000m above sea level.
  • Withstand up to 20G impacts.
  • Withstand up to 10G sudden acceleration.
  • Withstand shocks of 40G 6ms 1000 pulses.
  • Withstand freefall of up to 50cm.
  • Attain IP54/65 level of protection.
  • High saline resistance.
  • Operate in an acidic environment.
  • Operate in conditions that have been contaminated with hazardous liquids.
  • High resistance to mould and other microbe type species.

Another accomplishment by our distributors in the UK

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We supply a 900 kVA genset.

Another accomplishment by our distributors has allowed us to supply a 900 kVA genset prepared to run parallel to mains in one of the most luxurious areas of the UK, guaranteeing continuous electric power supply in the residential area in which it was installed.

Features

  • 1,500 L baseframe fuel tank featuring a leakage tray with a capacity of 110% the capacity of the actual fuel tank.
  • Parallel to mains with double automatic magnetothermic breakers, one of them motorised for parallel to mains operation and the other a manual breaker for connection with the load bank to carry out load tests with the already installed genset.

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

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Three combined-cycle plants located in three different departments in Bolivia, Tarija, Santa Cruz and Cochabamba, will increase electric power by 50% in the Andean country.

The project will not only improve the efficiency and availability of electricity in Bolivia, but it will also improve its economy and the overall environment, and Genesal has contributed towards this ambitious initiative by supplying 11 generator sets. Four have been installed in Tarija, another four in Santa Cruz and three in Cochabamba.

In this type of combined cycle power plant there are essential loads that must be permanently supplied power to in order for the installation to operate correctly. This is the case, for instance, of systems from the water treatment plant or the pumps from the lubrication units, which must continue operating so that, in the case of an emergency such as a power outage, the whole system can be safely shut down. This is precisely the task carried out by nine of the eleven supplied gensets.

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Two of the gensets are Black Start units, whose objective is to provide power to one of the most important elements of the gas turbine: the turning gear.

The remaining two gensets are Black Start sets whose purpose is to power one of the most important elements of the gas turbine, the turning gear, an element used for the cold start of the turbine after a programmed shut down.

The turning gear rotates the turbine rotor at a very low speed to ensure a slow and uniform cool down, in order to avoid any thermal deformations.

Genesal’s solution

Our client requested the gensets be completely managed, controlled and monitorized from the control panel. A control philosophy was implemented whereby the diesel genset is connected to the electric panel and said panel is connected to the installation’s essential loads’ busbars (in the case of the emergency gensets) or to the gas turbines (in the case of the Black Start gensets). For the implementation of this system, a PLC was installed in order to manage all the elements of the generating installation, as well as a protection relay and a synchronizer for the parallel with mains operation.

Therefore, we designed each soundproof genset in its respective container with diverse elements ranging from air conditioning to fire detection systems, motorised louvers, fans… all thought-out and tailor-made following the client’s needs,

Each genset is made to be integrated and coordinated with the elements of the power plant its installed in. Furthermore, the emergency system can be completely controlled by the central PLC.