Designing and supplying efficient energy for a Spanish paradise: The island of Ons

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Genesal Energy has designed a diésel generator to supply green energy to the Island of Ons, one of the most beautiful tourist destinations in the region of Galicia in northwest Spain.

The Island is a protected reserve within the National Park of the Illas Atlanticas, and due to its situation, it is completely isolated from the mainland power grid. It was for these reasons that our team of inhouse engineers along with our R&D department created a “different” type of electrical generator, focused on taking great care with the local environment. The tailormade end product entered into operation in the summer of 2017. The generator has been designed to supply energy for the camping site situated on the upper part of the island. The site occupies an area of 8,000sq metres with a capacity for 276 people.

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Considered the first self-sustainable camping site in the Galician region, the site already incorporates a system of solar panels to provide electricity. Yet, due to the limited hours of sunshine in this part of the world and the characteristics of the camping site, it has been deemed essential to ensure a round the clock power supply, and for that supply to be sustainable.

The solution designed by Genesal Energy, and in collaboration with Magaral engineering, is made up of a 60-66 Kvas genset in a 2900mm long soundproofed cabin. The genset high attenuating silencer for the exhaust pipe, not to mention many more specifications that make this much more than a conventional electrical generator. In fact, the word unique would be the most appropriate in this case.

The fitted engine for the genset was chosen according to the highest standards possible in relation to quality and established legal norms, ideal for a natural reserve as such is the Island of Ons. The genset supplies electricity, green energy and reduces by up to 50% atmospheric emissions. Also, the extra soundproofing qualities ensure a peaceful coexistence with the campers, especially at night time.

The real difference comes from the specialised system designed and incorporated in to the genset solution, which uses the heat and waste gases generated by the genset to provide sanitary hot water for the camping site kitchens, bathrooms and day to day activity on the campsite. It entails using a thermostatic controlled system to reuse waste gas for heating water. IN this case, unique really means unique.

Having to move the genset to an isolated island off the Galician coast meant overcoming two challenges

  • Logistic: The movement of a 1000 Kilo genset and components, which was executed by boat.
  • A protected nature reserve with no mainland power supply: As opposed to an emergency standby power generator it was important to provide a solution that covered needs continuously if necessary and fully respecting the surrounding environment. Mission accomplished!

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Energy with remote control modules for the French bank Credit Agricole, a leading European high street bank.

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Leading European banking institution Credit Agricole with their headquarters in France and a strong presence in Spain has put their trust in Genesal Energy to carry out a project from the design stages to execution in order to supply emergency power in one of their key branches in the famous Paseo de la Castellan in Madrid.

Not only are Credit Agricole a key credit supplier in France, they are also one of Europe’s biggest banks, and manage more active assets than any other bank on the continent. They are also Europe’s biggest insurer and financer of large projects.

The project undertaken by Genesal for CA consisted in supplying two emergency gensets, each with a rating of 630kVA. The gensets were to form part of the overall electrical set up within the building, and have been set up to start up automatically should the mains electricity supply cease to operate, and therefore guarantee the ongoing operational status if the bank.

In this particular case, as the end user is a major international bank, it is essential to have a back-up power system as the knock-on effect to the whole business in the event of a power loss can cause complex issues to arise. This particular site needs to be powered 24 hours a day, there is no margin for error.

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Any time, any place

The gensets supplied by Genesal Energy have been designed to incorporate a remote-control communication module, permitting start up and switch-off of the gensets online at any time from any location on the planet.

This type of communication system also allows for preventative maintenance to be carried out. Using a communication card, Genesal’s technical service department can visualise all the different parameters of the gensets. This permits instant recognition of potential alarms or anomalies that may occur in the future. This type of real time instant detection means Genesal Energy can ensure the gensets never reach a critical point which may affect their ability to function correctly.

Additionally, the gensets have been soundproofed so that they could be installed on the rooftop, and as such minimising the acoustic contamination in the vicinity.

Emergency back up power for the Machala General Hospital (Ecuador), a healthcare facility with 36 specialities and a catchment area of 350,000 people

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Genesal Energy has recently supplied 4 electrical generators as backup power for the Machala General Hospital in Ecuador.

A modern facility it’s healthcare options include 36 areas of specialisation for a region of 350,000 in the El Oro Province, one of the country’s most important administrative and financial centres.

Designed by Genesal Energy the emergency gensets form an essential part of the electrical installation within the complex, which covers 24,000 sq. metres and contains 200 patient beds.

The Genesal Energy solution is a guarantee of a continued power supply for the hospital in the event of a grid failure for national network, ensuring the hospital remains fully operational and that all vital healthcare continues. The Genesal Energy solution means the gensets have been prepared to operate in parallel two by two, supplying 1,254 kVA per genset pairing, as well as automatic start up if there is a g power cut in the external grid supply.

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The nature of these projects means that the any unexpected eventuality can be fatal. The gensets have therefore been designed with one clear objective, to immediately support the loads demanded should the normal external power supply stop functioning. Aside of their maximum operational precision, the gensets have been sound proofed for outdoor installation and to ensure that noise levels are kept to a minimum I the surrounding area.

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Features

  • Dimensions: 5,000 x 1,886 x 2,356mm
  • Weight: 5,680 kg

Genesal Energy Electrical Generator, dual voltage and dual frequency

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500-550 KVA genset designed for industry leader in cold storage installations for the South American market.

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The client, an industry leading company in cold-storage facilities, had a special request: On the one hand, they needed and emergency backup power option for their manufacturing plant at 50Hz. However, they also need an alternative energy source to carry out testing on machinery (freezers, water recovery systems etc) at 60Hz for products which would be sold to Latin American markets. Because of the different voltage and frequency used in Central & South American countries the power grid in the client’s European base prevents them from testing products in authentic conditions. Hence the reason for an alternative power source to allow testing in the conditions found in Latin American markets. It was for these reasons that GENESAL ENERGY designed a “dual frequency” solution to meet all their needs.

GENESAL ENERGY developed a specific project to ensure a power supply with two power supply functions:

  • Emergency back up to provide electricity to the clients European manufacturing plant in case of a power grid failure.
  • Provide an electricity source for testing machinery built with different voltage and frequency.

Project summary

Design and manufacture of a 500-550 KVA genset to operate in emergencies, giving an independent power supply in case of a power grid failure to two workshops at 400/230 V 50Hz. At the same time, it will also give a power supply to a testing bench at 400/230V 50Hz or 460/266V 60Hz in manual mode.

Project goals

Was to design a genset with three operational modes:

  • Emergency power for workshop 1 at 400/230V 50Hz
  • Emergency power for workshop 2 at 400/230V 50Hz
  • Power supply for a testing bench at 400/230V 50Hz or 460/266V 60Hz

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Solution

We opted for a newly designed 4500mm long canopy, with a view to easy access for maintenance and mechanical operations, along with an 800l fuel tank integrated in the base frame, to ensure a constant power supply for extended periods before having to refuel.

Only one control panel was installed for the entire control of all operations required from the genset, and at twice the size of a standard genset control panel This was integrated in to the interior of the genset with a front access window panel for visual access, although for safety and security, access is only gained by the authorised key holder to the control panel

Features

  • Dual voltage and dual frequency
  • Modbus TCP-IP (IB-LITE) communication device
  • Oil extraction pump
  • Automatic start up in case of grid failure
  • 800L internal base frame integrated fuel tank with
  • connections for future link to external fuel tank
  • Up to 11 hours of autonomy at 80% load, or 18
  • hours at 50%.
  • Battery disconnector

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Genesal Energy supplies emergency power to the Steinkjer fish-farm in Norway with gensets synchronised in parallel

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Precision pre-heating systems and a stable power supply to combat the very low temperatures found in Northern Europe were just some of the key characteristics of this customised project carried out by Genesal Energy for the Steinkjer fish factory (town pop. 21,000) in the Trondheim fjord in North Norway.

Fish factories are singular installation: containing water temperature, water flow and recirculation control systems, designed specifically to maintain and foment conditions as close as possible to the natural sea environment for ideal fish growth. They therefore require a constant and stable electricity supply due to the delicacy of the product. For this reason, back up emergency gensets that become operational if there is power grid cut are crucial, a power cut of just a few minutes can lead to large economic losses for the business.

In the case of the Steinjker fish factory there was an added difficulty – the climate; The town is in North Norway an area very prone to very low temperatures. For this project, an emergency backup system of 2,600 kVA was calculated in order to supply the load required for continued activity, and the overall design needed to fit in to a small area.

To meet the client’s needs, Genesal Energy came up with the idea of 4 gensets to run in parallel, each with a rating of 650 kVA, ensuring that if there was a power grid failure, the four engines are sharing the entire load and guaranteeing normal functionality in the fish factory itself.

Designed to meet the client’s needs

Not only was it important that the genset emergency system could supply the load in the minimum time possible and with maximum reliability, it was actually considered a high priority. Using 3D technology Genesal also designed the entire installation project.

The project, aptly named “Fishfarm”, included aspects such as made to measure gensets, ventilation in the room they were to be located, and a connected fuel supply system. Once an exhaustive study of the client’s needs had been carried out the entire design and manufacturing process was carried out at GENESAL’s headquarters in northwest Spain, as follows:

  • Assembly of 4 synchronised gensets in parallel, built to fit perfectly in the end-users on site storage room, and to secure handle the loads that will be required
  • High quality engines and alternators were chosen for their reliability
  • Manufacture of auxiliary systems for start-up in very low temperatures (guaranteeing optimal functionality)

Features

  • Automatic fuel transfer system
  • Parallel synchronisation
  • Automatic motor protection thermal magnetic circuit breakers, with the outlet in the top of the genset, due to the complex characteristics of the installation onsite.
  • Modbus communication board
  • Manual oil extraction pump
  • Low temperature start up system
  • 400 L internal mainframe fuel tank

The Fishfarm project is yet another example of Genesals focus on designing and participating in distinctive projects requiring a very distinctive touch. The integral service, along with constant innovation, in-house technology and the company’s ability to diversify, allows Genesal to take complex situations from the drawing board and make them a reality, just some of Genesals identifying marks.

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Genesal Energy has participated in the construction of the first submerged tunnel to be built in Latin America

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Genesal Energy was responsible for designing the diésel generator responsible for ensuring power supply in emergency situations.

GENESAL ENERGY has recently administered a project to supply emergency electrical power in the Coaztacoalcos (México)tunnel, the first submerged tunnel of its kind in Latin America and one of the largest engineering projects ever undertaken on the American continent.

GENESAL’s responsibility was such that not only were they to supply the generator power unit, they were also in charge of the installation on site. The diésel genset itself (ERP 2407kVa at 13.2Kv) was designed at GENESAL’s European headquartes and manufacturing facility near La Coruna, and has since been installed and is fully operational in the tunnel.

Requiring an investment of $250 million dollars the 2,280-metre tunnel with 4 lanes for road traffic, runs below the riverbed of the River Coaztacoalcos, connecting the two neighbouring municipalities of Coaztacoalcos and Allende in Veracruz State. Further afield it has provided improved links to the states of Tabasco and Chiapas, and the tunnel services over 500,000 people as well as the numerous petro-chemical businesses in the area.

The fully submerged tunnel entered in to active use in April 2017, connecting Coaztacoalcos and Allende in little more than 3 minutes, a 40-minute reduction on the pre-tunnel journey time. The structure, consisting of 4 traffic lanes and almost 3KM long, communicates 2 urban areas in the Veracruz area with a population close to 500,000.

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Synchronized Genset

The structure of the tunnel in some parts reaches a depth of 35 metres, and was constructed using pre-tensed reinforced concrete, with a total weight of 135,000 tonnes, equivalent to 355 Boeing 747 jumbos. The same type of construction used in the tunnel section of the structure connecting Copenhagen in Denmark to Malmo in Sweden was applied here.

Should the tunnel for whatever reason suffer a power cut in the mains supply, or if there is a drop-in voltage, the GENESAL ENERGY generator will switch on automatically, ensuring continued power supply. When the mains power returns to its previously normal state, the genset will synchronize with the mains power and close off the breaker switch, smoothly returning all load power to the mains without any discernible change in the origin of the power supply.

Indie the tunnel a special room has been constructed and designed by GENESAL ENERGY, and the genset has been installed in here. GENESAL also designed a second room for storing the medium voltage cells and transfer measurement.

Fitted with the latest technologies, the genset underwent stringent testing at GENESAL’s main plant before being shipped to Mexico on the 13th February 2017. Due to its size, the radiator was specially designed to meet with cooling requirements in this environment. This also allowed the whole set up to be constructed on one supporting frame, which later reduced the difficulties in the installation process.

This entire project was done in conjunction with the Mexican branch of GENESAL ENERGY.

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Genesal Energy supplies a fully operational Containerized Power Supply for a Mobile 3D Radar System

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The objective of this project was to supply fully operational power source for a Radar system.

The energy solution would supply independent electric power for the normal operation of a Tactical Radar System, with no requirement or dependence on other energy sources.

The Containerized Power Supply solution consisted of 2 gensets of the same type and model installed in a ISO-10’ container, each genset consists of an engine, alternator, fuel tank, switch panel, synchronisation and control panels, network monitoring and an Uninterruptible Power Supply (UPS).

In situations where the Radar System is deployed in places with a power supply, the Genesal System has been fitted with the capability to fully monitor the external power supply, and in case it should fail, switch to the emergency power supply or UPS. Should this situation occur it entails one of the gensets within the container initiating its operational sequence and consequentially ensuring a continued power supply to the Mobile Radar System. The Genset will operate for as long as the external power supply is off-grid.

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Our commitment with R&D allow us to offer the best energy solutions for the military and defense application. We have the expertise needed to adapt each solution to every specific necessity of this field, always with the most strict confidentiality that this projects required.

Genesal Energy military gensets are compact, light, silent and easy to transport. They are ready to operate under the most extreme weather conditions, guaranteeing the power supply in all tactical situations.

Some features of our military generating sets are:

  • Super-silent, for shelters.
  • Trailer-mounted for easy transportation.
  • Water-cooled or air-cooled.
  • AC or DC generators.
  • Compact and lightweight.
  • Wide range of powers available.

Features

  • Two 180/200 KVA military-grade generator sets in 10-foot ISO 1D containers, forming what is known as the Power Plant.
  • This Power Plant supplies the energy required to operate a complete Radar System in standard operating mode, independently and without reliance on any other external power source.
  • Containers equipped with integrated levelling and lifting jacks, flush-mounted within the ISO-10 standard dimensions.
  • Each container was also fitted with a 70 kVA Uninterruptible Power Supply (UPS) system, incorporating its own climate control unit, ensuring a minimum autonomy of 10 minutes at full rated load (70 kVA).
  • The Power Plant could operate in two modes:
    • Using both containers in a 1+1 configuration (main + standby)
    • Using a single container operating with one generator set only
  • Automatic change-over system based on running hours between main and standby units in 1+1 configuration.
  • Each generator was equipped with a military-grade power and control connection box.
  • Stainless steel base frame with an integrated 1,000-litre fuel tank, providing over 24 hours of autonomy at 100% load [Under standard operating reference conditions for this class of equipment BS 2869:1998].
  • The engine–alternator assembly and UPS were removable to facilitate maintenance operations.
  • The engine was designed for continuous operation, compatible with TF-03 diesel, NATO F-54 diesel and JP8 (F-34) fuel types.
  • Electric cable reel for storing 50 metres of power connection cables.
  • The maximum total weight of each module comprising the system was 8,000 kg.

Download project info here.

Combined Cycle Power Plant Valle de Mexico II

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Genesal Energy has supplied an emergency power genset with a power rating of 2178 kVa which will be used as a back-up for the Combined Cycle Power Plant Valle de Mexico II in the municipality of Acolman (Mexico State).

Once finalised the plant itself will have an output power capacity of 615 MW and will operate with natural gas, at an approximate cost of 700 million $USD in construction investment.

The power plant itself will contribute to a 4 % increase in available energy to meet the growing energy needs in the centre of the country.

This particular project has been delivered in conjunction with our Genesal Energy Mexican branch, which has for many years contributed and supported the growth of the Mexican energy sector.

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Emergency Gensets for substation Lastva in Montenegro

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Substation 400/110/35 KV

Genesal Energy supply to the Lastva substation in Montenegro, 2 gensets of special configuration to start at low temperatures, high capacity of autonomy and special programming for a perfect synchronizing with the substation’s own system.

Project background

Situated in Montenegro project SS 400/11-/35 KV consists of the construction of a sub-station with 2 x 300 MVA output and the expansion of the existing substation 400/220/110k Kv Pljevja 2.

The project is vital in terms of bettering the energy infrastructure in Montenegro as this project is an essential component to connect other substations within the country. This includes an underwater connection by cable to the Italian electricity supply network, leading to improved voltage and reactive conditions in the network leading to lower loss rated in the transmission grid.

Genesal’s involvement in this project was to construct and deliver 2 emergency generators as onsite back up for the construction of this project in Montenegro

Project development

In accordance with the clients’ specifications, Genesal Energy manufactured and supplied 2 emergency generators with 715 kVA ESP. This tailor made genset ensures a high level of autonomy (assisted by the integrated 1700 litre tank), as well as high reliability and a fail-safe system designed with sophisticated data readings and fault alarms.

The design was completed with the customers’ requirements at the forefront of our decision making, such as the location, the necessary soundproofing and the climatic conditions.

Features

  • Integrated Fuel tank of 1700 Litres (autonomy 12 hours +)
  • Maximum noise level at 1M : 85dB
  • Liquid retention basin.
  • Designed for ease of transport, loading and unloading.
  • Impregnated alternator for use in marine and corrosive environments.
  • Control panel for use in very low temperatures.
  • Sensors to measure temperature and exhaust gas pressure.
  • General thermomagnetic and differential protection
  • Monitoring of battery conditions as well as measurement of intensity, voltage and fault alarm for battery chargers.
  • Alternator alarm (voltage loss, low excitation, diode failure, bearings overheating, high/low frequency, and overload).
  • Temperature sensor for alternator windings.

Soundproof genset for a combined cycle power plant in Coatzacoalcos, Mexico

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Project objectives

The underlying objectives in this project contained the design, documentation, parts and materials, manufacturing, testing, supply (packaging included), transport and start-up of one diésel genset and associated electrical components. The genset specific use is to give power to low voltage back up auxiliary equipment for the combined cycle generation plant Afranrent in Coatzacoalcos in Mexico.

The combined cycle cogeneration plant in question is for electricity power generation, as well as the production of low pressure steam to power two absorption chillers, which themselves provide ice cold water for a cryogenic plant in the vicinity.

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The electrical installation in the cogeneration plant is made up of step-up transformers, the power generation system at 13,8KV, and the auxiliary systems power of 4.16/0.48KV. Energy is generated in the power-plant using a Gas-Turbine with a synchronous generator (output = 135 MVA with a power factor of 0.9, voltage = 13.8 kV ± 10%) and a Steam-Turbine with its corresponding synchronous generator (output = 55,412 MVA with a power factor of 0.85, voltage = 13.8 kV ± 10%). Through the use of step-up transformers or unit-transformers it goes from the generated voltage (13.8KV) to the transmission voltage (115kV). Generated power is then fed in to the grid through a link up sub-station at 115kV

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Project description

The project was developed during the last quarter of 2015. Initial studies on the technical specifications and preliminary designs were done prior to this in the middle of the year. The final specs and design work was approved in September 2015 leading to the contract being awarded to GENESAL ENERGY.

The project was launched in September 2015 at our Genesal European head offices. It was during this meeting that all project decisions were made including planning schedule management, milestones, documentation, and the necessary steps to complete the project.

Following on from the launch of the project detailed planning commenced to set the documented standards in developing the project and ensuring it met the deadline. The documentation included electrical designs, mechanics, signals lists, required materials, testing and all the calculations necessary for the design of the genset in accordance with the specified guidelines set out by ENGINEERING.

Upon completion of the documentation it was sent to the client for their comment and subsequent approval. The next phase was to commence the production of the genset using the finalised and approved design specifications for both electrical and mechanical engineering. At Genesal, mechanical engineering design is done using specialised software with 3D, this guarantees a pre-production design that is 99% of the finished product.

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Our electrical engineering design uses a specific design program to complete the electrical plans, single line circuit diagrams, materials required as well as detailed power & control cabinet layout.

When the manufacturing phase commenced the approved designs were strictly followed so that upon entering the in-house testing stage in the presence of the client, they could see this was in line with the testing document as approved by the client

In December 2015 the actual testing phase commenced on-site in Genesal’s main assembly plant, done with client present in order to demonstrate that the mechanical and engineering solutions and accompanying documentation had been adhered to. Checks were also done to ensure that the dimensions of the manufactured genset corresponded to the 3D designs and that all electric circuitry was in accordance with the electrical plans. Additionally (and following a very rigorous protocol) testing of safety alarms, the requested operational functions by the client was carried out. Next and very crucially the genset itself was placed on a load-bank for resistive and inductive testing which fully simulated the eventual working conditions it will operate in. During this final test the motor-alternator operated at 110% of its capacity to ensure the genset could meet the most extreme conditions.

In January 2016 with all the testing successfully completed and along with all the approved documentation, the logistics operation was undertaken to send the genset from our European manufacturing and assembly plant to its final destination at the cogeneration plant of AFRANRENT in COATZACOALCOS, MEXICO.

Upon arrival in Mexico the genset was then installed as per the customers’ requirements and the agreed solution. In June 2016 GENESAL ENERGY qualified technicians initiated the start-up process. This consisted of full on-site testing to ensure correct operational functionality, as well as ensuring all the parts and components were in perfect condition. Most importantly the on-site testing phase included the synchronization functions between the genset and the low voltage network which supplies power to the back-up auxiliary equipment. Upon completion of the start-up protocols the genset was finally operational and ready to provide the power when necessary for essential services within the cogeneration facility.

Additionally our technicians gave the operatives in the plant an exhaustive training course on the functions of the genset, its care and also safe working practices.

Features

In order to fall within noise level requirements, the genset was acoustically soundproofed on the inside using rockwool, encased in perforated sheet metal for maximum sound absorption. Also, silencers were fitted to air intake and outlet pipes. Also noise reducing filters for waste gas were actually installed within the container to facilitate easier on-site installation.

The container was divided into 3 separate compartments – motor-generator, electrics, fuel tank:

  • The engine compartment has two doors, one on each side for ease of access during maintenance operations, as well as normal lighting and emergency lighting.
  • The electrics control room contain an exterior access door, normal and emergency lighting as well as climate control. Situated within this compartment are the control panel (automaton, touch screen, protective relays, synchronization etc) and the power control panel (LSIG breakers for output and busbar connectors to power supply wires).
  • The fuel holding compartment has exterior door access and internal lighting. Inside is a cylindrical double walled fuel tank with a 1500L capacity.

Download project info here