Genesal Energy strengthens power supply in critical military operations

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In the demanding military context, where reliability and availability of energy is crucial, Genesal Energy has deployed its precision engineering to secure the power supply in critical situations.

Recently, a generator set was installed in Germany with the clear objective of keeping critical military infrastructures operational.

Generator sets such as this one are essential to meet the energy demands of units in the field, operating in locations that are difficult to access and far from conventional infrastructures. In addition to providing continuous power to keep machines and equipment operational, these systems are designed with advanced protection and safety features ensuring safe and reliable operation 24/7.

The implementation of Genesal Energy’s generators not only ensures operability in extreme conditions, but also demonstrates our commitment to innovation and reliability in energy solutions for the military sector. This project underlines our team’s ability to design and deploy solutions tailored to the critical needs of our customers, ensuring operational success in every mission.

Our Engineering solution

Genesal Energy developed a monoblock engine-alternator generator in a 3400mm soundproof enclosure. This design includes an integrated 450-litre tank that provides a 12 ½ autonomy, ensuring a continuous supply of energy without interruption. In addition, a fuel transfer system from external tanks was implemented, ensuring prolonged operation.

The engineering behind the genset includes advanced vibration isolation through a rubber anti-vibration system, as well as integral protections for moving parts and hot components. Elements such as emergency stop mushrooms ensure the safe operation of the equipment at all times, complying with the most stringent safety and quality standards.

The unit was branded and painted according to customer specifications.

Features

  • Type of construction: Monoblock engine-alternator in soundproofed 3400mm cabin.
  • 450 L base frame inserted tank, with liquid collection tray
  • Silencer model: GSI 230 (-30dB)
  • Control panel: ComAp InteliGen4 200
  • 250 A Circuit Breaker
  • Tudor TC1453 145 Ah battery

Genesal Energy ensures business continuity for a shopping area in Denmark

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The installation of a generator in a shopping centre is crucial to ensure operational continuity in the event of a widespread power outage. As these can cause significant economic losses, backup power can mitigate these risks by protecting food and perishable goods, as well as ensuring the safety of customers and employees on the premises.

The project presented considerable complexity, as the starting point was the need to fit a 660 kVA genset in a small room. To meet the customer’s needs, the engineering department designed a special canopy, with a completely redesigned frame that made it possible to reduce the height of the final assembly. This redesign was possible thanks to a made-to-measure silencer and the redesign of the cab’s longitudinal axles.

In addition, to meet the requirement to maintain an average noise level of 80 dB(A) at 1 meter, an external silencer was designed to be attached to the room’s air outlet, ensuring that the appropriate acoustic levels are maintained, and the comfort of the end customer is safeguarded.

‘This project in Copenhagen is a perfect example of how Genesal Energy adapts to the specific needs of each client, even in the most challenging conditions,’ explains Genesal Energy’s engineering department. ‘Our mission is to provide energy solutions that are not only effective, but also contribute to the safety and well-being of the communities in which we operate.’

Genesal Energy continues to reaffirm its commitment to innovation and quality in the energy sector, ensuring that commercial facilities across Europe have the solutions they need to deal with any eventuality.

Features

  • Generator room air outlet silencer-30 dB(A).
  • Special canopy with a maximum height of 2,000 mm and made-to-measure silencer, side-mounted exhaust outlet.
  • Double set of batteries with automatic changeover (AUTO+MANUAL).
  • Motorised circuit breaker.
  • Liquid collection tray.
  • Relays for control of motorised on-site grilles.

Genesal Energy key to guaranteeing supply in large hotels

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In Mexico, climate instability is a factor that cannot be ignored, especially in regions where weather phenomena such as tropical storms and hurricanes are frequent.

These can cause unexpected and prolonged power outages, affecting the operation of key sectors such as the hotel industry. To cope with these conditions, having a reliable energy back-up system, such as a generator, is essential.

Genesal Energy has designed and installed three generator sets in a renowned hotel chain in Mexico, ensuring that the establishment continues to operate safely and efficiently during adverse situations and guaranteeing the operation of emergency & IT systems, heating and air conditioning that ensure the safety and comfort of guests.

In the hotel industry, operational continuity is key to ensuring a safe and comfortable experience for guests. In this context, the installation of generator sets as a backup power source has become essential, especially in regions where power outages can jeopardize both safety and comfort.

Project objective: Safety and comfort, come what may

The main objective of this project was to provide a reliable back-up power source for the hotel, ensuring that essential services continue to operate during any power outage. Emergency systems, such as exit lights, fire alarms, automatic doors and security equipment. Maintaining comfort is also a priority, ensuring the operation of air conditioning, lighting and other basic services that directly impact the experience.

Thanks to this installation, the hotel now has a robust energy solution that ensures continuous power supply during critical situations. Guest safety and service comfort are assured, reinforcing Genesal Energy’s commitment to providing tailored energy solutions that meet the highest demands in any industry, including hospitality.

What solution did Genesal Energy engineer?

Genesal Energy designed and installed three open generator sets, each equipped with advanced features to ensure optimal performance and efficient integration into the hotel’s facilities. These generators have 600 litres baseframe integrated fuel tanks. In addition, an automatic fuel transfer system was incorporated to connect the daily tanks to a main tank, ensuring that the fuel supply is constant and efficient.

The units are equipped with a control panel that allows parallel operation between them, which facilitates management and ensures constant performance. A synchronisation board was also provided between the island of gensets and the grid. Motorised circuit breakers with trip coil were also integrated to protect the system against overloads and electrical faults. Safety was a priority in this design, including explosion-proof battery boxes, and hand pumps for both fuel transfer and oil drainage to facilitate maintenance.

Features

  • Open set.
  • 600L base frame integrated fuel tank.
  • Control panel for parallel operation between units.
  • Motorised automatic switch, with trip coil.
  • Battery protection box.
  • Automatic transfer system with electric pump.
  • Manual pump for safety fuel impulsion.
  • Manual pump for oil drainage.
  • Busbar for power output.

Genesal Energy strengthens energy security in the Dominican Republic

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According to official data, the Dominican Republic has experienced sustained growth in energy demand in recent decades, driven by increased industrial, commercial and residential activity.

To ensure a reliable electricity supply, a robust infrastructure and systems that guarantee continuity of service, even in the face of unforeseen events, are required. Genesal Energy has designed and installed a generator set for a critical electrical substation in Guayubín.

The main objective of the project is that the substation can effectively manage the electricity coming from power stations and power plants, transform the voltage and connect to the large distribution lines that supply large areas of the country.

The importance of the genset in an electrical substation

The role of a generator set in a power substation is essential to the safety and stability of the system. Substations, as key nodes in the power grid, are responsible for the distribution of power to large regions, and a prolonged interruption in their operation could leave thousands of people without power. A generator set acts as an immediate backup in the event of failures, keeping control, protection and communications systems operational. It also ensures the continuity of critical services such as transformer cooling, plant lighting and equipment overload protection, minimising the risk of damage.

Our customer needed a solution to guarantee the supply of the substation’s AC auxiliary services. So a soundproofed generator set was designed, which can be activated automatically according to the substation’s requirements, providing the necessary energy at key moments.

The Guayubín electrical substation project is an example of how Genesal Energy provides innovative and customised energy solutions to strengthen the Dominican Republic’s electrical infrastructure. Thanks to the installation of this generator set, the substation will be able to operate reliably and efficiently, guaranteeing a continuous supply of energy at critical times and contributing to the energy development of the country.

Our Engineering Solution

Genesal Energy’s engineering team developed a soundproofed 3800mm canopy genset with a 600 litre fuel tank, tailored to the customer’s specific requirements. The genset power was customised to allow for a 350 KCM gauge connection, per phase, with terminals for a 185 mm² cross-section. In addition, the design included a control system that allows cable entry to manage multiple connections.

As the project progressed, the need was identified to install an additional 500-gallon (approximately 2,000 litres) external tank, located 10 metres from the generator set. To ensure a continuous flow of fuel, an automatic transfer system with a booster pump and solenoid valves was implemented, which involved several adaptations to the canopy and tank design.

Features

  • Calculation of the necessary sections for the inlet and outlet of gases in the room.
  • Automatic fuel transfer system, with maximum level buoy, minimum level buoy by gauge, transfer impulsion pump, solenoid valve to cut off or control the system, among others.
  • Machining of the tank and canopy for the appropriate adaptations of the transfer.
  • Oversized silencer model (-30dB).
  • Engine heating system 1000W.
  • 600 L fuel tank.

Uninterruptible Power, the Key to Industrial Success in the Heart of Guanajuato

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Genesal Energy continues to strengthen its commitment to the industrial sector, offering power backup solutions adapted to the most demanding market needs. On this occasion, it has supplied a state-of-the-art open generator set for an automotive manufacturing plant in Guanajuato, Mexico. This equipment will provide contingency power to a new assembly line for painting, one of the most critical processes in the automotive production chain.

Backup generator sets in factories are not only a strategic advantage, but essential to ensure operational continuity. In high-demand sectors, such as the automotive industry, where every minute of production counts, having a backup power source prevents unplanned shutdowns that could lead to major economic losses and delays in the supply chain. In addition to protecting the investment, a generator set ensures that quality and safety standards are maintained even in the event of power failures.

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Power to ensure operational continuity

Thanks to our genset, uninterrupted operation of the assembly line ensures the workflow is not affected by possible electrical failures. It is installed in a hangar near the paint line and has been designed to meet the customer’s main need: long autonomy. This is achieved by means of an independent 3000 litre double-walled steel tank, designed to provide an energy reserve in accordance with the specific requirements of the installation.

The generator set supplied in Guanajuato stands out for its advanced specifications, which ensure its ability to operate reliably in demanding industrial conditions. With this project, Genesal Energy reaffirms its commitment to accompany the automotive industry in its growth, offering high quality energy solutions.

Features

  • Open genset with independent control cabinet, it can be unbolted and placed close to the generator set.
  • Large self-supporting power cabinet with the possibility of top entry of 10 power cables of 300mm^2 by the end customer.
  • 3000 litres independent double-walled (Steel-steel) fuel tank.
  • Fuel flow meter installed in control cabinet on independent display.
  • Critical -40 dB(A) silencer.
  • Analogue oil temperature sensor.
  • Due to the installation at high altitude above sea level, precise calculations of the power of the unit at the final location.

 

The UK’s largest pet care company entrusts its supply to Genesal Energy

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Genesal Energy has designed a generator set with very specific needs for one of the logistics centres of the UK’s leading pet care company, Pets at Home.

Emergency generator sets are crucial in a logistics centre. They guarantee the continuity of daily operations protecting the supply chain and customer service.
A tailor-made canopy – adapted to the space of 8100 x 2100 x 2475 mm – was designed: a soundproofed unit that guarantees an average sound pressure level of 85 dB at 1 metre and has exhaust gas silencers with -35 dB attenuation on the roof. The power panel is located on the outside in order to facilitate connection.

Dimensional restrictions solved; another challenge was that the new equipment had to be compatible with the existing one. Also sorted out.
A safe energy source in the event of any supply failure. Customer’s satisfaction best friend.

Our Engineering Solution

Although this generator set would be installed in a 40′ HC container in its standard assembly version, our engineering team designed a 8100 x 2100 x 2475 mm canopy with the power panel installed outside in order to facilitate the connection of power cables by the customer.

Features

  • 8100 mm modular soundproofed canopy guaranteeing an average sound pressure level of 85 dB at 1 metre.
  • The unit was equipped with a liquid collection tray to contain possible coolant, oil or fuel leaks.
  • An exhaust gas silencer with -35 dB attenuation was installed on the canopy roof.
  • The canopy was fitted with an integrated air silencer module.
  • A power output cabinet was designed external to the genset, with the following features:
  • 2 x 3-Pole circuit breakers. One for the genset and the other one for an external genset.
  • Castle key to prevent the closing of both breakers at the same time.
  • Powerlocks connection for an external genset.
  • Powerlocks connection for a load bank.
  • Busbar.
  • This power cabinet allowed an external genset to be connected to supply the loads in the event of the genset not being available.

 

Guaranteed power for essential services in Western England

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In the heart of Lancashire, Genesal Energy has successfully completed the installation of three soundproofed generator sets at a local authority in Blackpool.

We reinforce our commitment to the protection of critical spaces ensuring that patients and healthcare staff can carry out their activities without interruption in the event of a power failure.

In local government buildings, electrical power is not just a resource: it is the foundation on which many essential activities for the population are based. From issuing documents and processing paperwork to coordinating emergency services, any interruption in the power supply can cause delays, inconvenience and, in some cases, significant consequences for citizens.

Soundproof generator by Genesal Energy during installation.

Genesal Energy installed three generator sets of 330 kVA each, specifically designed to meet the hospital’s needs. The units, insulated not to exceed 75 dB(A) at 1 metre, were manufactured in specially dimensioned canopies and finished with C5M environmentally resistant paint. In addition, they are synchronised with each other by means of a DeepSea DSE8610 control system, which ensures perfect operability between the units.

Each generator has a 650 litre fuel tank and a transfer system that allows continuous fuel supply from an external tank at ground level. Anti-condensation heaters on the alternators and anti-corrosion treatment on the windings have also been added to ensure their operability in all climate conditions.

The careful design of this project not only responds to the high technical standards that these buildings require, but also to the importance of maintaining a safe environment for users and workers.

Soundproof generators installed by Genesal Energy at Blackpool Hospital.

Our Engineering Solution

Supply of an emergency network with the design, manufacture and commissioning of soundproofed generator sets which guarantee the operation and safety of the centre’s activities at all times.

Features

  • 3 x 330kVA Specially oversized soundproofed canopy 75db(A) @ 1m, C5M surface treatment in customised RAL.
  • DeepSea DES8610 Control panel for synchronisation between units.
  • 650 litres Integrated fuel tanks.
  • External fuel filling point with 3 x transfer pumps, solenoid valves, leakage sensors, fuel polishing systems, and connection boxes.
  • Anti-condensation heaters on alternator.
  • Anti-corrosion treatment on alternator windings, PMG and neutral contactors.

General view of the generators installed by Genesal.

Genesal Energy takes part in the construction of the world’s longest underwater tunnel

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Linking Northern and Southern Europe through new communication routes is one of the major engineering goals currently being realised.

Strong investments are being made in the development of infrastructures designed to reduce travel times and facilitate the movement of goods between countries.

One of them is the Fehmarnbelt tunnel, a mega construction that is pushing the boundaries of engineering. This unique $8 billion project will transform travel between Central Europe and the Scandinavian countries. Once completed, it will become the longest combined road and rail immersed tunnel in the world, spanning almost 20 km, crossing the Fehmarn Strait in the Baltic Sea and providing a direct connection between Northern Germany and the Danish island of Lolland.

It is a key component of the Scan-Med corridor, a transport network of more than 5,000 km, stretching from Malta in the south to Finland in the north.

A project of this scale demands the most reliable equipment to ensure its successful completion on time. To provide back-up power for the machinery involved in the tunnel’s construction, Genesal Energy’s engineering team designed and manufactured 16 generator sets, delivered in two phases.

These soundproofed units were customised with canopies of 3,800 mm and 2,900 mm, and fitted with fuel tanks of 630 and 350 litres, offering an autonomy of more than 17 hours at 100% load.

Due to the harsh environmental conditions, and in order to protect the alternators, a special marinisation treatment was applied to increase their resistance to highly corrosive atmospheres.

The generator sets were designed to operate in AMF mode, and are equipped with 3-way double valves to allow manual selection between the integrated tank or an external one for fuel supply.
This ensures a reliable energy supply throughout the construction phase, helping to keep the project on schedule.

Commitment and rigour

At Genesal Energy, we have built a solid reputation in the generator set sector, offering our customers products that stand out for their reliability, performance and quality.

We design and manufacture custom-made solutions tailored to each project’s technical requirements, delivering turnkey systems in which we take care of every stage.

This commitment has allowed us to take part in high-demand projects such as the Fehmarnbelt tunnel, where a reliable power supply is key to the project’s success.

Features

  • 16 soundproofed canopied generator sets: 16 with 3,800 mm length and 2 with 2,900 mm length
  • Integrated fuel tanks of 630 and 350 L, providing more than 17 hours of autonomy at 100% load
  • Fuel tanks fitted with liquid retention trays and leak detection systems
  • Exhaust gas silencers installed inside the canopy, achieving a -30 dB reduction
  • Cyclonic filters for engine air intake
  • Motorised louvres at air inlet and outlet, which open only during operation
  • 3-way double valves to manually switch between integrated and external fuel tanks
  • Quick external connectors for fuel supply and return
  • C5-scheme paint surface treatment, compliant with ISO 12944:2018
  • ComAp InteliLite AMF 25 IL4 control panel
  • Alternators with anti-condensation resistors and special marinisation treatment
  • Powerlock switchboards for power output

 

Genesal Energy designs a new set to guarantee supply to supermarkets

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Genesal Energy provides innovative solutions adapted to the needs of any sector, including large food & drink companies.

In their premises, maintaining the flow of electricity is crucial to guarantee the good quality of the products and service.

Firstly, the preservation of perishable goods requires constant refrigeration to ensure their safety for consumption and, secondly, the support of the operation of critical systems such as computer systems, lighting systems or security cameras. If a supermarket suffers a power outage, the financial and reputational losses can be considerable, as well as causing serious disruption to customers and employees.

To avoid this type of situation, Genesal Energy’s team of engineers designed a solution for one of these in Getafe, Spain. In addition to guaranteeing the supply, it was also adapted to the needs and measurements of the dedicated space. The energy autonomy of the establishment was secured ensuring that it remains operational in events such as overloads or short-circuits.

Our solution

Our engineering department developed a soundproof generator set, with a 450-litre tank and a liquid collection container designed to hold all the fluids that could be leaked (oil, coolant, diesel…).

In addition, a trip coil was fitted in the circuit breaker which acts when there is a power cut, activating the automatic immediately.

Features

  • Calculation of necessary cross-sections for air inlet and outlet in the room.
  • Circuit breaker with minimum voltage trip coil for possible overload, short circuit or earth fault events.
  • Exhaust gas silencer -30dB.
  • 1000W preheating system.
  • Leak tray for liquid collection.

 

Three Genesal Energy gensets for a combined cycle power plant in Mozambique

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A step forward in Mozambique’s energy development

The Temane Combined Cycle Power Plant, located in Inhambane, is a vital energy infrastructure in Mozambique. Genesal Energy has provided the necessary equipment for emergency power supply to secure its operation. It represents a step forward in Mozambique’s energy development, providing an efficient, reliable and cleaner source of energy, while boosting economic growth and employment in the region.

Combined cycle power plants are known for its high energy efficiency, which can reach 60% compared to conventional plants. What they do is combine two thermodynamic cycles: a gas turbine cycle and a steam turbine cycle. This technology allows for higher efficiency in electricity production and lower pollutant emissions compared to traditional plants.

Located in an area with significant natural gas reserves, it produces 450 MW that will supply power for 25 years and will serve as a beacon for the construction of almost 600 km of high voltage transmission lines across the country meeting the demand of 1.5 million households. It will also enable infrastructure development and industrial growth in Mozambique.

Genesal Energy engineering team designed and installed three 2,450 kVA soundproofed generator sets in 40′ HC containers.

These sets will be connected in parallel to a common busbar, synchronising between them and with the grid during restoration of supply.

This is one of our projects within the energy sector.

A tailor-made solution

Inside the container, all the systems were integrated for optimum operation of the equipment. A completely customised base frame was made for the required engine-alternator set, fitted with silent blocks to dampen vibrations and prevent them from being transmitted to the rest of the machine.

The Temane power plant needed generator sets that could operate both as emergency groups supplying the loads required during a plant shutdown and in Black Start mode, in which the groups will be capable of supplying the loads necessary to start up the turbines.

In terms of design, each of the generator sets has a control room, a fuel tank room and an engine room. Also, auxiliary systems such as engine heating – to guarantee an optimum starting temperature-, anti-condensation resistances in the alternators, lights and sockets in the different rooms, manual and automatic fuel transfer control systems…
Due to the high temperatures in the area, an air conditioning system has been fitted for the control room and extractors for the rest of the rooms. Considering the strong winds, plates and anchor bolts for fixing the containers were manufactured and supplied. Eventually, attenuators – both exhaust and cooling air – to reduce engine noise levels were fitted.

To increase reliability and safety, the machines are equipped with a fire detection and extinguishing system; an Uninterruptible Power Supply (UPS) for critical services; battery chargers and redundant battery banks that guarantee the start-up of the generator set in any event. The entire communications network between Generator Sets, Master Panel and Combined Cycle Power Plant is fibre optic.

Features

  • 40’HC container with independent rooms for genset, tank and control panel.
  • 4000 litre double-walled (steel-steel) fuel tank installed inside the container.
  • Automatic fuel transfer system from mother tank.
  • Fire detection and extinguishing systems in the engine-alternator and tank rooms. NFPA switchboard.
  • Air conditioning in control room.
  • Forced ventilation with air extractors in the engine-alternator and fuel tank rooms, with PT100 probes to guarantee that the internal temperature does not rise more than 5ºC above the external temperature. Hygrostat for humidity control.
  • Plates and anchor bolts for container.
  • AGM type batteries.
  • Engine equipped with: low coolant level sensor (digital), oil temperature and pressure sensors (analogue).
  • Alternator equipped with: transformers, anti-condensation resistor, PT100 probes in alternator bearings (2 per bearing) and windings.
  • Neutral earthing resistor (NGR).
  • Separate master panel with Siemens S71200 PLC multimode fibre communication. Optical fibre in group.
  • Control panel equipped with:
    • 87G protection relay.
    • Ethernet RJ45 card for modbus TCP/IP communication.
    • ComAp Inteligen BaseBox and ComAp Intelivision 5.
    • IEC61850 communication protocol.
    • OM2 LC Duplex multimode canbus to fibre optic OM2 LC Duplex Converters.