Genesal Energy ensures operational continuity at a thermal power plant in Dominican Republic

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In the current context, where energy transition and sustainability are global priorities, thermoelectric power plants continue to play a fundamental role in the electricity supply.

These facilities not only guarantee a secure energy source, but also, by incorporating advanced technologies such as the combined cycle, they achieve greater energy efficiency and reduce environmental impact.

Within this framework, Genesal Energy has designed and manufactured a generator set for a Combined Cycle Thermal Power Plant located in San Pedro de Macorís, Dominican Republic, intended to work with an already operational set and reinforce the electricity supply to a key region for the country.

With more than 10 million inhabitants, the Dominican Republic is experiencing a steady growth in energy demand, driven by industrial development, tourism and urbanisation. Thermal power plants, such as the one in San Pedro de Macorís, play an essential role in ensuring the stability of the electricity system and complementing renewable generation.

Backup power for essential systems

The main purpose of the diesel generator set supplied is to act as a contingency system. In the event of failures in the general power grid, voltage variations or scheduled maintenance shutdowns, the equipment guarantees the supply to the plant’s key systems, maintaining the operability of the equipment and the continuity of the electrical service until the grid is re-established.

To meet these demands, our engineering team developed a customised solution, which included:

  • Design and manufacture of a generator set in a 40ft HC container, with engine-alternator coupled directly on a steel base frame.
  • 1,500 litres fuel tank providing more than 4 hours of autonomy at full load.
  • 2x MSR250 (-30dB) Type A technology silencers, which considerably reduce noise emission.
  • CompAp InteliGen control panel for advanced equipment management.
  • Additional safety measures, such as anti-fire system, protections on moving and hot parts, and emergency stop mushrooms.

Combined cycle power plants make efficient use of resources, combining gas and steam turbines to maximise power generation and reduce emissions, guaranteeing the sustainable economic development of the region. Genesal Energy reaffirms its commitment to sustainability, energy efficiency and social progress.

Features

  • Supply: Monoblock engine-alternator in 40′ High Cube container.
  • Tank: 1,500L steel-steel tank, double walled.
  • Silenvcer: 2x MSR250 (-30dB) TYPE A
  • Control panel: CompAp InteliGen

 

Technology and commitment, Genesal Energy’s answer to healthcare challenges.

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Genesal Energy knows perfectly well that continuity of power supply is essential, especially in places where every second counts, such as a hospital.

That is why we have developed a tailor-made solution for the UK’s NHS Northwest, installing two 550 kVA open gensets specifically designed to meet the needs of this premises.

From vital medical equipment to security systems and medicines cooling, every component relies on electricity to operate 24/7.

Generator sets not only ensure the continuity of critical operations protecting the most important thing: patients’ lives.

Our engineering team developed a customised system including an engine-alternator monoblocks on steel frames with a capacity of 350 litres of fuel each and liquid collection trays with a capacity of 110% of the tanks.

They are also equipped with a Deep Sea DSE8610 MKII control cabinet, programmed to operate in permanent parallel with the grid ensuring the best efficiency parameters. There is also a Victron battery system to optimise energy management, allowing recharging during off-peak hours and support during peak demand. Both units are equipped with 800 A motorised circuit breakers, advanced protection systems and designs that facilitate transport and installation.

Industrial emergency generator set installed in a technical room.

Present at the Healthcare Estates exhibition and conference – IHEEM

The innovation that characterises Genesal Energy took us this year to the Healthcare Estates exhibition and conference – IHEEM held in Manchester Central. We had the opportunity to present one of these two hospital generators together with our partner Ingram Installations Ltd.

This event allowed us to show not only the technology that makes these projects possible, but also our vision for the future in the field of energy generation.

Our engineering solution

Our engineering department developed two 550 kVA open gensets, with the engine-alternator monoblock assembly on a 2800 mm long steel base, with a 350-litre capacity tank and a liquid collection tray designed to hold all the fluids that can be poured (oil, coolant, diesel…) with a capacity of 110% of the fuel tank. The engine radiator protrudes outside the bed, so the tray was designed to be large enough to accommodate this section. The fluid collection tray is supported on two omegas which serve as legs, protecting the tray from any contact against the ground that could damage it and facilitating the transport of the unit. By means of ‘zeta’ angles, they are joined to the main bedplate forming a single unit, with the base frame supports resting on the omegas and supporting the weight of the unit.

Generator set and control system for emergency power supply.

Equipment features

  • Construction type: Monoblock engine-alternator on 2800mm base frame.
  • Bunded tank on base frame with a capacity of 350 litres.
  • Liquid collection tray with capacity to hold 110% of the tank.
  • Four Tudor TC1453 145 Ah batteries.
  • Double set of batteries with protection box.
  • Victron system and positive disconnector for Manual battery change.
  • Alternator anti-condensation resistor.
  • Deep Sea DSE7410 MKII control panel.
  • Fully enclosed power output cabinet with no access to voltage parts.
  • No exhaust silencers.
  • Motorised circuit breaker with trip coil and position contact.

We supply emergency power to a combined cycle power plant in Brazil providing 14 million people with electricity

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The port of Açu is one of the main industrial and energy generation projects in Brazil.

Located in the north of the State of Rio de Janeiro, it has quickly established itself as an oil and gas hub thanks to its colossal dimensions and its capacity to transport people and goods. A 1.7 GigaWatts combined cycle power plant is being built at this strategic location as part of a mega-project that includes a similar facility and an LNG regasification terminal based on an already operating floating storage regasification unit (FSRU).

The size of this project has much to do with its optimal geographical location as Açu is close to Brazil’s two main gas pipeline systems in the north-east and south-east of the country.

The plants will have a combined total capacity of 3 GigaWatts and will be able to meet the energy requirements of 14 million households in Espírito Santo, Minas Gerais and Rio de Janeiro. The entire project is valued at around 1 billion euros. Genesal Energy is providing two 1750 kVA generator sets.

It is a state-of-the-art combined cycle power plant with gas turbines that will inject 1,672 MW of energy into Brazil’s integrated electricity system, so having an emergency generator set adapted for a combined cycle power plant to its needs was essential to guarantee its operation.

Social responsibility

Located about 400 km from Sao Paulo, the combined cycle plant (three natural gas turbine generators and one steam turbine) will deliver 1672MW of power at 500 KV to a distribution power line. Its commissioning will supply power to millions of homes.

Equipment features

  • Control Panel integrated in the soundproofed container.
  • Fuel tank inside the container.
  • Double-walled piping with leak detection.
  • Motorised louvers.
  • Air inlet and outlet mufflers for noise-level reduction.

Genesal Energy equipment to guarantee vital energy at the Montecelo hospital in Northern Spain

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Our engineering team has completed a significant project: the installation of three generator sets in the new Gran Montecelo Hospital, located in Northwest of Spain.

This project not only reflects our technical capability, but also our commitment to safety and reliability in environments where people’s lives are at stake.

Three high-power units were installed: two 1900 kVA units and one 1415 kVA unit. The main objective of this installation is to provide a backup power source to ensure the continuous operation of medical services, even in emergency situations.

Hospital facilities are critical environments where power loss cannot be allowed. In emergency situations, every second counts and the lives of many patients depend on the availability of power. It is therefore vital to maximise the reliability of electrical systems. Hospital gensets ensure that essential operation – medical care, life support equipment and lighting – is maintained without interruption.

Tailor-made solution

Our client required a solution adapted to the particularities of the installation and Genesal Energy’s engineering team developed implementation plans and customised solutions addressing crucial aspects such as air inlets & outlets soundproofing or the integration of the equipment in the corresponding rooms.

Three completely bespoke generator sets have been carefully designed to ensure that they can power the essential loads that depend on them. Also, tank capacity, which in this case is 1000 litres. This capacity has been defined in accordance with engine consumption and required operating time, ensuring an adequate supply of fuel during critical situations.

The custom-designed engine bed is also adapted to the dimensions of the resulting monoblock, radiator and power unit. In addition, the maximum suitable dimensions have been considered to facilitate transport and installation on site.

Among the features of the installed system are the following:

  • Special made-to-measure base frame: Designed to support the monoblock and associated components.
  • Double-walled tank: Made of steel-polyethylene, with a capacity of 1000 L.
  • Independent power panel: Vibration-isolated for the unit’s main switch, with a connection point for the connection of the power cables.
  • Air inlet and outlet silencers: Designed to reduce engine noise outside the room, with an attenuation level of -30 dB(A).

These silencers are designed to ensure that the generator both can breathe properly and meet the noise attenuation requirements, all while adapting to the available space in the building.

The installation of generator sets in hospitals such as Gran Montecelo is a clear example of how Genesal Energy is committed to providing safe solutions. Our engineering team not only designs and executes, but also ensures that people’s lives are at the forefront.

Features

  • Special made-to-measure base frame.
  • Parallel operation Control panels.
  • 1000 litres double-walled fuel tank: steel-polyethylene.
  • Motorised circuit breaker, independent of the monoblock and vibration isolated, with busbar for connection of power cables at the bottom.
  • 30 dB(A) air intake silencer.
  • 30 dB(A) air outlet silencer.

Genesal Energy’s key role in ensuring power stability in Taiwan

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In the current context, where the stability of the power grid is more critical than ever, the engineering behind generator sets plays an essential role in ensuring a continuous and reliable power supply.

Genesal Energy has taken on the challenge of designing energy efficient solutions as part of a project developed in Yunlin County, Taiwan.

This project not only highlights the technical capability of our engineering team, but also the importance of generator sets in the smooth operation of power substations.

Taiwan, with a population of 23 million people and a geographically complex terrain, relies heavily on the grid. Power on the island comes mostly from traditional sources such as coal and natural gas while renewable energies such as solar and wind continue to gain ground. This context requires power substations to be equipped with advanced technologies, capable of responding quickly to any eventuality. Genesal Energy has developed specific generators for this type of installation, designed not only to provide energy at critical times, but also to be environmentally friendly.

There are about 2,000 secondary substations on the island, many of them located next to residential neighbourhoods, some even right next to residential homes. To provide a stable power service locally Genesal Energy and our local partner, MACRO-e Technology, also considered environmental concerns.

A containerised soundproof generator was designed to take over in the event of a critical situation. The generator will also help the energy storage system to operate longer. Its aim is to stabilise power quality and reduce the possibility of grid collapse.

Advanced technology for Taiwan’s energy challenge

The customer needed a flexible solution tailored to local requirements. Genesal Energy offered a high degree of customisation, allowing MACRO-e Technology to optimise the installation of the generators according to the specific needs of each substation. This includes everything from the design of the containers to the implementation of soundproofing and gas after-treatment systems, ensuring that the highest quality standards are met.

The success of this project in Taiwan reflects Genesal Energy’s commitment to innovation and quality engineering. Our generator sets not only meet technical requirements but are also designed with the environment and safety in mind. Our team’s ability to adapt solutions to the specific challenges of each environment consolidates us as a benchmark in the energy sector, ensuring that each electrical substation is prepared for any contingency.

Our engineering solution

Our engineers designed 20ft containerised generators with Cummins engines and Stamford alternators, which operate with low noise and minimal emissions thanks to a 40 dBA silencer and a gas aftertreatment system.

The fuel transfer system, external access to the control panel and the corrosion protection with stainless steel grilles demonstrate the Genesal Energy team’s dedication to providing a comprehensive solution. In addition, all the necessary safety measures were taken, such as the integration of guards on moving and hot parts, as well as emergency mushrooms and other elements necessary to operate the unit safely.

Features

  • Construction type: Monoblock engine-alternator in 20′ Dry Van container.
  • Without integrated tank, unit prepared for a fuel transfer system.
  • Silencer model: GSI 650 (-30dB).
  • Deep Sea DSE7320 MKII control panel.
  • 2 x Varta M18 180Ah batteries.

Genesal Energy, part of Manchester Royal Infirmary’s refurbishment

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Genesal Energy is proud to announce its involvement in the refurbishment of the Manchester Royal Infirmary (MRI) Emergency Department.

This ambitious project not only aims to improve the hospital’s facilities, but also reaffirms the commitment to providing a first-class healthcare service in a constantly evolving landscape of medicine. The renovation of this facility is designed to increase capacity and improve efficiency, adapting to the changing needs of today’s healthcare.

With nearly 5,200 square metres, 27 Boxes, six new ORs and 10 resuscitation rooms, the hospital will be consolidated as a regional centre of reference for the management of emergencies, trauma and various specialised surgeries.

One of the biggest challenges is to ensure that the Emergency Department and the ORs remain operational during the construction works. Temporary access routes and segregated work areas will be implemented, allowing the hospital to continue to provide vital services with minimal impact to users.

A crucial element of this project is the design and installation of a 1770 kVA soundproof generator set for hospitals. This system not only provides a reliable power solution, but also meets the stringent acoustic requirements of the hospital environment, achieving an average attenuation level of 75-78 dB(A) at 1 metre.

This project was installed by one of our UK Partners Ingram installations Ltd. Ingram installations is one of the UK’s leading Standby Generator Specialist installers that has been working with the UK’s NHS for over 50yrs. Genesal Energy, together with Manchester University NHS Foundation Trust (MFT) and Ingram installations Ltd., is committed to leaving a lasting legacy for staff, patients and the community the hospital serves.

Our Engineering Solution

To guarantee a minimum noise level was paramount, so a 40 feet HC container with double rock wool acoustic insulation (100 mm) and an acoustic membrane on walls and ceiling was designed. It is also fire resistant for 60 minutes (RF-60 Panel).

For further noise reduction, large air inlet and outlet baffles have been installed, as well as an external reinforcement silencer on the air outlet. The – 30 dB stainless steel exhaust silencer has been incorporated to prevent corrosion.

To ensure total soundproofing while the unit is switched off, motorised air inlet and outlet louvres are fitted, which close automatically. The power connection of the generator is made by means of a Modular Busbar System, which has required the design of an external Link Box that allows a flexible and safe connection.

Installation of soundproof generator sets at Manchester Royal Infirmary.

This Link Box is powered directly from the genset power cabinet via internal wiring with six wires per phase of 240 mm², ensuring efficient power management. In addition, the genset is equipped with a 1,000 litre double-walled fuel tank feeding directly the engine via double-walled fuel pipes, with a vacuum leaks detection system. In the event of a fire, a mechanical safety shut-off valve is activated, shutting down the engine immediately.

To ensure efficient refuelling, the system includes a custom-designed redundant fuel transfer system with dual pumps and a ‘Flow Switch’ for automatic switching between pumps. This system can be connected to an external mother tank, ensuring a constant and reliable fuel supply.

Finally, the generator features a dual start system, which includes two electric starter motors and a double set of AGM batteries, ensuring operability in critical situations.

Features

  • 40′ HC container with double rock wool insulation in walls and ceiling. Air inlet and outlet baffles. Interior and external air outlet silencers attached. All to meet the specific attenuation level of 75-78 dB (A) at 1 metre.
  • 1,000 litres Double-walled (Steel-steel) fuel tank with leak detection (vacuum) at the rear of the container.
  • Double-walled, leak-detection (vacuum) fuel pipes.
  • Redundant fuel transfer system, with double pump (24Vdc & 230Vac). Both with manual shut-off valve and limit switch. In addition, a ‘Flow Switch’ for the automatic changeover from one to the other and a motorised valve (with spring return to closed position).
  • Easily accessible from the outside control panel
  • Power panel independent of the monoblock, and therefore isolated from vibrations, with adjustable LSI switch and busbar with top outlet.
  • External Power Link Box for power connection via customer-supplied Modular Busbar System.
  • Internal wiring from busbar to Modular Busbar System with 6 cables per phase (5 ‘phases’) of 240mm2 halogen-free (total 30 cables).
  • Normal and emergency lighting (at least 10 lumen) inside and outside the container.
  • Motorised air inlet and outlet grilles.
  • Double starting system with 2 electric starter motors and double set of AGM batteries.
  • Battery protection box.
  • Stainless steel exhaust silencer located in the upper external part of the container.
  • Automatic mechanical safety valve to shut off fuel supply in case of fire.
  • RF60 fire protection.
  • 3,000 W double engine preheating system with recirculation pump.

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.