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.

An engineering feat to ensure power supply to a data center in Northern Europe

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We design five unique gensets capable of providing a DCP output of 3,000 kVA each.

In an innovative and technological implementation, our engineering team has designed five generator sets that have been installed in a Data Center in Northern Europe. These are ad hoc machines designed to provide a DCP power of 3,000 kVA and meet the stringent technical and regulatory requirements of the project.
We have reached this milestone hand in hand with manufacturers Baudouin, ComAp and Friga-Bohn. The generators were designed to ensure continuous uptime and data security in one of the world’s most critical and demanding environments, protecting the infrastructure against grid outages.
The integration of advanced technologies, customisation to detail and compliance with the highest standards of security and efficiency, consolidate this installation as a model to follow in the industry.

The importance of investing in emergency power generators

The installation of these generators responds to the critical need to ensure operational continuity in data centres, essential for the IT infrastructures of global companies. The benefits include:

  • Data Loss Protection: They provide an alternative power source to protect unsaved data and prevent damage to storage systems.
  • Cooling Maintenance: Enable continuous operation of cooling systems, preventing equipment from overheating.
  • Prevention of Costly Downtime: Minimise downtime that can result in significant financial loss.
  • Regulatory Compliance: Help companies comply with regulations that require robust contingency plans.

Innovation and security in every detail

This completely customised solution exceeded the customer’s most demanding specifications. The design of the container – with special dimensions of 13.5 x 3 x 3 m – includes a structurally reinforced base with pipes running underneath to facilitate connections to the fuel tank and a liquid collection tray that guarantees total containment in case of spills.
In addition, the container was given a C5 type surface treatment in accordance with UNE-EN ISO 12944-2:2018 – ideal for marine environments – guaranteeing exceptional durability and resistance.
To ensure that noise requirements were met the exhaust system was optimised including a thermally insulated (rock wool and aluminium) -30 dB silencer, maximising safety and minimising environmental impact.
In terms of equipment protection, 5,000 A circuit breakers and Power locks were installed, as well as an oversized busbar, specially designed to facilitate the customer’s electrical connection of the system.
Our engineering team also developed an independent cooling system with motorised louvres and a fully integrated & automated fire suppression system to ensure a fast and efficient response in case of an emergency. The incorporation of wide accesses, advanced control systems, fire protection and adverse environment features completed this project and made it a benchmark in the industry.

Requirements and Customised Solutions

  • Non-full-flow: In terms of the cooling system, V-arranged Friga-Bohn air-coolers were installed in a room separated from the generator room. They were sized for a maximum ambient temperature of 38ºC at 100% load. This configuration allowed outside operation of a full flow system, significantly reducing air interference in the operating area.
  • Low noise level: The generators were required to operate at a sound pressure level of no more than 85 dB at 1 metre, at 100% load.
  • Fire protection: A Novec fire detection and gas extinguishing system and sectorisation panels were integrated, ensuring EI60 fire resistance standards.
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Business collaboration

After a thorough analysis of the customer’s specific power requirements, generator set models and capacities were selected based on a detailed list of electrical loads. The choice of Baudouin’s 3,000 kVA DCP engines was not a gamble; these engines have been specially designed for critical applications and meet the highest standards of reliability and performance.
Regarding the control system – and as it was essential to ensure the highest availability of the equipment – redundant systems were installed. Namely, a redundant battery rack of eight units in total, separated into two groups of four. Also, a redundant two-stage starting system. First stage fitting two starter motors and managed by the engine ECU and a second stage with one starter motor managed by an ComAp controller. This particular control centre allows, in addition to real-time management and monitoring of the status of the generators, a flexibility that traditional control systems do not provide.

Features

  • V-arranged air-coolers were installed in a room separated from the generator room. They were sized for a maximum ambient temperature of 38ºC at 100% load. This configuration allowed outside operation of a full flow system, significantly reducing air interference in the operating area.
  • The generators were required to operate at a sound pressure level of no more than 85 dB at 1 metre, at 100% load.
  • A Novec fire detection and gas extinguishing system and sectorisation panels were integrated, ensuring EI60 fire resistance standards.

Genesal Energy secures supply at Europe’s leading engineering research centre

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Investment in innovation & research ensures the competitiveness of a company.

This is often materialised in a research centre or campus which search for the best suppliers and solutions.

Genesal Energy has designed a solution to secure the power supply of Europe’s largest enclosures engineering space. These 29,000 sq. metres premises are devoted to the research of customised enclosures for large buildings around the world, with a team of 350 engineers and architects.

Our solution was a 250 kVA generator set with an autonomy of more than 6 hours, vibration isolation and a silent engine that does not interfere with advanced test benches or thermal and acoustic performance tests.

Genesal Energy has eliminated the risks of power supply instability, power cuts or voltage variations, ensuring the progress of research.

Our engineering solution: research center generator

An open generator set with an engine-alternator direct coupling on a steel bedplate. The integrated 350 L tank provides an autonomy of 6.8 hours. Vibration isolation between the base plate and the monoblock was achieved by means of a rubber anti-vibration system. The integration of protections for moving parts and hot parts has also been taken into account, as well as emergency stop buttons and other elements necessary to operate the unit safely.

Features

  • Supply: 2,800mm bedplate.
  • Tank: 350 L integrated in the bedplate.
  • Silent model: GSA 365 (-25dB).
  • Control panel: ComAp InteliLite.

 

 

 

We equipped a children’s hospital with a generator to avoid incidents due to lack of power supply

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Genesal Energy has equipped a children’s healthcare center in Bebington (Wirral), in the northwest of England, with a generator.

The children’s hospital, located just 8 kilometers from Liverpool, will now have an additional generator to ensure essential care for children, preventing a power outage or any other technical incident from disrupting the normal activities of the center. In this way, the safety of the children is ensured, and they can be attended to at all times both medically and emotionally.

It is crucial for such facilities to have an emergency generator, as its use would help prevent and respond to various adverse situations that may arise in such a center. Thus, it provides confidence and flexibility to ensure the power supply in areas where it is unstable or non-existent, such as rural areas, hard-to-reach areas, or establishments that need guaranteed electricity 24 hours a day. It acts as a power backup and support in situations where the quality of the supply is deficient or prone to frequent interruptions.

  • Generator installation at Claire House
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Among the differentiating advantages of using an emergency generator is the uninterrupted power supply. In this regard, Genesal Energy ensures that critical operations continue during power outages, avoiding economic and productivity losses.

Similarly, generators for hospitals and healthcare centers keep essential medical equipment running, which is vital for the life and well-being of patients.

Thus, an emergency generator is an essential tool to ensure operational continuity, safety, and resilience in different scenarios.

Its ability to provide reliable power in emergency situations makes it a fundamental and strategic investment for many organizations and infrastructures, especially those providing social and child care.

Guaranteed Safety

On the other hand, security systems are essential. Genesal’s generator will allow surveillance cameras, alarms, and other security systems to continue operating in the event of an electrical failure or power outage. In so-called critical infrastructures, such as water treatment plants or pumping stations, the generator would ensure that basic services are not interrupted.

But this system can also be used for temporary events. In outdoor activities, the generator provides power for lighting, sound, and other necessary equipment, while in construction areas, it allows power to be supplied to tools and equipment in places where there is no access to the electrical grid.

In this regard, Genesal is also positioned as a reference in disaster mitigation, such as earthquakes, hurricanes, or other catastrophes, providing power for shelters, rescue centers, and other emergency facilities. It thus contributes to resilience in extreme situations.

Children’s hospital generator: Solution designed by engineering

The project developed by our engineering department consisted of providing an emergency network with the design, manufacture, and commissioning of a silent generator that guarantees at all times and in any incident the operation and safety of the center’s medical activities.

The generator has a power of 160/176 kVA, in a soundproof cabin, with a bunded type tank integrated into the cabin, a main switch panel, and an external power output panel. The cabin, in addition to rain guards on the door frames, also has a mesh to prevent animals from entering.

Features

  • Soundproof generator in a 3,400 cabin, with a fuel tank integrated into the chassis, capacity 450 L.
  • Liquid collection tray integrated into the chassis.
  • External power output panel with connection plates and auxiliary service terminals to facilitate customer connection.
  • Battery box for explosion protection.

 

New care home generators to guarantee energy supply

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There is an undeniable demographic transition towards an ageing population and the well-being of senior citizens in care centres is a sensitive issue in our societies.

The role of care home generators

One of the key elements to provide such care is to ensure the safety and continuity of power supply during outages and emergencies, ensuring the health and safety of residents.

Power outages in these facilities can pose a real threat as they house elderly people who often have special medical needs such as infusion pumps or vital sign monitors. Also, communication lines can be disrupted, jeopardising alarm and security systems or mobile telephony.

A trustworthy care home generator set will also maintain emergency lighting systems which prevent accident and facilitate evacuation in case of need. This backup energy is also essential to power heating, ventilation and air conditioning systems. There are times when the weather is more unstable and the temperature in the premises must be kept within comfort levels.

High quality solutions

Genesal Energy specialises in offering highly innovative energy solutions. A manufacture that guarantees the supply in such sensitive environments as geriatric care homes.

Features

  • Soundproofed generator set in a 3,400 mm canopy.
  • 5,000 L base frame integrated fuel tank capable of providing an autonomy of 16.5 hours at 100% load.
  • Exhaust silencer was installed inside the canopy, provides a noise reduction of -30 dB.
  • Heating resistor in the cooling system to keep the engine at an optimum temperature for starting.
  • Control panel for automatic start-up in the event of mains voltage failure.