Generator set for a hangar at Barajas airport with a surface area equivalent to three football pitches.

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Adolfo Suárez Madrid-Barajas airport leads the ranking of air traffic in Spain. It closed the 2023 financial year with a passenger volume of more than 60 million and more than 380,000 operations carried out.

The figures reflect the importance of this airfield which, due to its colossal dimensions, needs to have many hangars where aircraft can “rest”. Premises equipped to carry out repairs and maintenance operations inside.

They are normally designed to house more than one aircraft and emergency power is key to their operation. With a surface area of more than 22,400 square metres, the equivalent of almost three football pitches, one of these airport hangars needed a special generator. Genesal Energy has just supplied contingency power to prevent a significant loss of time and money with a special genset for airports.

Tailor-made: generator set for a hangar

“The client required the customised manufacture of hoppers and bellows for the generator’s cooling air outlet, as well as a gas duct with 90° bends to adapt to the layout of the hangar’s generator room“, explain the engineering staff which developed this project. 

Our engineering team’s solution consisted of a highly customised generator set, which was manufactured according to the customer’s requests, seeking the best options for a special site with such particular dimensions.

Technical Data

  • Power panel integrated in the alternator, allowing the intake of two cables per phase.
  • Calculation of the necessary cross-sections for the inlet and outlet of gases in the room, tailor-made hopper and bellows.
  • Oversized exhaust silencer model.
  • Multicolour control panel.
  • Heating system.
  • Integrated 350 L tank.

Genesal Energy provides emergency power for two sugar farms in Tanzania

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Africa is a continent with great natural resources. Market studies of the states in the eastern region, formed by 14 countries, reflect a 3% growth of the energy sector in the coming years.

In this favourable scenario, one country stands out: Tanzania.

With a population of more than 63 million people, Tanzania’s agriculture is an important source of income, representing 25% of GDP, and sugar cane is one of its most profitable crops. Within this sector, the Kilombero Sugar company is a heavyweight. Its projects to increase production in the medium and long term require solid infrastructures capable of withstanding any unforeseen power supply eventuality, the country having a very deficient electricity network.

Reliability: emergency energy gensets for sugar farms

Genesal Energy has just reinforced the safety of the energy supply in one of its factories of brown sugar for direct consumption.

The company owns and operates two farms close to each other, Msolwa K1 and Ruembe K2, located on both sides of the Great Ruaha River and linked by a bridge. Both farms are involved in brown sugar production and need a very reliable network to carry out their daily business.

The project developed by Genesal Energy for Kilombero Sugar focused on the design, manufacture and commissioning of two soundproof generator sets with three different rooms each: engine-alternator room, control room and storage room.

2xGEN2000YC features:

  • Two soundproofed generator sets were designed in 40 feet containers, guaranteeing an average sound pressure level of 85 dB at 1 m.
  • The container has 3 separate rooms: engine-alternator room, control room and storage room.
  • A Baudouin engine was fitted with a Mecc Alte alternator on an electro-welded steel base with anti-vibration blocks.
  • A 2000 L, double-walled, certified tank was installed inside the container.
  • A water spray fire detection and extinguishing system was installed in the group room and the storage room.
  • CO 2 extinguishers were installed in the control room.
  • Air-conditioned control room.
  • C5 paint surface treatment, in accordance with ISO12944

GEN1100YC features:

  • 40ft Container, guaranteeing an average sound pressure level of 85 dB at 1 metre.
  • Container with 3 separate rooms: engine-alternator room, control room and storage room.
  • Baudouin engine & Mecc Alte alternator on an electro-welded steel base with anti-vibration blocks.
  • 2000 L, double-walled, type-approved tank installed inside the container.
  • Water-spray fire detection and extinguishing system installed in the genset and the storage rooms.
  • CO2 extinguishers in the control room.
  • Air-conditioned control room.
  • C5 paint surface treatment, in accordance with ISO12944

We bring energy to the “Carlos Tartiere”, the largest football stadium in Asturias with a seating capacity of 30,500

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With 30,500 seating capacity, the “Carlos Tartiere” municipal football stadium, home to Real Oviedo, is also the largest sports venue in Asturias.

Genesal Energy has designed an open and customised generator set for stadium to guarantee the electricity supply in the event of a possible failure of the main grid. If it happens, the show must go on.

For facilities of this type, the availability of emergency generators has become compulsory by law. The reason is to prevent a simple blackout from forcing the cancellation of a match or competition, with the consequent inconvenience that this would cause the players, spectators and, above all, the club, as it would have serious economic and reputational consequences.

Emergency generator for stadium

“The installation of a generator set in a football stadium guarantees 100% of the electricity supply and that the events in the stadium can take place normally, without problems”, explained the Genesal Energy Engineering Department.

In this type of project, the generator sets must have highly reliable engines to assume the loads quickly in the event of a grid failure, maintaining not only the frequency but also the generation voltage.

Genesal Energy is perfectly aware of the importance of small details and precision in the manufacturing process of generating sets for sports venues and we have carried out numerous projects in this sector. Among our latest works we can highlight the emergency systems for the Mendizorroza stadium and for the municipal stadium of Anduva.

Which was our solution for Real Oviedo FC?

Our client needed to replace a generator in poor condition and reorientate the air inlet and gas outlet due to works being carried out at the sports facility. Based on this premise, the engineering department developed an open generator on a laminated ‘U’ with an independent 1,000 litre tank, switch on alternator and compact box of two batteries. The customer required the input to the group power with two cables per phase and the customised manufacture of the hopper and bellow for the air outlet of the radiator.

Features

  • Emergency unit with external start-up.
  • Open skid on laminated ‘U’.
  • 4-pole CB on alternator.
  • Dimensions adapted to customer’s room.
  • ComAp InteliLite4 AMF 25 controller.
  • Additional heating pump.
  • Additional tank 1,000 litres.

Emergency generating sets for the 4.0 conversion of a large shipyard in Spain

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Genesal Energy has designed three special shipyard generator sets to reinforce the security in the power supply of one of the main Galician shipyards, a benchmark in Spain.

The purpose of the works is to convert the shipyard into a ‘smart factory’ improving all the processes and tools of its value chain and production centres to incorporate them into the new digital ecosystem. A 4.0 Shipyard.

The equipment was manufactured to complement the renovation works on the facilities of the famous shipyard. This works cover four fields of action: machinery and products, applications, people and company. The customer required three generator sets for the supplementary power supply station with a production capacity of 4,5 MVA with an option to extend it by 2,2 MVA.

If there was a power failure at the substation supplying the shipyard, there would be a serious problem, hence the importance of back-up power: our generator sets would be up and running within seconds. Guaranteeing the safety and optimal operation of the facilities.

Shipyard generator: versatility, a plus

The tailor-made generator sets are adapted to work in a saline environment and are 100% versatile. The control system is adapted to operate in parallel with the grid, and an automatic diesel fuel transfer system was designed for refilling from a central tank.

“We took into account the loads that are going to feed the equipment and the type of control that the client is going to use in the installation”, explained Engineering. The containers were also customised according to the final location of the machinery with the colour and design requested by the client.

Features

Equipment for saline environment:

  • Stainless steel exhaust gas silencer.
  • Marinised alternator.
  • Alternator anti-condensation resistor.
  • PT100 probes in alternator windings.
  • Motorised air inlet and outlet louvres.
  • Stainless steel ventilation louvers.
  • Surface paint treatment according to ISO12944 – C5M.
  • Container design requested by the customer.
  • Motorised CBs.

We take part in the extension of Extresol, the solar thermal plant in Badajoz

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When it came into operation in 2010, Extresol-1 was the second plant of its kind in the world.

A budget of 300 million euros, 50 MW of installed power and the use of the most advanced technologies. Extresol uses cylindrical-parabolic collectors within a solar radiation concentration system equipped with a sun-tracking mechanism. The task of these plants is to direct solar radiation from the reflecting surfaces onto the receiver tube and concentrate it about eighty times.

A generator for a solar thermal plant

Built on 2,25 square kilometres of land in Badajoz, Southwest Spain, Extresol currently supplies electricity equivalent to the consumption of more than 30,000 homes and avoids the emission of 149,000 tonnes of CO2 per year. Genesal Energy takes part in the expansion works of this infrastructure doing what we do best: reinforcing the security system with a solid emergency network to avoid issues and shutdowns in the event of failure in the network.

Customer’s need

Our client needed to guarantee the emergency supply in the event of a failure in either of the two existing transformers and it had to be done independently. Genesal Energy installed a 935/1010 KVA open genset placed inside one of the plant buildings, with double switching mounted on the genset itself due to the existing space limitations, and also double mains detection, operating the equipment independently for each of the transformers.

Technical Data

  • 1000 litre specially designed fuel tank on the bedplate.
  • Switchboard integrated in the bedplate, equipped with two 1600A 4P 230V motorised ATS.
  • ATS Mains detection system.
Gas generator in natural environment

We bring our energy to the Montseny Natural Park, World Biosphere Reserve

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The southernmost fir forest in Europe is located in the Montseny Natural Park (Barcelona), declared a World Biosphere Reserve by UNESCO in 1978.

A privileged environment that extends over more than 30,000 hectares. There, in the heart of nature, you can find holiday camps & farmhouses where vulnerable families’ children can enjoy unforgettable summers in a film-like area.

The challenge: installing a generating set in a protected place

Genesal Energy has provided emergency power to guarantee the electricity supply in one of these holiday homes located in Sant Pere de Vilamajor. In such a special and protected place, from an environmental point of view, the care taken when developing the project was of the utmost importance.

Gas generator in natural environment

Genesal Energy’s engineering department paid utmost attention to the location of the generator set, which had to operate in a natural park protected by UNESCO. So, from the very beginning one of the objectives was to reduce the acoustic and visual impact of the generator set so as not to spoil the beauty of the site.

The project included the installation of a gas generator, which is more environmentally friendly in terms of CO2 emissions than a diesel generator. The generator set was manufactured in a soundproof cabin to lower the noise levels of the machine as much as possible.

Technical Data

These are its main features:

  • LPG gas engine.
  • Alternator with auxiliary winding.
  • No fuel tank on the base frame, which functions as a tray for liquid collection.
Containerized soundproof generator sets

Genesal Energy supplies 6 containerized soundproofed generator sets to a data centre in Norway

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The strategic importance of data centers

Data Centres are facilities that allow companies and users to quickly access data and, due to the function they perform, they have become essential in an increasingly digitalised world. Their electricity consumption is considerable and this high demand is not only used to run the IT equipment, but also to cool these rooms that house it.

Maintaining optimal temperatures in data centers

The optimum operation temperature in a data centre to ensure proper performance of the servers is between 18 and 20°C. To keep the temperature within these values, an uninterrupted power supply is vital. Any brief network outage could paralyse all the activities of a company and cause not only economic losses but also reputational damage that is difficult to recover from in most cases.

Generating sets: guarantee of continuity

For this purpose, redundant supply sources are used to ensure operational continuity in the event of any failure in the electricity grid, namely, electrical generators. An efficient and specialised solution to guarantee the constant availability of electrical energy.

Data Centre generator sets require cutting-edge engineering and experienced personnel. Genesal Energy provides both and for this reason the projects we develop are in great demand in this market.

One of our latest projects in this field has taken us to Norway, where we have supplied a total of six generator sets to power the emergency network of a data centre. The cold climate of this Nordic country was not an obstacle to the success of the project, as the six generator sets were designed to withstand the country’s low temperatures.

The engineering solution: 6 soundproofed generator sets in a container

Six 2250-2500 kVA soundproofed generator sets in a 40 feet HC container ready to work in permanent parallel with the grid. Two were designed with the power output on the right-hand side and four sets, symmetrical to the first two, with the power output on the left-hand side, which facilitated the installation of the power cabling.

Characteristics of containerized soundproof generator sets

  • 4.000 L Certified double-walled fuel tank which provides autonomy for more than 9 hours at 100% load.
  • Connections for fuel transfer from an external tank.
  • High-capacity fuel filtration system.
  • Container floor covered with checker plate.
  • Double starter motor.
  • Double set of batteries.
  • Motorised air inlet and outlet louvers.
  • Heat exchanger integrated in the base frame for heat recovery.
  • Customised power output busbars for easy connection.
  • C3 paint surface treatment, according to ISO12944, in RAL7016 colour.
  • Exhaust gas silencer installed on container, heat-insulated, with external aluminium coating.
  • The sound pressure level at a distance of 1 m is 85 dB.

Clean energy with Stage V units to guarantee supply to a degassing plant in the Basque Country

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Environmentally friendly, less polluting and silent.

Our Stage V generator sets have been manufactured to keep gas emissions at bay and that comply with the demanding European Regulations.

As part of our sustainability strategy and in the search for the best solutions within energy transition, our Engineering Department has just designed a Stage V generator set for a mobile degassing container.

The task was to supply emergency power to a degassing plant in the Basque Country so that in the event of a grid failure there would be no problems. “Providing emergency power supply via a Stage V degassing plant generator set, we guarantee the correct operation of the plant, and we help the environment”, says Genesal Energy’s engineering department.

Our proposal

Our Engineering Department developed an open skid genset with a 300L tank capacity where the various maintenance elements, automatic, control panel and filling points (both for diesel tank and urea tank) are located to the left of the genset. Special attention was also paid to the protection of hot parts, as well as the location of the different elements required by the Stage V groups.

Degassing plant generator set features

  • 2,200mm Open Skid Generator Set
  • Standard 300 L tank.
  • Reduced dimensions to adapt to the customer’s container.
  • Control panel and switch located on the same side.
  • Elevated diesel fuel inlet.
  • ComAp InteliLite4 AMF 25 controller.
  • Oversized 135 kVA alternator to guarantee starting of motors and compressors.

Emergency power for the new water-treatment plant in Palma de Mallorca, which will serve one million inhabitants.

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