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.
  • 1500 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: 1500L steel-steel tank, double walled.
  • Silenvcer: 2x MSR250 (-30dB) TYPE A
  • Control panel: CompAp InteliGen

 

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.

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.

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.

Generating set installed in a spanish large shipyard

 

Technical Data

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 bring energy to Kenya

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Emergency power for a photovoltaic plant in Mexico with more than one million solar panels and 300 MW

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The sun provides 100% clean, silent energy and greenhouse emissions are zero.

Solar energy is an inexhaustible source of energy which does not pollute throughout the transformation process, and for this reason it has become one of the best alternatives to less environmentally friendly energy systems.

México is one of our strategic markets when talking about our commitment to renewable energy. Among the latest projects carried out in this North American country, our participation the construction of one of the large solar plants stands out. We have collaborated in the design of the emergency system by supplying two made-to-measure generator sets: one soundproofed 250 kVA unit and another 220 kVA open type set.

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Electricity to 300,000 homes

All these characteristics are brought together in this great Mexican park. With more than one million photovoltaic panels and 300 MW of power, it is planned to supply renewable energy to more than 300,000 homes once it comes into operation. The two generating sets designed at Genesal Energy to reinforce its emergency system were conceived by our engineers to fulfill their goal: to provide power to the switching and lifting substations installations of the photovoltaic plant.

The launch of this mega-facility will not only actively contribute to the economic and social progress of the area, but it perfectly reflects our philosophy as well: a way of doing things that is part of the company’s strategy and that materializes with specific actions, as for instance the recent adhesion of Genesal Energy to the 2030 Agenda through the fulfillment of four of the Sustainable Development Goals (SDG).

220 kVA opentype unit features

  • Four pole circuit breaker.
  • DNP 3.0 communication protocol.
  • Signal wiring according to the client’s specification.
  • Commissioning and training.
  • Space heaters in the alternator windings (220V/127V).
  • Analog excitation voltmeter and ammeter.
  • 24V starting system.
  • Space heaters and thermostat on the electric board.
  • Engine and alternator yellow painting (RAL 1021).
  • Electronic speed governor.
  • Ethernet port.

250 kVA soundproof unit features

  • Soundproof Canopy
  • Signal wiring according to the client’s specification
  • Commissioning and training
  • Four pole circuit breaker
  • Ethernet port

We reinforce our commitment to the planet: emergency power for two green hydrogen plants in Spain

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Hydrogen is a clean fuel that allows electricity to be generated. And it is the future.

When hydrogen is renewable, it is called green hydrogen and it has a great future ahead of it in the energy sector. Its possibilities are immense.

At Genesal Energy we have supplied emergency power to two green hydrogen plants in Spain, in Puertollano (Ciudad Real) and Barcelona. In both cases, its construction represents a change in the energy model, marking a turning point in the market and on the path to ecological transition.

Puertollano plant

With an investment of more than 150 million euros, will create 700 jobs and will avoid emissions of 48,000 tCO2/year. It is the largest green hydrogen plant for industrial use in Europe and is made up of a 100 MW photovoltaic plant, a lithium-ion battery system with a storage capacity of 20 MWh, and it also has one of the largest productions of hydrogen by electrolysis in the world (20 MW). Everything from 100% renewable sources.

The new plant is located in an ideal place, very close to the National Hydrogen Centre, and its start-up represents a great advance for green hydrogen to become a solution for efficient decarbonisation in the medium term.

The generator set designed for this large infrastructure is an emergency diesel generator housed in a soundproof cabin. All the components have been designed and manufactured to meet the specific needs of the client (e.g. tank with fuel collection tray and prepared for external transfer, large control panel adapted to all the components that had to be mounted, etc.).

The control and automation of the generator set for its integration into the other plant systems has been also tailored so that a central PLC can fully control the emergency system.

Puertollano plant features

  • 350 L standard bunded fuel tank.
  • Generator prepared for fuel transfer, including maximum level float, control system and tank bushings inside the canopy to facilitate the connection of the pipe coming from the external tank.
  • Recirculation system and engine coolant heating to provide the right temperature when the generator starts.
  • Motorized circuit breaker
  • Paint surface treatment according to ISO12944 – C4H w/o Zinc
  • PT100 probes in alternator windings
  • Made-to-measure control panel

Control panel

For the project carried out in Barcelona, we designed a generator set for the Green Hydrogen Supply Station in the free zone. In this type of power plant there are essential loads that must be supplied permanently for the correct operation of the installation, such as, for example, air compressors, refrigeration systems, uninterruptible power supplies for the control system, etc. This is precisely the role of the supplied generator.

On the other hand, our client requested the generator set to be fully managed, controlled and monitored from the generator’s own control panel. The control panel consisted of the generator being connected to a main connection panel, and this in turn connected to the supply bars of the essential loads of the installation. Besides, the generator set is locally prepared to be controlled remotely by the customer’s control system, both by communicated and wired signals. 

Barcelona plant features

  • 450 L standard bunded fuel tank.
  • Engine coolant heating to keep the engine at an optimum temperature for starting.
  • Paint surface treatment according to ISO12944 – C4H w/o Zinc
  • Generator set prepared for fuel transfer by means of a gauge, high security level in the tank, selector and manoeuvre. Tank bushings inside the canopy to facilitate the connection of the pipe coming from the external tank. Pump was not included.
  • Smoke fire detection system installed inside the canopy with available contact.
  • Motorized circuit breaker.
  • Made-to-measure control panel.

‘Black Start’ emergency power for a petrochemical plant in Tarragona

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At Genesal Energy we have supplied a 2,250 kVA black start generator set to a petrochemical plant in Tarragona (Spain).

The facility is equipped with a cogeneration plant that required tailor-made emergency power, that is, special equipment to guarantee the electricity supply at all times and in any situation. The project for this infrastructure was developed by our engineering team after analysing in detail the specific requirements our client had. Carrying out the black-start of the cogeneration plant in the face of a black-out of the external electricity supply was one of their main concerns.

Black Start equipment allows energy to be restored without depending on the external network, which is essential for the optimal maintenance of a power plant such as the one in Tarragona, since operation is guaranteed with no need of being linked to the power transmission network, allowing the servicing of the own turbines without any problem.

Likewise, the control and automation of each generator set for its integration into the other systems of the plant was also tailor-made so that a PLC panel can fully control the emergency system. Furthermore, in this case the generator is capable of operating in parallel with two mains.

The operator decides by means of a button on the corresponding control panel or remote order with which network it wishes to synchronize to restore the bar to normal situation. The system is equipped with a RS485-Modbus communication module to monitor all variables remotely.

Specialists in starting from scratch

Black Start technology is ideal for a project such as the petrochemical plant in Tarragona as it allows the power systems to be restarted without any problem in the event of any unforeseen event or collapse in the electricity network. The Autonomous Start or Black Start makes this possible and, therefore, reduces the threat of lack of supply, which is the greatest fear in this kind of plant. Start-up is guaranteed. At Genesal Energy we have the knowledge and experience to offer this kind of customer service. Always with a personalised attention.

Features

  • Fuel tank installed inside the container.
  • Attenuators inside the container.
  • Motorized breaker.
  • Neutral earthing switch.
  • Recirculation and engine coolant heating systems to reach the proper temperature when starting the genset.
  • Air inlet and air outlet motorized louvers.
  • Parallel operation between two networks.

We have increased our presence in Africa with the supply of three generator sets to the largest hydroelectric power plant in Cameroon

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The largest hydroelectric power plant in Cameroon will be powered by Genesal Energy. We participated in the project through the supply of emergency power to the electrical construction, which will allow the country to increase its installed electrical capacity by 30%.

The power plant is undoubtedly a key infrastructure in the development of Cameroon, where the electricity supply network, together with the transmission network, are the great pending issues of a country that spires to become the greatest emerging economy of Central Africa in the next 5 or 20 years.

The Cameroonian government’s mid-term goal is to provide sufficient energy capacity to meet the needs of its citizens.

Guaranteeing access for all countries to affordable and non-polluting energy is a commitment made by the United Nations in the 2030 Agenda through the achievement of the Sustainable Development Goal (SDG) 7, which at Genesal Energy we have incorporated into our Plan of Social Responsibility.

The project involves the design of three customized generator sets: two of 1000/1100 kVA to power the plant’s facilities, and one of 100/110 kVA to be used at site during the construction process. Once the plant is finished, this smaller unit will become back up power for the facilities too.
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¿Why is this a special solution?

In facilities of this kind, there are essential loads that must be powered permanently for the correct operation of the plant, as for instance, water treatment systems or lubrication pumps that need to run continuously so that a safe shutdown can be guaranteed in the event of an emergency situation, (e.g., a power outage). This is precisely the role played by one of the supplied generators.

The client required the generator sets to be fully managed, controlled and monitored from the generator’s own control panel. The control philosophy is that the diesel generator is connected to a main board and this in turn to the feeding busbars of the installation’s essential loads. In this case, at Genesal Energy we designed a generator set system to work either in parallel or alternatively, depending on the client’s loads needs (it is the case of the emergency genset).

In these gensets, it is possible to indicate a preferential start of Generator 1 or Generator 2, depending on which one is required to start fist. We also manufactured a fuel system consisting of four tanks: two daily tanks of 1000 L and two nurse tanks of 10 000 L in order to ensure long periods without refuelling the generator.

Difficult location

The difficult conditions of the location where the hydroelectric power plant is built forced our engineers to take additional steps to avoid any risk and guarantee the gensets’ operation at any time and in any situation. Thus, a fuel transfer system has been designed allowing the fuel to be pumped or transferred in such a way that, if any part of the system is out of service, the other can be used without problem, ensuring the control unit’s continuous power supply.

Our participation in the construction of this plant reinforces Genesal Energy’s presence in Africa and specifically Cameroon, a key state in our international expansion strategy due to its great energy opportunities. In this sense, our company has already participated in several projects related to the modernization of its infrastructure aimed at improving the living conditions of Cameroonians.

One of the latest projects carried out in this African country has been the design and installation of the electricity supply to a water treatment plant, which is a fundamental installation to bring drinking water to populations of the country that still don’t have a proper supply.

Features

  • Two units of 1000-1100kVAs, open type
  • One unit of 100-110kVAs, soundproof type, off-road trailer
  • Custom fuel transfer system, both automatic and manual, for 4 fuel tanks, 2 of 1000L and two of 10 000L capacity.