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.

Emergency power for Togo’s first thermal power plant

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Togo’s first gas power plant will feature emergency power by Genesal Energy, who will participate in the project through a generator set prepared to face any setback and guarantee the facility’s correct operation.

In this type of combined cycle power plants, there are essential loads which must be powered permanently, such as the treatment plant systems or specific lubrication unit pumps designed to remain operative in any circumstance.

Therefore, in the event of an emergency situation like a power outage, it will always be possible to bring the whole system to a safe shutdown. This is precisely the function of the generator set supplied by our company for the thermal power plant, with a production capacity of 65MW and which has lead to an energy revolution for the Togolese citizens.

Control panel

For the combined cycle power plant in Togo, and according to the client’s needs, a generator set capable of being entirely controlled and monitored from its control panel was designed. The electrical schemes consisted in a diesel generator set connected via a protection breaker mounted on its container to a supply panel in the client’s facilities, and through this panel, all essential systems would be powered. As far as control equipment goes, apart from the PLC in charge of managing the genset’s operation, a protection relay was installed as well as a synchronizer for parallel to mains operation.

It is an entirely special solution, from start to finish. Thus, the container in which the genset is installed features bespoke elements, from the air conditioning system, to the fire detection system, motorized louvers, fans… all elements have been designed to adjust to the area’s needs, without of course forgetting those of the client.

The control and automatization of the genset for its integration within the rest of the plant’s control systems was designed made-to-measure in such a manner that a central PLC could completely control the emergency system.

International expansion

The arrival of gas to Togo is a major milestone for the African country, where up until this point power generation was based on less efficient and more pollutant systems. On the other hand, Genesal Energy’s participation in this project consolidates our presence in the African continent as well as our great focus on sustainability.

Guaranteeing power supply in any part of the world is our raison d’être and Africa is a strategic point in our international expansion plans. Our presence in the continent is evergrowing thanks to projects which are completely customized and above all, prepared to operate in the most extreme and strenuous conditions. The Gambia, Guinea Bissau, Guinea Conakry or Cameroon are just some of the countries for which we’ve supplied emergency power.

Features

  • Genset with EI-120 fire resistance.
  • Genset container divided in three separate chambers: genset room, control room and fuel tank room.
  • Fire detection and extinction system via nebulized water in the genset and fuel tank rooms.
  • Cooling system for genset room temperature control.
  • Air conditioning system in control room.
  • C5 surface treatment, according to ISO 12944-2:2018 norm.
  • Bespoke control system based on PLC.
  • AGM type batteries.
  • Engine liquid collection tray.
  • Automatic breaker with power output busbar adapted to client’s installations.
  • Engine cooling liquid recirculation and heating system to provide adequate startup temperature for the genset.
  • 2000L double-walled fuel tank.
  • Fuel tank leakage detection system.

The Fenicias wind farm, in Mexico, our latest project in our quest for the wellbeing of our planet

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Electricity demand in Mexico grows at a rythm of 3% a year and in the solar power sector, the development of solar plants in the country increases year by year, generating investments of millions and thousands of jobs.

It’s no surprise that Mexico is one of the ten countries with the largest investment in clean energy of the whole planet and when it comes to power efficiency, it’s amongst the leading countries in Latin America.

The photovoltaic plant is a modern facility with capacity to generate 200 MW, which contains a booster substation, of medium voltage network, and two high voltage evacuation lines, both of 230 kVA.

We participated in the project through the manufacture and supply of three special generator sets, one of 250 kVA and two of 100 kVA. Each one of them was developed following state specifications and norms, an official certification which grants only few foreign companies the possibility to work on great governmental projects in Mexico.

The generator sets were designed in order to guarantee power supply if ever a mains failure were to happen and to operate as a back up for the booster and switching substations, in compliance with the client’s specifications.

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Features

Gensets complying with CFE W4700-10 specifications, featuring:

  • GEN110FC: Dual Voltage 240/120V.
  • GEN220F: Dual Voltage 220/127V.
  • Soundproof canopy.

Genesal emergency power for the largest combined cycle power plant in Latin America

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As part of our expansion plans in Latin America, at Genesal Energy we have designed, manufactured and supplied three generating sets of 1705 kVA, 300 kVA and 110 kVA, aiming to reinforce safety in the largest combined cycle plant in Latin America, which is located in Mexico.

The three units have been manufactured after studying the specific requirements and terrain conditions, and their function will consist of guaranteeing the energy supply in phase II of this huge electricity generation plant, which has a capacity of 1,187 MW and is composed of two generation modules, two gas turbines and a steam one.

This kind of installation always requires special loads that must be supplied permanently for the correct operation of the plant. Based on this premise, the main mission of the three Genesal generator sets will be to support the construction works of this second phase, strictly complying with the current regulations and client’s specifications.

Tailor-made solution

The solution provided by Genesal Energy consisted in equipping the plant with bespoke generators. In addition to the 300 kVA and 110 kVA gensets, the third unit (1705 kVA) has been designed to carry out a safe shutdown of the entire system in the event of an emergency.

In this sense, the client requested that the generator set was fully managed, controlled and monitored from the control panel itself, and that it was also able to start up in the event of the failure of two supply networks that the essential busbars could supply.

Thus, if the essential bus is de-energized and the external ATS system cannot recover it, the generator set starts up and takes control of the transfer system to supply the essential loads in less than ten seconds. Upon mains return, and provided that the operator validates it, the loads are returned to the network without zero crossing, guaranteeing the continuity of power supply of the loads during the process of returning from the network. Likewise, the automation of the generator allows the necessary integration with the external ATS and with the various switches that the generator set has to operate, so the starting and stopping sequence provided by the customer is followed at all times.

Like the other two gensets, this 1705 kVA unit – which has been designed to start without the need for any type of external voltage and without the need for safe voltage for the voltage circuit – has been mounted on a bespoke soundproof container with specially designed air conditioning system, motorized louvers and fans, amongst others.

On the other hand, given the space limitations of the generator set, a 4,000 liters double walled fuel tank was integrated into the container, guaranteeing a continuous operation for more than ten hours at 100% load.

Respect for the environment

Since the project was launched in 2005, the construction of the combined cycle plant generated more than 1,500 direct and indirect jobs, which has contributed to the economic development of the area as most of the jobs are local.

Combined cycle power plants generate electricity through the coexistence of two thermodynamic cycles: one uses water vapor and the other uses flue gases. In addition, combined cycle plants are considered clean energies and very low polluting, as the discarded gases are reused to produce more energy from water vapor.

We participated in the biggest photovoltaic plant in Andalusia: Cabrera Solar

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Four solar power plants, each of 50 megawatts, shape Cabrera Solar, the biggest photovoltaic project in Andalusia and one of the largest in Europe.

It’s located in Alcalá de Guadaíra (Seville), and we participated in the proyect through the supply of emergency power to ensure everything runs smoothly in the event of a mains power failure.

The project, which has obtained the Declaration of Public Utility by the Regional Government of Andalusia, will produce enough power for 145.000 homes and the plant’s activity will prevent the emission of 300 equivalent kilotons of CO2.

Our client needed a tailor-made generator set, designed to provide power to the substation’s emergency components. The solution provided by our team consisted in designing a generator set with very special features, capable of ensuring the normal operation of the whole power plant at all times, just as the client required.

The Cabrera Solar project has been praised for ensuring sustainability, and the power plant’s construction works are almost finalized. Since the start of the project, more than 350 direct jobs have been created, and it has the backing of the European Fund for Strategic Investments (EFSI) as well as an investment of over 43 million euros from the European Investment Bank (EIB).

Features

  • 100/110 kVA generator set with Baudouin engine and Leroy Somer alternator
  • Soundproof in 2.600 mm canopy
  • 160A ATS
  • Low coolant level sensor
  • High oil temperature sensor
  • BIO 8 signal expansion module, allowing the configuration of up to 8 digital inputs or outputs according to the client’s requirements.

Emergency power to guarantee supply to a new photovoltaic plant in Mexico

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Electricity demand in Mexico grows at a rythm of 3% a year and in the solar power sector, the development of solar plants in the country increases year by year, generating investments of millions and thousands of jobs.

It’s no surprise that Mexico is one of the ten countries with the largest investment in clean energy of the whole planet and when it comes to power efficiency, it’s amongst the leading countries in Latin America.

The photovoltaic plant is a modern facility with capacity to generate 200 MW, which contains a booster substation, of medium voltage network, and two high voltage evacuation lines, both of 230 kVA.

We participated in the project through the manufacture and supply of three special generator sets, one of 250 kVA and two of 100 kVA. Each one of them was developed following state specifications and norms, an official certification which grants only few foreign companies the possibility to work on great governmental projects in Mexico.

The generator sets were designed in order to guarantee power supply if ever a mains failure were to happen and to operate as a back up for the booster and switching substations, in compliance with the client’s specifications.

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Features

  • Baseframe fuel tank for 12 hours autonomy at full load.
  • PTC´s in control panel.
  • Double-walled (steel – polyethylene) 600L external fuel tank pared for 8 hours autonomy at full load.
  • DNP 3.0 communication protocol for connection with SCADA system.
  • Inspection of FAT procedure by third party (BV).
  • Spare parts according to CFE specifications.
  • Electronic speed regulator.
  • 24V starting system.
  • Paint and painting procedure according to CFE specifications.
  • Canopy interior lighting.
  • Panel space heaters and thermostat.
  • Prepared for external start-up command.
  • Heating resistors in windings.
  • Analog excitation voltmeter and ammeter.

Emergency power for a photovoltaic plant in the Chilean region of Atacama

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Our extensive experience in the manufacture of customised generator sets is a guarantee for our clients.

In Chile, a country in which we’ve already participated in the construction of a thermosolar power plant and a photovoltaic power plant in Cerro Dominador, high up in the Atacama desert, we’ve just supplied an emergency generator set for a very special project: to power the alternating current auxiliary services of a photovotaic solar plant’s substation in Region III, Atacama.

With 28 megawatts in power and an investment of 78 million dollars, the plant is one of the country’s greatest power projects, and has the approval of Chile’s Environmental Impact Assessment (EIA). It’s composed of 13 blocks of two megawatts each and two blocks of one megawatt respectively, and features 114.000 crystalline solar modules and tracking systems.

In order to provide the best service, our engineering team carried out an in-depth analysis and examined the area’s special conditions, an essential step in providing the most adequate solution.

And so, both the startup and the shutdown of the genset will occur through external commands and will be able to operate in parallel to mains. With this solution, the brief power cut-off experienced upon mains return which would have been generated in the client’s substation and sectioning centre auxiliary service panels, is avoided.

Features

  • Genset in parallel with mains, for non-zero crossing upon mains return.
  • Special canopy with double-walled base frame fuel tank.
  • Reinforced genset for 0,3g seismic compliance.

We supplied generator sets for the Argelian state-owned enterprise, Sonelgaz, to operate in extreme temperatures of 55ºC

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High temperatures are never a great ally for generator sets. Excessive heat affects the performance of their engines and as such, the correct operation of the units as a whole.

From 40ºC onwards, air quality is no longer optimal, gensets lose power and failures in the cooling system are frequent.

At Genesal Energy, we’re experts in anticipating these issues and we have the solution to prevent irreparable damage, which is why we design gensets capable of operating at peak performance in such extreme environmental conditions.

The generator set we’ve just manufactured for the state-owned gas enterprise in Argelia, Sonelgaz, is a prime example of this. The genset has been created by our engineers to operate in this kind of environment without any issues, and supplies emergency power to the 220 kV Boughezoul substation through a generator set which withstands heat conditions without compromising the delivery of power. Furthermore, it’s been designed to perfectly adapt to the installation and communication systems of the substation.

Antiseismic regulations

It’s a 125/138 kVA generator set capable of operating at peak performance at an environmental temperature of 55 ºC and, given the area’s terrain, of complying with seismic regulations, for which the structure of the generator set was reinforced to be able to withstand 0,4G.

Reliable 220kV Generators for Extreme Heat Conditions

  • Base frame fuel tank of great capacity.
  • Oversized power output.
  • Signal expansion kit.
  • Structural reinforcement and installation of special antivibration mounts to comply with seismic regulations.

We increased our presence in the Dominican Republic through antiseismic generator sets

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At Genesal Energy we’re experts in manufacturing highly specialized generator sets adapted to the peculiarities of all kinds of terrain.

Amongst the latest projects of this kind is the one developed for a photovoltaic power plant, in the Dominican Republic. A generator set was designed to resist the effects of earthquakes and was manufactured following the client’s needs after studying the area’s special seismic features.

The Dominican Republic, just like its neighbour Haiti, is located in an area of great seismic activity, caused by a system of 14 active faults which span across great part of its land and sea, meaning both Carribean countries are at considerable risk of experiencing earthquakes and tsunamis. The power plant is built in Matanza, in the Dominican province of Peravia, and received the green light by the National Energy Commission at the beginning of last year. The facility will have a power rating of 58MW, will employ 145.000 panels, and produce some 100 GWh once in operation.

145.000 panels

The generator set for the photovoltaic power plant, of 200 kVA, is part of the customized generator set range, and complies with all features which characterize an “antiseismic” generator set, as established by current regulations. The genset’s task is to supply power to the power plant in the event of a mains failure.

Features

  • Antiseismic generator set.
  • C5M treatment.
  • Control system adapted for external startup and electronic engine governor.

At Genesal Energy we’re reinforcing our commitment with renewable energy through the manufacture of gensets and transformers for two new solar power plants in Mexico

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Design, manufacture and supply of two generator sets and two transformers

The renewable power market is currently experiencing a great period in Mexico, whose privileged climate makes it the perfect place for the development of this market, and where administrative entities have been promoting the construction and implementation of numerous photovoltaic power plants throughout the latest years.

In two of them, the Cuyoaco and Border Solar power plants, in Puebla and Ciudad Juárez respectively, Genesal Energy participated in the design, manufacture and supply of two generator sets and two transformers within the company’s strategy to reinforce its presence in the American continent and the world of clean energy.

Both gensets, of 220 and 125 kVA, were manufactured for the client complying with the specifications and standards set by the Federal Electricity Commission. Both units needed to provide backup support for the booster and switching substations in the Border Solar photovoltaic power plant in Ciudad Juarez (Chihuahua). This power plant will generate around 456,5 gigawatts per hour a year, and is expected to supply electricity to companies of both the private and public sectors.

manufacture of transformers for two new solar power plants in Mexico

The final destination of the transformers, yet another achievment by Genesal Energy’s branch in Mexico, was the Cuyoaco power plant, the first of its kind to be built in this state. The Mexican Government will invest more than 230 million dollars in this project.

Main features

  • 600L double-walled (steel-steel) external fuel tank.
  • Prepared for startup via external command.
  • Winding heaters.
  • Analogical excitation voltmeter and ammeter.
  • Space heaters and thermostat in panel.
  • Paint and painting process according to CFE norms.
  • Electronic speed regulation.
  • DNP 3.0 communication protocol.
  • Third party inspection (BV) of the FAT procedure.
  • Spare parts according to CFE specifications.