We participated in the construction of Cuyoaco, the great solar power plant which will power 163.000 homes in Mexico

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Genesal Energy participated in the construction of Cuyoaco’s first solar park, located in the Mexican state of Puebla and built on a surface of 755 hectares between the municipalities of Cuyoaco and Ocotepec.

The future 200MW photovoltaic power plant will become a reality thanks to the Mexican Government’s 235 million dollar investment, which will allow this region to have access to 730.000 panels to provide cutting-edge renewable energy, offering clean and renewable electricity.

With a total of two substations, one booster and one switching, the construction of the plant has had a great economic impact on the area through the creation of 1.000 jobs.

Genesal Energy will provide all of its experience in the renewable energy sector to this important project, through the design, manufacture and supply of a 395 kVA emergency genset for one of the substations. Specifically, the generator set will support the solar power plant’s booster substation.

Commitment with the environment

Genesal Energy’s focus on renewable energy is evergrowing, both nationally and internationally, and this is because of its great advantages and benefits in the industry as well as the company’s commitment with the environment.

In this case, the Cuyoaco photovoltaic plant isn’t only the first in the region to offer this type of technology, but it will prevent the emission of more than 145.000 tons of CO2 to the atmosphere, and will generate 551 GWh every year, the equivalent of supplying power to 163.000 Mexican homes.

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Features

  • 360-395 kVA soundproof generator set with FPT engine and Mecc Alte alternator (60Hz, 1800rpm, 220/127V).
  • Prepared to operate upon mains failure (automatic start).
  • Genset painted in the colour required by the client (RAL 1021).
  • Monoblock painted in the colour required by the client.
  • Alternator anti-condensation heating.
  • Control panel anti-condensation heating.
  • IB-Lite module for Modbus TCP/IP communication.
  • 1050 L bunded tank.
  • Analogic voltmeter and ammeter.

Genesal Energy supplies emergency power to Cerro Dominador, the greatest solar complex in Latin America, located in the desert of Atacama

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The Galician company designed five special generators to operate in extreme conditions in one of the areas with most solar radiation on the planet

At the top of the Chilean desert of Atacama is Cerro Dominador. Comprised of a great thermosolar power plant as well as a photovoltaic plant, it is the largest solar complex in Latin America, and Genesal Energy participated in its construction through the manufacture and supply of five emergency generator sets designed to withstand the area’s high temperatures.

The units have been manufactured to operate at the top of the desert, in very extreme conditions, both in temperature and height, ensuring a correct level of ventilation at all times while maintaining a comfortable sound level in the thermosolar power plant. That way, the five special gensets guarantee power supply in all of the plant’s installations, from the lighting to the startup of the turbines or the administrative buildings.

Low permeability against sand

Cerro Dominador is located in María Elena, in the region of Antofagasta, one of the areas with the highest solar radiation index in the world. The complex will produce clean energy and, according to previsions, will prevent the emission of 640.000 tons of CO2 a year into the atmosphere, as well as create over 1.000 jobs.

To take power to this inmense complex, Genesal Energy adapted to the areas conditions, as the client needed customized generator sets, of the highest precision, with a low permeability facing sand and other impurities carried by the desert’s wind.

Features

  • Air inlet and outlet silencers.
  • Fans for cooling of the engine-alternator rooms.
  • Air conditioning system in the control room.
  • 2000-3000l double-walled fuel tank, approved under Chilean norms, with fuel transfer system for external fuel supply.
  • Made-to-measure control system logic to power the low and medium voltage systems and integration with the plant’s control system.
  • Motorised louvers to prevent the entry of impurities when genset is off.
  • 1mm aperture mesh to prevent entry of sand and other fine impurities when genset is on.
  • Motorized breaker installed independently to isolate it from vibration.
  • Seismic reinforcements of high reliability in all equipment to support seismic events, which are very frequent in the area.

We’ve supplied 18 new super-soundproofed generator sets to the Chilean market

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In Latin America, as well as in Europe, there are many countries with a growing demand for gensets providing low sound levels (therefore contributing to a greater social well-being), which are also guaranteed to be able to cover power requirements, whether it be for continuous use or in emergency situations.

One of these countries is Chile, a market with great possibilities and in constant expansion in the energy sector (especially in the field of renewable energy), for which we’ve designed, manufactured and supplied a total of 18 super-soundproof gensets.

The generator sets were tailor-made according to the client’s needs, and two different models were designed (five gensets of 500/550 kVA and 12 of 1000/1100 kVA), but with a common denominator: their great level of sound attenuation: 65 dB at seven metres distance at the point of maximum emission.

To achieve this, the engineering team and the sales department, which at Genesal Energy always work hand in hand, kept the basic cooling requirements into account, without surpassing the length and width of the 40’HC shipping container which encases the generator sets.

Double-walled fuel tank

Specifically in the 550kVA unit, we also installed a medium voltage step-up transformer, and in the 1.100 kVA, a 3.000 litre double-walled fuel tank inside the container, as well as control cabinets, silencers, etc.

On the other hand, to achieve a sound level of 65dB it was necessary to decrease the sound levels by 43’5 and 48 dB respectively. To reach this goal, we selected different materials and solutions, some applied in exactly the same way in both models, but others had to be adapted due to the unique characteristics of each unit, which went beyond their engine’s respective power ratings, to be able to comply with the technical specifications requested by the client.

Finally, once the open-field tests of the prototypes had been carried out following the indications and procedure set by the applicable regulations, the results were as follows:

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  • GEN1100TC: 64.5dB (A) at 7m distance
  • GEN550TC: 64.5dB (A) at 7m distance

These are the main features of both models manufactured for Chile by Genesal

GEN550TCGEN1100TC
PRP power500 kVA.
1000 kVA.
STP power500 kVA.
1100 kVA.
Voltage400/230 V + 23kV transformer.
400/230 V
Frequency50 Hz.50 Hz
RPM1.5001.500
Engine brandMTUMTU
Alternator brandMECCALTE WITH PMG.MECCALTE WITH PMG.
TypeSoundproof in 40 HC container.
Soundproof in 40 HC container.
Specific installation roomsThree independent areas
Two independent areas
Fuel tank1.500 L integrated in the base frame.3.000 L double-walled and approved according to Chilean regulations
Sound emission level56,3dB (A) 7m64,5dB (A) 7m.
PaintISO 12944 C5M.ISO 12944 C5M.
CouplingElastic between engine-alternator.
Elastic between engine-alternator.
Control systemCOMAP (possibility for parallel operation).DEIF (possibility for parallel operation).
Circuit breakerSchneider, removable and motorized.Schneider, removable and motorized.
Cooling systemRemovable for maintenance.
Removable for maintenance.

Our power conquers Africa: special gensets to withstand the extreme heat

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Ensuring power supply in isolated areas is one of the guarantees that Genesal Energy provides its clients.

Our gensets are prepared to withstand extreme climate conditions, from temperatures below zero to the highest on the planet.

One of our latest projects has taken us to Africa, a continent full of contrasts and a real challenge from an energetic point of view. In Gambia, Guinea Bissau and Guinea Conakry, we’ve supplied emergency power for electric substations in these three countries. We designed, manufactured and supplied nine completely customised gensets, adapted to operate in the different substations.

We searched for the best solutions for our client which would completely cover their needs, that’s why the nine gensets have been designed to operate in perfect condition in isolated areas and at temperatures of up to 45°C.

Características

  • Spare parts kit for extensive operation.
  • 1000L fuel tanks for increased autonomy.
  • Fuel filters with water separators to ensure operation with low-quality fuel.

We supplied an emergency genset with an aseismatic system for the Carrasco electrical substation (Bolivia)

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Guaranteeing power supply in extreme situations is one of Genesal Energy’s specialties. Genesal’s emergency genset designs are always carried out according to the client’s needs.

The Carrasco electrical substation, in Cochabamba (Bolivia), is one of our latest projects in the country and a great example of seismic engineering.

For the Carrasco substation, the client needed a genset with very specific needs, as the installation is located in a very sensitive area, which is quite vulnerable to earthquakes. With the objective of facing this possibility and avoiding a catastrophe, our engineering team carried out a thorough study after listening to the client and analyzing the site in which the genset would be installed.

Upon receiving all required information, Genesal Energy manufactured a very precise genset, with all the necessary special systems to protect the Carrasco electrical substation. The result is a unit which, amongst other features, has anti-seismic mounts, and spring mounts between the base frame and the floor. A vent for the channelling of the cooling air to the outside, and a 1.700 litre fuel tank -which in this case was reinforced to comply with anti-seismic regulations- are just a few examples of the features of this genset, whose goal is to avoid failures in the mains supply which provides power to millions of citizens, at all times.

Features

  • Anti-seismic mounts.
  • Spring mounts between the baseframe and the floor.
  • Vent for the channelling of the output cooling air to the outside.
  • Reinforced 1700 litre baseframe fuel to comply with anti-seismic regulations (without certificate).
  • IVECO NEF67 TE2A engine at 24V.
  • Mecc Alte ECO 38-2S alternator at a voltage of 380/220.
  • 3400×1350 mm soundproof canopy.
  • RAL 9002 genset colour.
  • IEC61850 communication.

Genesal emergency power for Topolobampo III, the combined-cycle power plant which will provide electricity to 2,5 million Mexican citizens

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The Topolobampo III combined-cycle power plant, located in the Mexican state of Sinaloa features a special soundproof genset, with a control cabinet integrated inside the container, designed and manufactured in our headquarters in Bergondo (A Coruña).

With an investment of more that 400 million dollars, Topolobampo III is the latest great power generation project in Mexico, a country in which our company has a great presence, and where it has had its own branch office for years. The 767 megawatts (MW) combined-cycle power plant, carried out by the Mexican Federal Electricity Commission (CFE), is located in the municipality of Ahome, and will provide electricity to more than 2,5 million citizens. The plant will begin operating in 2020.

Due to our strong presence in Mexico and our knowledge of its terrain, the genset designed for Topolobampo III was adapted to the special conditions of this type of combined-cycle power plant, which contains special loads which must be permanently powered for the correct operation of the facilities. For instance, the lubrication pumps or cooling units must always be operational so that, in the event of an emergency such as a power outage, the whole system can be shut down securely. This is precisely the function of the genset we manufactured for the plant.

Made-to-measure

We designed a bespoke genset, soundproofed in a container which was also tailor-made with specific elements (air conditioning, motorized louvers, fans, etc.), manufactured to adapt to the client’s concretes needs.

Furthermore, the automation of the genset allows the necessary integration of the external ATS and the different switches managed by the genset, so that the start-up and stop sequence expected by the client is followed at all times.

Due to space limits, a fuel capacity of 4000L was integrated inside the container through double-walled fuel tanks to guarantee the continuous operation of the genset for over 10 hours at 100% load. The unit is also designed to start up without the need of any type of external voltage, without needing secure voltage for the control circuit.

Main Features

  • Exterior build: 40’’ HC container suitable for marine transport 
  • Control cabinet integrated inside the container 
  • Engine cooling liquid recirculation and heating system, in order to provide the right temperature for genset start-up. 
  • Air conditioning system in the genset’s control room. 
  • Motorized louvers in the air inlet and outlet. 
  • Redundant fans to control the temperature in the engine room.
  • C51 container surface treatment according to the ISO 12944 standard.
  • Alternator anti-condensation heating. 
  • Temperature sensors in the alternator’s windings and bearings. 
  • 4000L fuel tank integrated in the container with leakage detection. 
  • Management of the genset’s control system and associated systems of the client’s facilities through a controller and touch-screen. 

Toyota chooses a Genesal emergency genset for its factory in Guanajato (Mexico)

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Toyota has trusted in Genesal to deliver emergency power to its Mexican factory in Apaseo el Grande, Guanajato.

The client needed something very specific: a back-up genset for the auxiliary equipment of the switching substation which serves the factory, for which we designed and supplied a 220 kVA special set, capable of providing the necessary support to the factory in the event of a mains failure.

The factory is one of the biggest projects carried out in the Apaseo el Grande municipality and will cause a great economic impact in the area, generating employment for 1.100 people. Furthermore, the installation will complete the production that the Japanese multinational corporation carries out in Baja California, where it currently produces around 170.000 units a year, of which nine out of ten are exported to the United States.

Precision and maximum reliability

In its first stage, this factory will assemble an average of 100.000 units a year of one of their star models: the Tacoma truck. In its second phase, the factory is estimated to produce 200.000 vehicles, reaching 300.000 before the year 2025. According to the company’s estimations, the factory is set to be operational towards the end of this very year.

The design of special generator sets to provide emergency power to great factories has been one of Genesal Energy’s focuses from the very beginning. Likewise, all of our gensets are custom-made after listening to each unique client with the objective to comply with their specific needs. In this case, the unit manufactured for Toyota’s new factory in Mexico has, amongst others, the following features:

Main Features

  • Double-walled 1000L fuel tank for 12 hours autonomy at 100% load.
  • Start-up through external command.
  • Communication system with SCADA System through TCP/IP protocol.

We designed an ‘anti-hurricane’ generator set for a great wind farm in the Dominican Republic

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Our engineering team has designed and supplied emergency power to the Agua Clara wind farm in the Dominican Republic, a large power station capable of providing power to 250.000 citizens.

The wind farm, whose first phase has already come to a close, has 25 wind turbines, of two megawatts (MW) each, which represents an estimated annual production of 170.000 MW/hour. 

With an initial investment of 100 million dollars, the project produces 50 MW of renewable power and the objective is to install up to 200 MW once the four phases of the project have concluded. Genesal Energy has designed and supplied a special generator set, adapted to face the complicated climate of the región of Monte Cristi, where the wind farm is located.

Agua Clara is in a hurricane-prone area, which means the wind farm’s infrastructure requires special equipment capable of facing this type of phenomena. In order to reduce the pressure exerted on a wind turbine by a potential hurricane, it must direct its nacelle and blades with the help of electric and hydraulic motors in such a way that the wind exerts the least force possible on the structure, avoiding harm.

One hundred percent personalized

At the windfarm, the client needed that, in the event of a hurricane or a cyclone and in consecuence, a mains failure, the wind turbines could position themselves correctly and avoid serious damage through the use o fan alternative source of energy. To achieve this, we manufactured a generator set capable of powering the auxiliary services which drive the positioning of the windmills.

The generator which we’ve designed is 100% customised and can be completely managed, controlled and monitored from the wind park’s control centre (SCADA). Inside the actual container, the local control system was installed, along with a PLC to manage communication with the farm’s SCADA through fiber optics, and a protection relay.

Genesal Energy ha diseñado y suministrado un equipo especial, adaptado para hacer frente a la complicada climatología de Monte Cristi.

The Genesal Energy unit will receive start-up and shut-down commands from the wind farm’s control centre and will start-up and energize a step-up transformer. From that momento onwards, the genset will power the whole wind farm and, therefore, the auxiliary systems needed to position each one of the wind turbines to avoid damages in the event of a hurricane.

To compensate the capacitance of the medium-voltage cable runs to the turbines, of hundreds of metres of height, an inductor bank was also installed in the wind farm’s substation. The generator set must power the bank during the first seconds after the hurricane, while the wind turbines and the medium-voltage cable runs aren’t being powered. In order for the generator set to be able to support this strong inductive load, its alternator was oversized, through the installation of a top of the range 3.000 kVA alternator.

Features

  • Engine and alternator pre-heaters.
  • ModBus TCP/IP communicaition.
  • Tailor-made control logic carried out through PLC & DEIF AGC4 controller.
  • Dedicated electrical protection relay.
  • Oversized alternator to support high inductive currents.
  • Automatic fuel transfer system.
  • Special application for an anti-hurricane system in a wind farm.

 

Emergency power for the Los Llanos wind farm, a new source of renewable power

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The first wind park to be raised in the province of Malaga was in the Casares municipality and since then the offer for this type of renewable power has not stopped growing.

Genesal Energy’s focus on alternative and sustainable power has also increased considerably in the last decade, with an ever-growing market, and Andalucía is no exception in our line of business.

This way, one of our latest projects has taken us to the Los Llanos wind park, one of the pioneers in this autonomous community, through the manufacturing and supply of a “turnkey” generator set, made-to-measure for the client, which amongst other requirements, asked that the genset be prepared for remote start-up and that it could provide power to the primary loads in the substation facing a possible mains failure.

The generator set, which will operate in Los Llanos, will start-up remotely when the control system of the substation detects a mains failure because precision is vital in this type of installation where wind is the basic power source.

Features

  • Approved double-walled 1.000L fuel tank for outdoors
  • Baseframe fuel tank prepared as leakage tray
  • Electronic engine speed regulation
  • Signal and alarm remote expansion module
  • Remote start-up

 

Made-to-measure power for a thermoelectric power plant in Sumatra

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We’ve designed, manufactured and supplied one of our tailor-made gensets to the Sumbagut (Sibolga Baru) thermoelectric power plant in Sumatra (Indonesia).

It’s a 400-440 kVA generator set whose goal is to maintain power supply in the event of a mains failure. Our client’s request was, therefore, very clear: the genset had to carry out a basic but vital function: to provide power to the power plant’s emergency loads if ever the mains were to fail.

The genset designed by our engineering team for the Indonesian power plant has, amongst other features, anti-condensation heating in the alternator and control panel and three voltage monitors in order to monitor up to three networks.

Features

  • IBLITE communication module for TCP/IP communication.
  • Approved steel-steel double-walled 2.500 litre fuel tank.
  • Remote signal expansion module.
  • Automatic fuel transfer system.