A wind farm in Baja California, key in Genesal’s efforts towards clean energy

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Baja California is one of the Mexican states with a strong focus on renewable energy, and the San Matías wind farm is one of the latest examples.

The installation, now in its construction phase, will generate 30 MW, and include eight wind turbines of 2,5 MW and 20 MW. Its comissioning, expected in 2021, will improve the lives of Baja California’s inhabitants, including the kiliwas, an indigenous tribe living in Baja California.

At Genesal Energy we participated in the project though the design, manufacturing and supply of two 200-220 kVA gensets. At Genesal Energy, renewable energy is a market in expansion in which we believe, and we position ourselves in the first positions in the ranking with international projects such as those carried out in Mexico, Oman and the Dominican Republic.

Features

  • Engine with electronic speed regulation.
  • Approved, double-walled 2.000L fuel tank for the GEN220F and 3.000L for the GEN220FI.
  • 24V start-up, to comply with CFE standards.
  • Yellow 17 paint, in compliance with CFE standards.
  • Alternator anti-condensation heater.
  • Excitation current and voltage measurement.
  • Control panel heater.
  • DNP 3.0. communication gateway.

We supplied emergency power to the hydroelectric power plants in the Miño-Sil river basin

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At Genesal Energy, we’ve designed and installed generator sets of different power ratings for emergency operation.

The goal was to guarantee the continuous supply to the stream, and to provide electricity to the Velle, Castrelos and CH Frieiras dams in the event of a mains power failure. Before executing the project, we carried out a study to correctly establish the dimensions of the gensets, dimensioning the power rating in each sluice gate keeping in mind factors such as voltage drops and slow speeds.

The result, gensets adapted to the conditions of each power plant. Because at Genesal Energy, we provide made-to-measure solutions. It’s the only way to achieve efficiency and reliability.

Features

450L fuel tank integrated in the baseframe, including a leakage tray with a capacity of 100% the capacity of the fuel tank, and a leakage sensor which sends a remote alarm through a dry contact.

  • Gel batteries to increase the starting capacity (allows 10 start-ups).
  • Ethernet / modbus TCP/IP communication module.
  • The system is designed for 400v and is capable of being regulated to 380v.
  • Alternator anti-condensation heaters in the units installed outdoors.

Special generator sets for substations in Zaragoza

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Special generator sets for substations in Zaragoza.

A special canopy with sound attenuators and a 1.300 L fuel tank for 72 hours of autonomy – at 75% load – is one of the features of the genset we’ve designed for different substations in Zaragoza

It’s been tailor-made for the client and, as such, the unit contains optionals completely adapted to their needs. Genesal Energy’s engineering team has given their all in the project as each order is unique, and each client is special.

Features

  • Special canopy with 1300 litres in the base frame to achieve an autonomy of 72 hours at 75% load. One of them is double-walled.
  • The canopy also includes sound attenuators to decrease the sound level to 68 db(A) at 10 metres.

We continue to reinforce our presence in the Middle East

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Oman has inmense potential in the field of renewable energies, especially solar and wind.

One of our latest projects in this country consisted in the supply of a 500 kVA made-to-measure generator set for a great wind farm.

It’s designed to operate in parallel with the mains, to withstand elevated temperatures and to guarantee the farm’s auxiliary services based on the characteristics of the site itself, installation and operation. At Genesal Energy, we’re able to grow in the Middle East thanks to new projects in countries such as Oman, Qatar and Saudi Arabia.

Features

  • Generator set prepared to operate in parallel with the mains, equipped with a motorized thermal-magnetic breaker for the genset.
  • Alternator with Class B temperature rise and anti-condensation heating.
  • 800L fuel tank integrated in the base frame with leakage tray.
  • Independent, approved, double-walled 4000L with an automatic fuel transfer system.
  • Neutral earthing resistor to limit the earth fault current.
  • Control panel heating system.

More projects in Mexico: emergency power for Topolobampo II

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Another accomplishment by our branch office in Mexico.

We’ve been able to supply a 220 kVA genset under CFE (Comisión Federal de Electricidad or Federal Electricity Commission) specifications. Said generator set will supply power to the Topolobampo II (Sinaloa) switching substation, guaranteeing power to one of the most important ports of entry of the mexican pacific coast.

Features

  • RAL 1021 yellow canopy according to CFE specification W4700-10.
  • 24v starting system.
  • 4 pole & 630A transfer system.
  • Heaters in the alternator’s windings.

Supply of two generator sets for a solar power plant

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Another achievement by our distributors.

We’ve supplied two gensets of 220 and 462 kVA, 220-127Vac at 60Hz, prepared to operate under CFE norms according to the degree of seismicity in Mexico as well as the area’s semitropical characteristics.

With a capacity of 170 MW, the Santiago photovoltaic power plant is located in the state of San Luis Potosí (México). It’s a large complex, whose construction began in 2017 with the participation of 1.000 workers. The power plant was built with the idea of supplying enough electricity to power 138.000 homes.  

Its 672.000 solar panels turn the Santiago power plant into one of the largest renewable energy installations in terms of investment (250 million dollars) and also one of the most spectacular, not only in regards to its size (it occupies 750 hectares), but also to the results its expected to achieve: it was built with the objective of preventing the emission of 340.000 tons of CO2 into the atmosphere each year.

The Galician company Genesal Energy participated in this megaproject through the design and supply of two generator sets of 220 and 462 kVA, 220-127 Vac at 60 Hz, prepared to operate in the area’s special conditions, such as the semitropical climate.

Both units were manufactured in Genesal Energy’s headquarters, located in the town of Bergondo, in A Coruña (Spain), with the goal of guaranteeing the correct operation of the booster and switching substations during emergency situations, providing the power necessary for the auxiliary services, emergency lighting, etc.

Genesal Generator in a solar power plant

High precision

Both gensets are high precision units, whose design has been thought out to the very last detail to comply with the client’s requests. They have the following features:

The first unit (GEN220FC) is soundproof type and has a 500 L fuel tank integrated in its baseframe, while the second (GEN462F) has a 1.000 L fuel tank. Both special gensets comply with all technical requirements established by CFE (Comisión Federal de Electricidad or Federal Electricity Commission) norms, the prestigious certification that the CFE awards and which elevates the company to the category of trusted supplier.

The CFE-LAPEM certification is granted by the LAPEM (Laboratory for Equipment and Materials Testing), an organization dependent on the CFE, and Genesal Energy received said distinction last year upon passing the audit process carried out by LAPEM in the company’s headquarters, thus becoming part of the select group of companies which have been awarded this certification, a true symbol of excellence.

Features

  • GEN220FC 500L fuel tank integrated into the base frame, Soundproof type, and with technical features following CFE (Federal Electricity Commission of Mexico) standards, painting with finish according to CFE norms.
  • GEN462F Approved 1000L double-wall fuel tank for external installation, with technical features following CFE (Federal Electricity Commission of Mexico) standards, painting with finish according to CFE norms.

 

We supplied two “turnkey” generator sets to the biggest combined-cycle power plant in Jamaica

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One of our latest projects in America has taken us to Jamaica.

We’ve had the pleasure of participating in one of the largest engineering projects in the island, the Old Harbour Bay combined-cycle power plant, the biggest in the country, for which we’ve designed and provided two special gensets.

Located in the fishing port of Old Harbour Bay, at almost 100 kilometres from Kingston, the 190 MW power plant is designed to operate with two fuels, gas and diesel, and uses a seawater cooling system. In this type of power plant there are special loads that must be fed permanently for the correct operation of the installation, for example, systems from the water treatment plant or the pumps from the lubrication units. These elements must continue operating so that, in an emergency situation such as a power outage, the whole system can be safely shut down. This is precisely the job of one of the gensets supplied by Genesal Energy.

The other is a Black Start unit, whose purpose is to power a motor in charge of the rotation of the main turbine, an element used for the cold start of the turbine after a programmed shut down. Furthermore, this genset has the particularity of supplying medium voltage directly (6600V).

Our client requested that both gensets be managed, controlled and monitorized completely from the genset’s control panel. The control philosophy consists in the diesel generator set being connected to the main power panel which is connected to the power busbars of the installation’s special loads -in the case of the emergency unit- or of the gas turbines – in the case of the Black Start unit.

Adapted to the client’s needs

For the implementation of this control system, a PLC was integrated in order to manage all of the elements of the generating installation, as well as a protection relay and a synchronizer for parallel with mains operation.

Both units were designed according to the client’s needs: special sets with a turnkey service. This way, each genset is soundproof and installed in a completely adapted container which includes all of the elements requested by our client (air conditioning, fans, motorized louvers, fire detection systems…).

Where we’ve had the pleasure of participating in one of the largest engineering projects in the island, the Old Harbour Bay combined-cycle power plant.

Features

  • Power panel integrated in the same soundproof container. In the case of the Black Start set, they’re Medium Voltage Switchgear.
  • Recirculation and heating system for the engine’s cooling liquid in order to provide the correct temperature during engine start-up.
  • Air conditioning system in the genset’s control.
  • Motorized louvers.
  • Fans in the engine room to keep the temperature under control.
  • Superficial treatment for the container according to the ISO 12944 standard, with a C5I coating.
  • Anti-condensation heater in the alternator.
  • NFPA fuel tank
  • Management of the genset control system and associated systems from the client’s installation through a PLC and a touch-screen.
  • Protection relays and mains analyzer for the generator.
  • Fire detection system integrated in the client’s installation’s detection loop.
  • Fire extinction system through water sprinklers.

We designed the gensets for two biomass power plants: the Viseu and Fundão power plants, in Portugal

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Genesal Energy has designed and supplied two special gensets for two biomass power plants in Portugal

The Viseu and Fundão power plants, two twin installations which, according to experts, will prevent the emission of 88.400 Tn of CO2 to the atmosphere. Both are a prime example of clean, renewable energy production.

Biomass power plants are thermoelectric power plants that use organic matter as fuel, whether it be of plant or animal origin, susceptible to being used for power purposes. These installations generate electricity through the combustion of the biomass to heat the steam in boilers. The steam, in turn, moves a turbine which spins a generator, which transforms the electric power into mechanical power.

As this process relies on combustion systems, great quantities of power are needed to cool the power plant’s systems to guarantee its operation.

  • Power plant generator
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Slow combustion

In the event of a mains failure, the biomass power plants must be brought to a safe shut-down. To achieve this, it’s neccesary to maintain and power different cooling systems in order to avoid material or personal damages due to the overheating of the systems as, by its own nature, biomass combustion is a slow process.

In the event of a mains failure, this type of installation must be brought to a safe shut-down

If an electrical failure arises in this kind of power plant, the biomass inside its boilers will continue to burn, generating thermal power which won’t dissipate if the cooling systems aren’t operational. At Genesal Energy, we designed two units for these plants capable of starting up when a failure to power the essential services’ busbar is detected.

If the genset in question starts up and starts powering loads, the power plant will be in the process of shutting down and during this time it’s fundamental the cooling systems be active.

This way, when the genset is powering loads, even if mains returns, the power plant operator is the only one who can stop its operation and bring back mains power, guaranteeing that the shut-down process is always carried out in safe conditions.

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Maximum security

On the other hand, each of these units has different security systems which prevent the control over the breakers that power the essential systems’ busbar by other systems which aren’t the actual genset, in order to avoid short circuits due to errors in the operators’ handling.

The manifactured units are capable of starting up as soon as a failure to power the essential services

The only moment in which a system other than the genset can control the busbar’s mains breaker is during the power plant’s start-up, as in that moment the genset won’t be active.

Technical Features

  • Remote control panel in the installation’s electrical room
  • 1000 L base frame fuel tank
  • Fuel filler neck on the outside of the container
  • Installation in a 20” soundproof container with an air outlet silencer to achieve a sound level of 85dB at 1 metre
  • Communication via MODBUS TCP/IP with power plant control system
  • Integrated web server with access from the power plant’s control system
  • Genset load system in a sequence of up to 14 steps.

We designed 11 gensets for three combined-cycle power plants in Bolivia that will increase the electric power in the country by 50%

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Three combined-cycle plants located in three different departments in Bolivia, Tarija, Santa Cruz and Cochabamba, will increase electric power by 50% in the Andean country.

The project will not only improve the efficiency and availability of electricity in Bolivia, but it will also improve its economy and the overall environment, and Genesal has contributed towards this ambitious initiative by supplying 11 generator sets. Four have been installed in Tarija, another four in Santa Cruz and three in Cochabamba.

In this type of combined cycle power plant there are essential loads that must be permanently supplied power to in order for the installation to operate correctly. This is the case, for instance, of systems from the water treatment plant or the pumps from the lubrication units, which must continue operating so that, in the case of an emergency such as a power outage, the whole system can be safely shut down. This is precisely the task carried out by nine of the eleven supplied gensets.

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Two of the gensets are Black Start units, whose objective is to provide power to one of the most important elements of the gas turbine: the turning gear.

The remaining two gensets are Black Start sets whose purpose is to power one of the most important elements of the gas turbine, the turning gear, an element used for the cold start of the turbine after a programmed shut down.

The turning gear rotates the turbine rotor at a very low speed to ensure a slow and uniform cool down, in order to avoid any thermal deformations.

Genesal’s solution

Our client requested the gensets be completely managed, controlled and monitorized from the control panel. A control philosophy was implemented whereby the diesel genset is connected to the electric panel and said panel is connected to the installation’s essential loads’ busbars (in the case of the emergency gensets) or to the gas turbines (in the case of the Black Start gensets). For the implementation of this system, a PLC was installed in order to manage all the elements of the generating installation, as well as a protection relay and a synchronizer for the parallel with mains operation.

Therefore, we designed each soundproof genset in its respective container with diverse elements ranging from air conditioning to fire detection systems, motorised louvers, fans… all thought-out and tailor-made following the client’s needs,

Each genset is made to be integrated and coordinated with the elements of the power plant its installed in. Furthermore, the emergency system can be completely controlled by the central PLC.

Genesal Energy has supplied an emergency genset for the combined cycle power plant (CCPP) known as Empalme II, a huge engineering project in the Sonora State of Mexico

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Back start 2,000 kVA genset

Empalme II is a thermal energy combined cycle power plant with 2 gas turbines and output peak level of 791 MW, an initiative led by the Federal Electricity Commission (CFE in Spanish) of Mexico. Empalme II is a fantastic example of a large-scale engineering project in Sonora State, of which Genesal Energy has had the privilege of participating in. Our role has been to install a black start 2,000 kVA genset, whose purpose is to restore full functionality and start up of the power plant in the event of a mains power cut. The genset has been developed uniquely for this customer and as part of the overall project.

Back start 2,000 kVA genset

Alongside Chihuahuha and Baja California, Sonora is a reference in Latin America as a whole for the commissioning of projects which promote the use of renewable energies. In installations such as Empalme II, whose investment borders on $400 million, the inclusion of gensets is fundamental. This is for a variety of reasons, for example in CCPPs there are essential loads which must be permanently supplied with power for the correct functioning of the installation.

At Emplame II one of the most important loads is for the turning gears or barring gears, consisting of an electric motor which turns the turbine shaft at low speed to ensure balanced cool down and avoid rotor bending or “hog”. In terms of automation, the client asked for System Control And Data Acquisition (SCADA) to be available in the main control panel.

How does it work

In these cases, the emergency genset is connected to the main electrical power cabinet, which at the same time is connected to three different busbars, feeding the panel for general essential services and the essential services for the 2 gas turbines. In an emergency, the genset will feed the essential loads in the power plant and will even be capable of identifying each busbar individually, permitting it supply energy either individually or together.

To correctly install this system, Genesal Energy proposed a redundant PLC using 2 computers, so if one should breakdown, the other will immediately and automatically take full control of the genset, without any noticeable change in the rest of the power plant. Additionally, protection relay was installed and a synchroniser allowing parallel operation with the mains grid. The genset also includes an electrical control room with air conditioning, fire detection and suppression system that can differentiate where it will operate in the genset using FM200 gas agent.