Designing and supplying efficient energy for a Spanish paradise: The island of Ons

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Genesal Energy has designed a diésel generator to supply green energy to the Island of Ons, one of the most beautiful tourist destinations in the region of Galicia in northwest Spain. The Island is a protected reserve within the National Park of the Illas Atlanticas, and due to its situation, it is completely isolated from the mainland power grid.

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It was for these reasons that our team of inhouse engineers along with our R&D department created a “different” type of electrical generator, focused on taking great care with the local environment. The tailormade end product entered into operation in the summer of 2017. The generator has been designed to supply energy for the camping site situated on the upper part of the island. The site occupies an area of 8,000sq metres with a capacity for 276 people.

Considered the first self-sustainable camping site in the Galician region, the site already incorporates a system of solar panels to provide electricity. Yet, due to the limited hours of sunshine in this part of the world and the characteristics of the camping site, it has been deemed essential to ensure a round the clock power supply, and for that supply to be sustainable.

The solution designed by Genesal Energy, and in collaboration with Magaral engineering, is made up of a 60-66 Kvas genset in a 2900mm long soundproofed cabin. The genset high attenuating silencer for the exhaust pipe, not to mention many more specifications that make this much more than a conventional electrical generator. In fact, the word unique would be the most appropriate in this case.

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The fitted engine for the genset was chosen according to the highest standards possible in relation to quality and established legal norms, ideal for a natural reserve as such is the Island of Ons. The genset supplies electricity, green energy and reduces by up to 50% atmospheric emissions. Also, the extra soundproofing qualities ensure a peaceful coexistence with the campers, especially at night time.

The real difference comes from the specialised system designed and incorporated in to the genset solution, which uses the heat and waste gases generated by the genset to provide sanitary hot water for the camping site kitchens, bathrooms and day to day activity on the campsite. It entails using a thermostatic controlled system to reuse waste gas for heating water. IN this case, unique really means unique.

Having to move the genset to an isolated island off the Galician coast meant overcoming two challenges:

  • Logistic: The movement of a 1000 Kilo genset and components, which was executed by boat.
  • A protected nature reserve with no mainland power supply:  As opposed to an emergency standby power generator it was important to provide a solution that covered needs continuously if necessary and fully respecting the surrounding environment. Mission accomplished!

DOWNLOAD PROJECT INFO HERE

Energy with remote control modules for the French bank Credit Agricole, a leading European high street bank.

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Leading European banking institution Credit Agricole with their headquarters in France and a strong presence in Spain has put their trust in Genesal Energy to carry out a project from the design stages to execution in order to supply emergency power in one of their key branches in the famous Paseo de la Castellan in Madrid.

Not only are Credit Agricole a key credit supplier in France, they are also one of Europe’s biggest banks, and manage more active assets than any other bank on the continent. They are also Europe’s biggest insurer and financer of large projects.

The project undertaken by Genesal for CA consisted in supplying two emergency gensets, each with a rating of 630kVA. The gensets were to form part of the overall electrical set up within the building, and have been set up to start up automatically should the mains electricity supply cease to operate, and therefore guarantee the ongoing operational status if the bank.

In this particular case, as the end user is a major international bank, it is essential to have a back-up power system as the knock-on effect to the whole business in the event of a power loss can cause complex issues to arise. This particular site needs to be powered 24 hours a day, there is no margin for error.

Any time, any place

The gensets supplied by Genesal Energy have been designed to incorporate a remote-control communication module, permitting start up and switch-off of the gensets online at any time from any location on the planet.

This type of communication system also allows for preventative maintenance to be carried out. Using a communication card, Genesal’s technical service department can visualise all the different parameters of the gensets. This permits instant recognition of potential alarms or anomalies that may occur in the future. This type of real time instant detection means Genesal Energy can ensure the gensets never reach a critical point which may affect their ability to function correctly.

Additionally, the gensets have been soundproofed so that they could be installed on the rooftop, and as such minimising the acoustic contamination in the vicinity.

TECHNICAL DATA

  • Prime Power: 570Kva
  • Emergency Power Rating: 630Kva
  • Voltage: 400/230V
  • Frequency: 50Hz
  • RPM: 1,500rpm
  • Dimensions: 5000mm x 1886mm s 2356mm
  • Weight: 5,680 Kg
  • Modbus TCP/IP communication protocol
  • Electronically adjusted engine

Genesal Energy Electrical Generator, dual voltage and dual frequency

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500-550 KVA / designed for industry leader in cold storage installations for the South American market.

The client, an industry leading company in cold-storage facilities, had a special request: On the one hand, they needed and emergency backup power option for their manufacturing plant at 50Hz. However, they also need an alternative energy source to carry out testing on machinery (freezers, water recovery systems etc) at 60Hz for products which would be sold to Latin American markets. Because of the different voltage and frequency used in Central & South American countries the power grid in the client’s European base prevents them from testing products in authentic conditions. Hence the reason for an alternative power source to allow testing in the conditions found in Latin American markets. It was for these reasons that GENESAL ENERGY designed a “dual frequency” solution to meet all their needs.

GENESAL ENERGY developed a specific project to ensure a power supply with two power supply functions:

  • Emergency back up to provide electricity to the clients European manufacturing plant in case of a power grid failure.
  • Provide an electricity source for testing machinery built with different voltage and frequency.

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PROJECT SUMMARY

Design and manufacture of a 500-550 KVA genset to operate in emergencies, giving an independent power supply in case of a power grid failure to two workshops at 400/230 V 50Hz. At the same time, it will also give a power supply to a testing bench at 400/230V 50Hz or 460/266V 60Hz in manual mode.

PROJECT OBJECTIVES

Was to design a genset with three operational modes:

  • Emergency power for workshop 1 at 400/230V 50Hz
  • Emergency power for workshop 2 at 400/230V 50Hz
  • Power supply for a testing bench at 400/230V 50Hz or 460/266V 60Hz

SOLUTION

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We opted for a newly designed 4500mm long canopy, with a view to easy access for maintenance and mechanical operations, along with an 800l fuel tank integrated in the base frame, to ensure a constant power supply for extended periods before having to refuel.

Only one control panel was installed for the entire control of all operations required from the genset, and at twice the size of a standard genset control panel This was integrated in to the interior of the genset with a front access window panel for visual access, although for safety and security, access is only gained by the authorised key holder to the control panel

TECHNICAL SPECIFICATIONS

  • Prime Power: 500 KVA
  • Standby power: 550 KVA
  • Frequency : 50Hz/60Hz
  • RPM: 1500 /1800
  • Dimensions: Length 4515mm, width 1710mm,
  • height 2260mm
  • Weight: 4510 kg

SPECIAL CHARACTERISTICS

  • Dual voltage and dual frequency
  • Modbus TCP-IP (IB-LITE) communication device
  • Oil extraction pump
  • Automatic start up in case of grid failure
  • 800L internal base frame integrated fuel tank with
  • connections for future link to external fuel tank
  • Up to 11 hours of autonomy at 80% load, or 18
  • hours at 50%.
  • Battery disconnector

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DOWNLOAD PROJECT INFO HERE

Genesal Energy supplies a fully operational Containerized Power Supply for a Mobile 3D Radar System

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The objective of this project was to supply fully operational power source for a Radar system. The energy solution would supply independent electric power for the normal operation of a Tactical Radar System, with no requirement or dependence on other energy sources.

The Containerized Power Supply solution consisted of 2 gensets of the same type and model installed in a ISO-10’ container, each genset consists of an engine, alternator, fuel tank, switch panel, synchronisation and control panels, network monitoring and an Uninterruptible Power Supply (UPS).

In situations where the Radar System is deployed in places with a power supply, the Genesal System has been fitted with the capability to fully monitor the external power supply, and in case it should fail, switch to the emergency power supply or UPS. Should this situation occur it entails one of the gensets within the container initiating its operational sequence and consequentially ensuring a continued power supply to the Mobile Radar System. The Genset will operate for as long as the external power supply is off-grid.

OVIDIO ALDEGUNDE

Our commitment with R&D allow us to offer the best energy solutions for the military and defense application. We have the expertise needed to adapt each solution to every specific necessity of this field, always with the most strict confidentiality that this projects required.

GENESAL ENERGY military gensets are compact, light, silent and easy to transport. They are ready to operate under the most extreme weather conditions, guaranteeing the power supply in all tactical situations.

 Some features of our military generating sets are:

  • Super-silent, for shelters.
  • Trailer-mounted for easy transportation.
  • Water-cooled or air-cooled.
  • AC or DC generators.
  • Compact and lightweight.
  • Wide range of powers available.

DOWNLOAD PROJECT INFO HERE

Power supply for Spain’s most important Nuclear Power Plants

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LOCATION: NUCLEAR POWER PLANTS, SPAIN (COFRENTES, ALMARAZ and TRILLO) 

INSTALLED POWER: Prime power 630kVA; Standby power 700kVA; 400/230V 50Hz with output factor of 0.8.

Special Configuration: Gensets, control panels, changeover control and power panel, connection panels, fuel transfer pump, specially built to withstand earthquakes as per seismic definitions and norms stated in “IEEE 344 Standard for Seismic Qualification of Equipment for Nuclear Power Generating Stations”

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PROJECT AIMS

The goal of this project was the successful installation andl start-up for 3 gensets with their respective control panels to provide power for the ALTERNATIVE EMERGENCY CONTROL CENTRE (AECC) in the three distinctive Nuclear Power Plants. The focus was on a fully integrated star to finish project and included the; design, documentation, manufacturing, testing, seismic certification, supply, and logistics.

In the after math of the Fukushima-Daiichi Nuclear Power Plant incident in Japan during the tsunami of 2011, the Western European Nuclear Regulators Association (WENRA) defined amongst other factors, the stress tests to be carried out in European Nuclear Power Plants.

As a result of these evaluations the Spanish Nuclear Safety Council (CSN) requested that each nuclear power plant should create an alternative centre to implement and continue emergency operational management should a situation arise forcing the evacuation or abandonment of the Centre for Operational Support and the Technical Support Centre, and as determined by the assessment of the power plants director. The CSN determined that the implementation of the ALTERNATIVE EMERGENCY CONTROL CENTRE (AECC) should be carried out in all the Spanish nuclear power plants.

PROJECT DETAILS

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This particular project was developed in the first half of 2015. The initial study of the technical specifications and the preliminary designs were undertaken during the last quarter of 2014. GENESAL was finally awarded the contract by the client in early 2015. On the date the contract was formally agreed a meeting was held to launch the project in the clients offices during which the project timing and delivery, stages, documentation and the steps necessary to reach a successful conclusion, were established.

As we were dealing with a “critical” project, classed as a last resort energy powered solution in the event of the requirement to shut down the nuclear reactor due to an emergency or natural disaster, we focused the first stage of the project on the development of prototypes of each individual generator. This then led on to seismic resistance testing for the gensets based on the estimated seismic activity levels which could occur in their operational location. The results determined that the Genesal prototypes were able to withstand this potential seismic activity and continue functioning correctly after a potentially serious incident.

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During the design phase of the prototypes, we undertook a serious of diverse seismic studies with the collaboration of the Mechanical Engineering department of the University of La Coruna in North West Spain. Simulations were carried out to study the behaviour of the different control panels, floor fixings, and the genset support frame with a 700 litre fully enclosed fuel tank. Upon completion of the testing and simulation, and with the design approved by the client, we constructed the pro-types. These were subsequently sent to a laboratory specialising in vibration where seismic testing was done and validated satisfactorily allowing for production of the final product in series.

SOLUTION

Upon completion of the gensets and their validation by the CSN (Spanish Nuclear Safety Council), they were installed in the ACEM (Alternative Centre for Emergency Management) in a specially designed room for the genset and associated control features. The genset and control elements then went through the start-up procedure and were incorporated into the management systems of the power-plant.

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SEISMIC TESTING

As determined by the “IEEE 344 Standard for Seismic Qualification of Equipment for Nuclear Power Generating Stations, and the seismic response spectra as provided by our client (which reached 3g, we carried out the seismic validation testing procedures of all the equipment involved for each individual nuclear power plant using two different methods:

• A computer simulation was carried out with the University of La Coruna in North West Spain. The following – components were tested:

– control panels,

– changeover control and power panel,

– connection panels,

– secure floor fixings

– fuel transfer pump

Once manufactured, all the parts were sent to a laboratory specialising in vibrations to seismically validate and certify them in accordance with the requirements of IEEE 344. We should highlight that upon successful completion of the testing all the parts used were disposed of as they are now not considered apt for end user facilities, and new identical parts are built.

• In the case of the Genset as a whole, due to the elevated investment required, the validation of each unit was carried out through simulations, calculations and reports on finite materials. Testing requirements were in line with those as determined by the standards incorporated in IE344 as well as the Eurocodes standards for structural design in order to calculate the legs and the secure floor fittings.

More information here

Super-compact GEN33D Power Generator

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Application: auxiliary power generator for special vehicles.

Power: 30 kVA DC, 33 kVA emergency supply.

Special configuration: super-compact power generator.

SPECIFICATIONS

  • The power generator has to be installed in a small compartment measuring only 1105 x 950 x 750 mm (length x width x height).
  • We have to adapt the installation to the existing air inlets and cooling air outlets in the vehicle.
  • The power generator has to have a power of at least 30 kVA.
  • Integration with the vehicle’s electrical system.
  • High cooling capacity and ability to work with overloads at high temperatures.
  • Capable of withstanding the typical motion of a vehicle of this kind over rugged terrain.

CASE STUDY

A series of questions have been raised at engineering level:

We have been informed of the need to provide power for high-tech auxiliary electronic equipment located in a special vehicle. The equipment has to be able to operate during long daily periods under adverse conditions (high temperatures), with a load of practically 100%.

Its position in the vehicle must ensure that maintenance can only be carried out from one side, as the outer housing is armoured, and only one of the protective covers can be removed. The air outlet must be located on the top, and the air inlet on the bottom, due to the design of the vehicle.

The ultra-compact layout of the cabin and size/power of the motor means that we have to consider a design in parallel to the monoblock, with a power transmission using a toothed belt. The bottom support for the power generator must also be as low as possible to avoid exceeding the necessary height, which means that the crankcase must be at a distance of only 10 mm from the ground, and the bottom support must have an opening so that it can be fitted in place. A series of anti-vibration mountings have been installed to prevent shearing, which are capable of withstanding the movements and acceleration caused by the vehicle during its normal operation.

Finally it has been decided to use a refrigeration system using an oil-cooled motor instead of a more conventional water-cooled motor. These oil-cooled motors can reach much higher operating temperatures, under the same environmental conditions. In a conventional water-cooled motor, the maximum temperature that can be reached by the coolant is normally 100ºC, while in the case of an oil-cooled motor, this temperature can reach 135ºC, which means that the equipment can operate at environmental temperatures of 50ºC without any loss of performance. Also, there are two funnels for channelling the inlet air (cold air from the bottom part) and outlet air (hot air from the upper part), so that the air circulates correctly and cools the equipment properly.

The electrical installation is supplied separately and in different modules, so that it can be integrated into the vehicle’s control panels that allow it to be controlled from the interior, even if the equipment is installed in an external compartment.

 Super-compact GEN33D Power Generator

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GEN80FC – Extra Soundproof Genset

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CHARACTERISTICSGen80FC-2

Extra Soundproofed Genset

Power: 80 kVA COP, 100 kVA PRP & 110 kVA STANDBY

Project: Data Processing Centre, Abanca.

Location: Paseo de Recoletos – Madrid

SPECIFICATIONS

  • Diésel genset with 65dB(A) sound measurement at 1M distance.
  • Integrated silencers on the air intake and the exhaust.
  • Double thickness sound absorbing rock wool as standard issue for the entire enclosure including the base.
  • Electronic Engine Control Unit installed, which guarantees a more stable performance.
  • Alternator provides voltage stability of ±0,5%.
  • Card for Modbus set up.
  • Sub base fuel tank for a 20 hour plus autonomy at COP rating.
  • Integrated fuel level sensors for automatic fuel transfer management.
  • Extra addition of silent blocks to add to those mounted between the bench frame and the engine-alternator mono block, in order to eliminate any residual vibrations once installed in the building interior.

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CASE STUDY

In the engineering side we had to consider various needs.

On the one hand, and due to the unusual location of the genset inside a building in the middle of Madrid, it was necessary to ensure a genset design solution which met with the local regulations pertaining to legally permitted acoustic levels. Genesal’s engineering department proposed the manufacture of a specially built genset to comply with Madrid’s legally permitted acoustic levels. This involved several key design aspects such as extra thick walls on the genset enclosure, silencers integrated in to the air intake and exhaust systems, as well as sound proofing the base frame. This led to the development of a one piece completely enclosed mono block. Additionally Genesal went a step further and researching the need for added silent block anti-vibration parts to the standard number used in manufacture, to eliminate residual vibrations that may increase the noise output.

This was not the only consideration. Genesal’s engineers correctly assumed that the complexity of the location required a unique fuel transfer and control system for the loads to be handled by the genset. This required a fuel tank to be situated in the basement of the building, and a controlled transfer method to be installed. A special alternator was added to guarantee very high stability at different frequencies regardless of the genset load levels, with an added electronic engine speed control unit (ECU) to ensure continuous stability.

GEN80FC – EXTRA SOUNDPROOFED GENSET

ÁLVARO CUNQUEIRO HOSPITAL

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LocalizationNUEVO HOSPITAL DE VIGO

Situated in the city of Vigo, north-west of Spain, the new hospital Álvaro Cunqueiro covers an area  of 280,000 m², has beds for 1465 patients and will provide healthcare servides to a population of 600,000 people.

Requirements

The customers asked GENESAL ENERGY for a full back-up energy solution in case of a mains failure, to cover a total of 11.2 MW (14,000 kVA) with automatic start system and conection to the SCADA room. The solution needs also to comply with high noise attenuation standars to not affect the normal functioning of the hospital when running.

Solution

Hospital Vigo generadorGENESAL ENERGY designed, manufactured and commissioned eight gensets to provide the hospital with the 11.2 MW needed:

  • Six GEN1875H (1875 kVA/1500 kW)
  • Two GEN1375H (1375 kVA/1100 kW)

With the following special features:

  • Automatic start upon mains failure with 3-phase monitoring of mains.
  • Full control system and automatic transfer switchboards.
  • Modbus communication between generator and SCADA room.
  • Maximum sound attenuation through -40dB silent exhaust system and sound attenuator.
  • Automatic fuel transfer system between each individual fuel tank and the main fuel tank of the facilities.

BenefitsGenerador Hospital Vigo

GENESAL ENERGY provided the customer with an fully automatic and an over-the-top reliable solution, designed under a strict specification sheet, both for safety and comfort.

 

 

 

Supply and installation of an adapted genset for the airport of La Coruna in Northwest Spain

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