Tag Archive for: Genesal Energy

Mobile power for airport environments: reliability and regulatory compliance at Manchester Airport

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Airports require flexible energy solutions capable of meeting operational needs across different areas of the infrastructure, sometimes far from fixed power sources.

Genesal Energy has designed and supplied Manchester Airport with a mobile generator set delivering power wherever it’s needed, quickly and efficiently.

A GEN440VA Open generator set model was designed to operate as a portable solution within the airport environment. Compliant with European Stage V emissions regulations, the unit can be moved and used across different areas without restrictions, facilitating its integration into maintenance and support operations.

Mobility, efficiency and regulatory compliance

Supplying power autonomously across different airport locations, this set reduces the need to move heavy machinery or install complex installations. This design helps optimise response times and improve efficiency in maintenance tasks, while also contributing to reduced operational costs.

Compact design with high performance

Genesal Energy engineering team developed a design with compact dimensions and an optimised configuration to facilitate transport and operation.

This set reduces the need to move heavy machinery or install complex installations.

It includes a 750-litre bunded fuel tank with leak tray, ensuring high autonomy. Also, an additional silencing system enables compliance with the acoustic limits set by the client.

The unit is completed with a Deep Sea DSE8610 control system, an 800A circuit breaker suitable for synchronisation, a heater to improve starting performance, and sockets adapted to the UK standard, among other elements. These features ensure reliable operation and seamless integration into the airport’s operational environment.

Features

  • Open generator set compliant with Stage V regulations.
  • Silencer GT MX175.
  • Deep Sea DSE8610 MkII control panel.
  • Fuel tank with spill containment tray and 750-litre capacity.
  • Hotstart 2000W heater.
  • Eaton 800 A circuit breaker, suitable for synchronisation.
  • UK-standard control panel sockets, type G.
  • Battery set with easily accessible isolator.

Genesal Energy equips a combined-cycle power plant in Brazil with two high-power, high-autonomy generator sets

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Genesal Energy has designed and supplied a solution for a combined-cycle power plant located in Brazil, which uses gas from the Azulão field in the Amazon basin.

This project is based on the premise that thermal power plants require reliable energy sources at all times to maintain full coordination and operation of essential equipment in the event of any grid disturbance.

The project consisted of the installation of two GEN2750YC generator sets as contingency system.

Operational continuity under any circumstance

In power generation environments, incidents such as voltage fluctuations, supply interruptions or unscheduled maintenance shutdowns may occur. In such scenarios, generator sets are activated to keep essential systems running until the main supply is restored.

Tailored engineering for high power and autonomy

The Genesal Energy engineering team developed a solution based on two 2,750 kVA units installed in 40ft HC Containers. The engine-alternator assembly is mounted on a steel base frame with elastic coupling, contributing to improved stability and performance.

This project is based on the premise that thermal power plants require reliable energy sources at all times to maintain full coordination and operation of essential equipment in the event of any grid disturbance.

To ensure high autonomy, each unit is equipped with an integrated 1,500-litre fuel tank, complemented by an external 7,500-litre tank, enabling up to 17 hours of continuous operation at full load. The system is completed with 2.2 MW load banks housed in independent containers, one for each generator set.

As part of the project scope, key elements have been included to enhance system safety, operability and maintenance:

  • Alternator terminal box with IP45 protection rating.
  • Container with 120-minute fire resistance.
  • Complete external fuel storage system of 7,500 litres.
  • Piping for connection to the external tank using double-wall flexible piping.
  • 2,200 kW resistive load banks in containers for outdoor installation.
  • Spare parts list for 2 years of operation.
  • Anchor bolts for container fixation.

The advanced control system is based on the ComAp InteliGen range of controllers with Siemens PLC, 15-inch HMI, battery charger and redundant power supplies, ensuring high operational reliability and integration into critical systems.

The units have also undergone specific testing, including 8-hour continuous operation at full load without exceeding thermal limits, open circuit characteristic (OCC) testing, and noise level verification.
The scope of supply includes factory acceptance tests (FAT) with client presence, project technical documentation in English, operation manuals in Portuguese, and delivery of the final Databook.

Commissioning services

The project was completed with on-site commissioning supervision services for 4 days, training in Portuguese, and technical support.

Features

  • Construction type: Engine-alternator monoblock in 40-foot High Cube container.
  • Integrated tank: 1,500 L double-wall approved steel.
  • Day tank: 7,500 L double-wall approved steel (1 per unit).
  • Silencer model: 2x MSR250 (- 30 dB) TYPE A STAINLESS STEEL.
  • Generator and load bank circuit breakers SIEMENS 3WA1240-4CE01-1AA0.
  • Control panel ComAp InteliGen 1000.

Mobile Back-up Power for Extreme Conditions in Saudi Arabia

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Saudi Arabia is characterised by vast desert areas, extremely high temperatures and significant levels of airborne dust. These harsh conditions pose a major challenge for any electrical system, where reliability and mobility of power supply are essential to maintain continuous operations.

Genesal Energy developed a project specifically tailored to this environment, based on multiple truck-mounted generator sets designed to operate reliably even under the most demanding circumstances.

A Mobile and Autonomous Solution

The client required an agile, reliable and robust power source, capable of moving across Saudi territory and operating without interruption in critical situations. Furthermore, the generators had to withstand particularly challenging environmental conditions, including temperatures exceeding 55°C and high concentrations of airborne dust.

In response to these requirements, the engineering solution consisted of designing 18 truck-mounted generator sets capable of providing immediate back-up power in the event of grid failures, maintenance operations or emergency scenarios.

Designed to operate reliably even under the most demanding circumstances.

Each unit is equipped with a 450-litre stainless steel fuel tank, providing more than 24 hours of autonomy without refuelling and ensuring continuous operation in critical situations.

These units were built with oversized components, special filtration systems and optimised ventilation systems suitable for high temperatures. They also incorporate exhaust gas treatment systems, automatic changeover switches for adaptation to different electrical networks, motorised cable reels providing up to 25 metres of power output, quick-connect Powerlock outlets and a multi-connection box, ensuring maximum operational versatility.

Among their additional features are rotating warning beacons, reflective elements for enhanced night-time visibility, extendable ladders, fuel and oil level indicators, and external drainage points for fluids.

Tailored Engineering for Reliable Performance

Genesal Energy’s engineering team adapted each generator set to the specific environmental conditions, ensuring the solution was agile, durable and fully operational under extreme circumstances.

This project reinforces Genesal Energy’s commitment to delivering reliable power wherever it is needed most — even in the world’s most challenging environments.

Features

  • Special canopy manufactured to client specifications
  • External lighting and rotating warning beacons
  • Reflective markings for night-time visibility
  • Fuel, oil and fluid level indicators
  • External drainage outlets
  • Motorised cable reels for four cables up to 25 m
  • Quick-connect Powerlock connections
  • Automatic voltage changeover switches
  • Heavy-duty air filter
  • By-pass fuel filter with water separator
  • Anti-shear mountings
  • Side and extendable ladders
  • Door retainers
  • Stainless steel fuel tank

Large-scale power backup: delivering a megaproject for telecommunications infrastructure in Latin America

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Telecommunications networks require a continuous power supply to ensure connectivity and service operability, particularly at remote sites or in locations exposed to demanding environmental conditions.

In this context, Genesal Energy has taken part in a large-scale project, supplying a total of 55 generator sets specifically designed to guarantee service continuity in the event of any grid disturbance.

The project involved the manufacture and supply of a significant number of units with different power ratings, aimed at reinforcing critical telecommunications infrastructure distributed across Latin American territory.

An engineering challenge: autonomy, modularity and robustness

The main technical challenge of the project lay in the design of the baseframe and fuel system. The client required a solution that would allow the fuel tank to be easily decoupled from the rest of the canopy, facilitating transport and installation of generator sets that need to be partially installed by helicopter in areas inaccessible by road.

This requirement led Genesal’s engineering team to develop a special baseframe, more complex than usual, capable of ensuring a robust connection while remaining easily dismantled into three parts that are simple to handle and quick to assemble and disassemble.

Grupo electrógeno instalado en el megaproyecto de telecomunicaciones

The need for increased autonomy also resulted in the design of large-capacity fuel tanks, featuring 1,000-litre double-wall tanks. These tanks not only store fuel but also fulfil a structural function, acting as the base of the generator set.

Advanced customisation for critical environments

The project was completed with the integration of numerous optional features requested by the client, providing a high level of customisation and operational reliability. These include fuel transfer systems, automatic oil level control, door retainers for windy environments, and corrosion protection through marinised alternators.

The project involved the manufacture and supply of a significant number of units with different power ratings, aimed at reinforcing critical telecommunications infrastructure distributed across Latin American territory.

In addition, the generator sets incorporate advanced control and communication solutions, enabling remote monitoring and efficient operational management—key aspects in distributed telecommunications installations.

Features

  • Special baseframe with easy dismantling system
  • 1,000-litre double-wall fuel tank integrated into the baseframe
  • Fuel transfer system with 12 VDC electric pump
  • Automatic oil replenishment system with level control and auxiliary tank
  • Canopy door retainers to prevent wind-induced closure
  • Marinised alternators for enhanced corrosion protection
  • Cold-start programming
  • Oversized batteries and battery charger
  • Modbus TCP/IP communication via RJ45 Ethernet card
  • ComAp InteliLite AMF25 IL3 control system with expansion modules
  • Digital fuel level measurement with alarms and automatic shutdown on low level

Genesal Energy designs a generator set for a waste-to-energy plant that transforms waste into resources

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Genesal Energy’s strong commitment to sustainability has led the company to develop projects linked to renewable and green energy, such as the design of a generator set for a waste-to-energy plant located in the south of London.

This facility generates electrical energy through the incineration of waste, producing power from materials that cannot be separated or recycled. With the aim of reducing environmental impact and promoting reuse for energy generation, waste is transformed into energy through biomethanisation or incineration processes.

Taking this function into account, Genesal Energy’s engineering team designed a generator set intended to supply the auxiliary services of this power generation plant. Its role is to guarantee the electrical supply to the plant’s main turbine, enabling a black start, and to act as backup in the event of grid failures, ensuring continuous operation. This solution is essential to guarantee the safe operation of critical installations, where even a simple grid outage could lead to serious incidents, accidents or major breakdowns.

The project was carried out jointly with the client and the civil works subcontractor.

According to World Bank forecasts, global waste generation will increase by 60% by 2050. In addition, Eurostat data show that 24% of municipal waste in Europe is still sent to landfill, with the associated environmental and public health challenges. For this reason, the development of waste-to-energy plants is essential, as they give a second life to non-recyclable waste that would otherwise be difficult to manage from an environmental perspective.

A unique design to generate energy

According to data from the United Nations International Environmental Technology Centre, waste-to-energy processes have the capacity to reduce the volume of waste sent to conventional landfills by up to 90%. The report also highlights that in countries most advanced in the use of this technology, between 25% and 30% of waste is already being treated in this way.

Guarantee the safe operation of critical installations, where even a simple grid outage could lead to serious incidents, accidents or major breakdowns.

All of this data was taken into account by Genesal Energy’s engineering team when designing an open, non-soundproofed generator set, operating at medium voltage (11,000 V). The solution includes air silencers in the generator room, a large-capacity fuel tank and a remote cooling system installed on the rooftop, including heat exchangers, a secondary circuit circulation pump and an air cooler. A special structure was also designed to support this equipment on the roof of the client’s building.

The entire project was developed in close collaboration with the client, ensuring that both the operational performance and the installation procedures, as well as the overall functionality of the equipment, met the highest standards.

Engineering solution delivered

The project developed by our engineering department involved the design of an open, non-soundproofed generator set, operating at 11,000 V medium voltage, with air silencers in the generator room, a large-capacity fuel tank and remote rooftop cooling. This includes heat exchangers, a secondary circuit circulation pump and an air cooler, supported by a specially designed structure on the client’s rooftop.

The engineering of the project was carried out jointly with the client and the civil works subcontractor to ensure that operation, installation procedures and equipment performance were fully optimised.

Grupo electrógeno instalado en la planta waste to energy

Key features

  • 11,000 V medium-voltage generator with remote rooftop cooling, heat exchangers integrated into the baseframe, and pumping and filtration systems mounted on the generator skid.
  • Air cooler installed 4 m above rooftop level for integration with the plant’s HVAC systems, including supporting structure, guardrails and access ladder.
  • Generator room fuel system compliant with UK regulations and connected to the plant’s fuel installation.
  • Integrated earthing resistor.
  • Integrated room ventilation system with air intake and exhaust silencers to ensure high external noise attenuation.
  • Integrated control system.
  • Exhaust silencers mounted directly on the generator baseframe.
  • Double-wall stainless steel chimney, painted to match the building façade for aesthetic integration.

Tailored backup power for a data centre at a telecommunications company in Madrid

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Ensuring electrical continuity in DPCs is essential. Servers, storage systems and other critical equipment must remain operational 24/7.

Any interruption in the power supply can affect thousands of users and compromise data availability.

Genesal Energy designed and supplied a 165 kVA generator set for the data centre at the headquarters of a telecommunications company in Madrid, ensuring that both the DPC and the auxiliary facilities can continue operating normally even in the event of prolonged mains outages.

A compact, autonomous and high-performance generator set which can maintain uninterrupted operations.

The client required a robust, reliable unit with long autonomy. To meet this need, we integrated a 995 litre fuel tank directly into the generator’s baseframe, optimising the available space and facilitating its installation within the DPC environment.

Additionally, we customised the unit with the company’s corporate colours, combining functionality with aesthetics and ensuring perfect integration within the facility.

The generator set also includes a 250A 4 Pole 230V motorised transfer switch, enabling quick and safe switching between the grid and the generator. This ensures that DPC operations continue without interruption, even under critical circumstances. This level of autonomy and control makes the solution ideal for facilities requiring a constant and reliable electrical backup.

Efficient, collaborative engineering

To deliver this project, our engineering team reviewed all the client’s specifications and adapted existing solutions from our design library, making the necessary adjustments to meet the requirements for power, autonomy and available space. Once the 3D design was completed, all drawings were validated with the client before manufacturing began.

The client required a robust, reliable unit with long autonomy.

Collaboration between engineers and plant personnel was key to anticipating potential challenges and optimising the assembly of the generator set. The team’s experience and the technicians’ insights enabled us to improve the manufacturing process and ensure a reliable, efficient and safe product, ready to respond to any eventuality affecting the DPC’s power supply.

A result that makes a difference

The final result is a compact, autonomous and high-performance generator set which can maintain uninterrupted operations, safeguarding essential systems and information, even in the face of unexpected electrical failures.

Key Features

  • Separate Power Cabinets and Control Cabinet integrated into an independent electrical room inside the soundproof container.
  • Canopy painted in the client’s corporate colours, NCS S 3560 R80B, combining aesthetics and functionality.
  • 995-litre fuel tank integrated into the skid, optimised for space saving and extended autonomy, featuring a liquid collection system.

Energy security in car parks: a new project in a public car park in France

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Car parks, particularly when underground or large-scale, require a continuous power supply to ensure car & people’s protection (energy security in car parks). In the event of an outage, ventilation systems would stop working, and the risk of poisoning could rise within minutes.

Similarly, without emergency lighting or active signage, evacuation during a fire could be compromised, creating dangerous and panic situations.

Our latest project in this area has been the design and manufacture of a bespoke tailor-made genset for a public car park in France to guarantee power supply in the event of a mains failure ensuring compliance with the strict safety regulations applicable to public spaces of this kind.

A vital need in a busy environment

Our engineering team developed a 250/275 kVA genset housed in a 3400mm soundproofed canopy, equipped with a Baudouin engine and a high-performance Leroy Somer alternator. This design ensures reliability, durability and ease of maintenance.

Guarantee power supply in the event of a mains failure ensuring compliance with the strict safety regulations applicable to public spaces.

The generator is fitted with a built-in 500-litre tank, providing up to 8 hours of autonomy, thereby ensuring critical systems remain operational for an entire day in the event of an incident. To further enhance safety, we integrated specific features such as externally operable fuel shut-off valves, redundant control & battery systems, protections against moving and hot parts, and emergency stop push-buttons.

Reliability, safety and continuity

Beyond the robustness of the equipment itself, reliability in this project is reflected in compliance with strict French safety regulations, specifically NF-E-37-312, applicable to this type of installation. This means that the genset not only provides backup power but also ensures the installation meets the highest standards of protection and risk prevention.

Features

  • Design type: Monoblock in 3400mm soundproofed canopy.
  • Fuel tank: 500 litres integrated into the base frame.
  • Control panel: ComAp InteliLite AMF25 IL4.
  • Redundant battery system.
  • Emergency start controller: ComAp InteliNano.
  • Safety fuel shut-off valve.
  • Compliance with NF-E-37-312 safety regulations.

Genesal Energy designs tailor-made generator sets for large retail outlets.

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Genesal Energy has designed a generator set to guarantee energy in a shopping centre in Germany and replace its previous generator.

The genset had to be integrated without the need to modify the existing installations and to have a high autonomy and direct connection to an external fuel tank.

With these indications, our engineering team designed a solution with the necessary features to replace the previous equipment without the need for major modifications existing infrastructure. The control unit was located in a special position that allows access without the need to open the side doors, enhancing space and operability at both an operational and aesthetic level, as it also complied with the specific colour and marking requested.

Our proposal included a control unit in a special position which can be accessed without having to open the side doors of the set.

Bearing in mind that shopping centres are spaces where activity does not stop, the electricity supply must be guaranteed at all times to ensure its proper functioning, as a failure in the grid can lead to operational interruptions, affecting customers, generating economic losses and compromising the safety of the premises.

To prevent this kind of situation, this set has an automatic start-up system, ensuring its immediate activation in the event of a failure in the main network. In order to achieve maximum autonomy, the engineering team designed an external fuel tank by means of wall-bushings, allowing a continuous supply without the need for frequent refuelling.

Thanks to this Genesal Energy design, the shopping centre has a reliable solution adapted to its needs, ensuring that, in the event of any grid failure, activity continues without interruption.

Our Engineering Solution

Based on the client’s specific need to replace an old unit with this new one, we designed a unit as similar as possible to the already existing. Our proposal included a control unit in a special position which can be accessed without having to open the side doors of the set. It was installed in the same precise location without having to make any modifications.

Features

  • AMF Mains failure start.
  • Deif AGC 150 control panel.
  • No fuel tank integrated in the base, only liquid collection tray with sensor for leak detection.
  • Wall bushings for fuel lines (suction and return) from external tank.
  • Protective mesh against animals (at air inlet and outlet).
  • Special customer marking.
  • Unit painted in the customer’s required colour – RAL 5003.
  • Oil extraction hand pump.
  • Heating water recirculation pump.
  • Fuel pre-filters with water decanter.
  • Special batteries.
  • Completely covered power supply preventing any access to live parts.

Tailored Power for a Shopping Mall in Germany

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Genesal Energy understands that every client is unique and when it comes to securing power supply in critical facilities, there’s no such thing as a one-size-fits-all solution.

A key part of our work lies in listening carefully, understanding each project in depth, and designing fully customised gensets capable of meeting even the most specific requirements.

This was the case in one of our most recent projects: the design and manufacture of a generator set for a shopping centre in Germany. The client presented us with a highly specific set of technical requirements. It was an ambitious challenge, as they needed a reliable emergency power solution with clearly defined criteria regarding autonomy, aesthetics, corporate branding and weight restrictions.

The client required a high-autonomy genset, connected to a 3,000-litre belly tank fully integrated into the base frame, a design that enables the installation to operate for extended periods. Additionally, there was a strict total weight limit of 8.5 tonnes, including the fuel tank, which meant we had to completely redesign the canopy and manufacture it in aluminium to reduce weight without compromising strength or performance.

A full redesign of the canopy, which was manufactured in aluminum to reduce weight.

Accordingly, the genset was customised both functionally and aesthetically. It was painted in the client requested RAL and featured special corporate branding. From a technical perspective, the set includes an oversized alternator to ensure optimal performance under demanding conditions, a ComAp InteliGen4 200 control panel, animal ingress protection mesh, and a fully covered power section to eliminate access to live parts, among other specifications.

This project is a clear example of what we do at Genesal Energy: delivering power solutions that combine innovation, flexibility, and deep technical expertise. Whether the challenge lies in the design, available space, local regulations or visual integration, our team is always ready to respond with the best solution.

The Engineering Solution

A full redesign of the canopy, which was manufactured in aluminum to reduce weight. This ensured the final equipment – including the full 3,000-litre tank – remained under the specified weight limit.

Main Features

  • ComAp InteliGen4 200 control panel.
  • 3,000-litre belly tank integrated into base frame.
  • Spill containment tray with leak detection sensor.
  • Animal protection mesh at air inlet and outlet.
  • Special client-specific branding.
  • Painted in RAL 7035 (client’s specified colour).
  • Manual oil extraction pump.
  • Coolant recirculation heating pump.
  • Fully covered power section to prevent contact with live components.
  • Oversized alternator.

Backup power to preserve marine life: we designed a generator set for a fish farm prepared for a marine environment

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Genesal Energy has developed a tailor-made power solution for a fish farm located in the Atlantic Coast of Northwest Spain, an area especially exposed to corrosion issues.

The project involved the design and manufacture of a 440 kVA genset operating in parallel with two existing generators, ensuring production continuity even in the event of grid failures or instability.

Fish farms require a constant and reliable power supply to run essential systems such as water pumps, aerators, recirculators and sensors. A power outage can reduce oxygen levels in the water and suffocate the fish within hours, with severe economic and environmental consequences.

A highly demanding environment

The coastal location posed an additional challenge in terms of resistance and durability. Genesal Energy engineering department designed an open generator protected by an ISO12944-C5 anti-corrosion coating, ideal for harsh marine environments. The alternator was also marinised and fitted with anti-condensation heaters, increasing its resistance to humidity and salinity.

The solution includes an integrated 350-litre fuel tank providing up to 4 hours of autonomy, and a rubber anti-vibration system to protect the structure against mechanical vibrations.

Synchronisation and full control

The key to the project was to ensure seamless operation alongside the two existing units. To achieve this, a ComAp InteliLite AMF 25 IL4 control panel was integrated, enabling the load distribution management and remote control of the installation. Specific safety features such as emergency stop buttons and guards for hot and moving parts were also added, meeting the required safety standards.

Thanks to this bespoke design, the fish farm now benefits from a robust, efficient backup system ready to operate under extreme weather and environmental conditions, ensuring not only production continuity but also the survival of thousands of fish in the event of an energy emergency.

Features

  • 440 kVA (Standby) / 400 kVA (Prime) genset.
  • Operation alongside two existing generators.
  • Integrated 350 L tank (4 hours’ autonomy).
  • ISO12944-C5 anti-corrosion paint treatment.
  • Marinised Mecc Alte alternator with anti-condensation heaters.
  • ComAp InteliLite AMF 25 IL4 control panel.
  • Legrand 630 A circuit breaker.
  • Tudor TC1453 2x 145 Ah batteries.
  • SE 45 silencer model (-28 dB).