Tag Archive for: Genesal Energy

Generator sets for events: keep the fiesta going

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Spain is a country of events, recordings, fairs, concerts, festivals or travelling sporting events that bring together thousands of people around and which depend on a stable electricity supply for their correct development.

Otherwise, the absence of reliable power can lead to problems with safety, the operability of technical equipment or even affect the audience’s experience. Therefore, for the music, events or audiovisual industry, having generator sets specifically designed for these applications is key to guaranteeing the success of any celebration.

Genesal Energy has designed a lightweight generator set for vehicle mounting, not exceeding the permitted road weight limits and facilitating access to the fuel supply from the same side as the HGV.

Reliability and efficiency are key aspects in the provision of energy in dynamic and demanding environments such as mass events.

The mobility of the unit was a determining factor, so it was necessary to optimise its design without affecting its performance and autonomy. To meet the requested requirements, our team developed a soundproof generator set with an aluminium canopy, a key choice to reduce its weight and improve its manoeuvrability. In addition, we incorporated a horizontal opening system with shock absorbers, which facilitates access to the interior of the genset for maintenance and refuelling in a safe and efficient manner.

Mobile generator set for events with lightweight design.
Resistance to vibrations and impacts

It has a 200-litre tank for greater autonomy and an anti-shock system to absorb vibrations and prevent structural damage. In this way, the mobility of the generator set will not be a handicap as the design ensures its solid condition for a longer period. Genesal Energy adapts its solutions to the needs of each client and application. Reliability and efficiency are key aspects in the provision of energy in dynamic and demanding environments such as mass events. Ensuring a continuous and secure power supply is our priority, allowing each event to run smoothly and meet the expectations of organisers and attendees.

Our Engineering Solution

Faced with this challenge, our team designed a soundproofed unit with a canopy made of aluminium to significantly reduce the weight of the unit and meet the limitation set by the customer. Another aspect to highlight is that this canopy had horizontal opening doors with shock absorbers to regulate its opening and closing when refuelling.

Features

  • Aluminium made Canopy
  • ComAp control panel
  • Integrated fuel tank with a capacity of 200l
  • Adjustable opening door dampers
  • Anti-shock system to reinforce structural solidity as it is a mobile unit.
  • Upper air outlet.

Genesal Energy reinforces Poznan heat network with an emergency generator set

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Genesal Energy has designed an emergency diesel generator set for a cogeneration plant in Poznan, Poland.

A key facility in the supply of heat and electricity for the city. In the search for efficient and sustainable energy solutions, heat networks emerge as a key alternative for the transition to more responsible consumption patterns.

This power plant supplies approximately 60% of the inhabitants of the city, as well as providing energy to industries, public institutions, shopping centres and other services. The incorporation of our generator set for energy plant ensures supply in the event of a plant shutdown, including battery chargers and part of the lighting network.

These installations consist of a generating plant and a network of pipelines and supply homes, hospitals, schools, shops and offices in an efficient and sustainable manner.

Our engineering team designed a unit that ensures a low sound pressure level thanks to the interior lining and a space divided into three separate rooms: the engine-alternator room, the control room and the storage room. In addition, the system has a Baudouin engine coupled to a Mecc Alte medium voltage (6300 V) alternator, mounted on an electro-welded steel base with anti-vibration blocks to minimise vibrations and noise.

For fuel storage, a 3.000 litres double-walled steel tank has been installed, equipped with a leak detection system. Exhaust gases are managed by stainless steel silencers integrated into the container eliminating the need for external installations. Finally, the container has undergone a C4 paint surface treatment in accordance with the ISO12944 standard, providing additional protection against corrosion and environmental wear and tear.

Genesal Energy emergency generator set installed at a cogeneration plant in Poznan, key to strengthening the urban district heating network.

Heat networks: an alternative to the traditional model

Heat networks consist of a centralised infrastructure for the production and distribution of thermal energy. These installations consist of a generating plant and a network of pipelines and supply homes, hospitals, schools, shops and offices in an efficient and sustainable manner.

Details of the generator set at the Poznan cogeneration plant.

Features

  • 40feet HC container, guaranteeing an average sound pressure level of 85 dB at 1m.
  • The walls were lined with 100 mm thick acoustic panels, guaranteeing EI120 fire resistance.
  • The container had 3 separate rooms: the engine-alternator room, the control room and the storage room.
  • A Baudouin engine was fitted with a Mecc Alte medium voltage (6300 V) alternator on an electro-welded steel base with anti-vibration blocks.
  • The coupling between the engine and the alternator is by means of an elastic coupling.
  • 3.000 litre double-walled (steel-steel) tank inside the container.
  • Tank fitted with a leak detection system.
  • The fuel supply and return pipes were double-walled, with a leak detection system.
  • High-capacity fuel filtration system.
  • Locks with electric lock and position contact were installed on the access doors to the group room and control room.
  • Fire extinguishers were installed in the group room and control room.
  • The control room was air-conditioned.
  • The exhaust gas silencers were made of stainless steel. They were integrated into the container, avoiding on-site installation.
  • The unit was fitted with motorised louvers at the air inlet and outlet.
  • Surface treatment with C4 paint, according to ISO 12944.

Technology and commitment, Genesal Energy’s answer to healthcare challenges.

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Genesal Energy knows perfectly well that continuity of power supply is essential, especially in places where every second counts, such as a hospital.

That is why we have developed a tailor-made solution for the UK’s NHS Northwest, installing two 550 kVA open gensets specifically designed to meet the needs of this premises.

From vital medical equipment to security systems and medicines cooling, every component relies on electricity to operate 24/7.

Generator sets not only ensure the continuity of critical operations protecting the most important thing: patients’ lives.

Our engineering team developed a customised system including an engine-alternator monoblocks on steel frames with a capacity of 350 litres of fuel each and liquid collection trays with a capacity of 110% of the tanks.

They are also equipped with a Deep Sea DSE8610 MKII control cabinet, programmed to operate in permanent parallel with the grid ensuring the best efficiency parameters. There is also a Victron battery system to optimise energy management, allowing recharging during off-peak hours and support during peak demand. Both units are equipped with 800 A motorised circuit breakers, advanced protection systems and designs that facilitate transport and installation.

Industrial emergency generator set installed in a technical room.

Present at the Healthcare Estates exhibition and conference – IHEEM

The innovation that characterises Genesal Energy took us this year to the Healthcare Estates exhibition and conference – IHEEM held in Manchester Central. We had the opportunity to present one of these two hospital generators together with our partner Ingram Installations Ltd.

This event allowed us to show not only the technology that makes these projects possible, but also our vision for the future in the field of energy generation.

Our engineering solution

Our engineering department developed two 550 kVA open gensets, with the engine-alternator monoblock assembly on a 2800 mm long steel base, with a 350-litre capacity tank and a liquid collection tray designed to hold all the fluids that can be poured (oil, coolant, diesel…) with a capacity of 110% of the fuel tank. The engine radiator protrudes outside the bed, so the tray was designed to be large enough to accommodate this section. The fluid collection tray is supported on two omegas which serve as legs, protecting the tray from any contact against the ground that could damage it and facilitating the transport of the unit. By means of ‘zeta’ angles, they are joined to the main bedplate forming a single unit, with the base frame supports resting on the omegas and supporting the weight of the unit.

Generator set and control system for emergency power supply.

Equipment features

  • Construction type: Monoblock engine-alternator on 2800mm base frame.
  • Bunded tank on base frame with a capacity of 350 litres.
  • Liquid collection tray with capacity to hold 110% of the tank.
  • Four Tudor TC1453 145 Ah batteries.
  • Double set of batteries with protection box.
  • Victron system and positive disconnector for Manual battery change.
  • Alternator anti-condensation resistor.
  • Deep Sea DSE7410 MKII control panel.
  • Fully enclosed power output cabinet with no access to voltage parts.
  • No exhaust silencers.
  • Motorised circuit breaker with trip coil and position contact.

We supply emergency power to a combined cycle power plant in Brazil providing 14 million people with electricity

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The port of Açu is one of the main industrial and energy generation projects in Brazil.

Located in the north of the State of Rio de Janeiro, it has quickly established itself as an oil and gas hub thanks to its colossal dimensions and its capacity to transport people and goods. A 1.7 GigaWatts combined cycle power plant is being built at this strategic location as part of a mega-project that includes a similar facility and an LNG regasification terminal based on an already operating floating storage regasification unit (FSRU).

The size of this project has much to do with its optimal geographical location as Açu is close to Brazil’s two main gas pipeline systems in the north-east and south-east of the country.

The plants will have a combined total capacity of 3 GigaWatts and will be able to meet the energy requirements of 14 million households in Espírito Santo, Minas Gerais and Rio de Janeiro. The entire project is valued at around 1 billion euros. Genesal Energy is providing two 1750 kVA generator sets.

It is a state-of-the-art combined cycle power plant with gas turbines that will inject 1,672 MW of energy into Brazil’s integrated electricity system, so having an emergency generator set adapted for a combined cycle power plant to its needs was essential to guarantee its operation.

Social responsibility

Located about 400 km from Sao Paulo, the combined cycle plant (three natural gas turbine generators and one steam turbine) will deliver 1672MW of power at 500 KV to a distribution power line. Its commissioning will supply power to millions of homes.

Equipment features

  • Control Panel integrated in the soundproofed container.
  • Fuel tank inside the container.
  • Double-walled piping with leak detection.
  • Motorised louvers.
  • Air inlet and outlet mufflers for noise-level reduction.

The UK’s largest pet care company entrusts its supply to Genesal Energy

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Genesal Energy has designed a generator set with very specific needs for one of the logistics centres of the UK’s leading pet care company, Pets at Home.

Emergency generator sets are crucial in a logistics centre. They guarantee the continuity of daily operations protecting the supply chain and customer service.
A tailor-made canopy – adapted to the space of 8100 x 2100 x 2475 mm – was designed: a soundproofed unit that guarantees an average sound pressure level of 85 dB at 1 metre and has exhaust gas silencers with -35 dB attenuation on the roof. The power panel is located on the outside in order to facilitate connection.

Dimensional restrictions solved; another challenge was that the new equipment had to be compatible with the existing one. Also sorted out.
A safe energy source in the event of any supply failure. Customer’s satisfaction best friend.

Our Engineering Solution

Although this generator set would be installed in a 40′ HC container in its standard assembly version, our engineering team designed a 8100 x 2100 x 2475 mm canopy with the power panel installed outside in order to facilitate the connection of power cables by the customer.

Features

  • 8100 mm modular soundproofed canopy guaranteeing an average sound pressure level of 85 dB at 1 metre.
  • The unit was equipped with a liquid collection tray to contain possible coolant, oil or fuel leaks.
  • An exhaust gas silencer with -35 dB attenuation was installed on the canopy roof.
  • The canopy was fitted with an integrated air silencer module.
  • A power output cabinet was designed external to the genset, with the following features:
  • 2 x 3-Pole circuit breakers. One for the genset and the other one for an external genset.
  • Castle key to prevent the closing of both breakers at the same time.
  • Powerlocks connection for an external genset.
  • Powerlocks connection for a load bank.
  • Busbar.
  • This power cabinet allowed an external genset to be connected to supply the loads in the event of the genset not being available.

 

Guaranteed power for essential services in Western England

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In the heart of Lancashire, Genesal Energy has successfully completed the installation of three soundproofed generator sets at a local authority in Blackpool.

We reinforce our commitment to the protection of critical spaces ensuring that patients and healthcare staff can carry out their activities without interruption in the event of a power failure.

In local government buildings, electrical power is not just a resource: it is the foundation on which many essential activities for the population are based. From issuing documents and processing paperwork to coordinating emergency services, any interruption in the power supply can cause delays, inconvenience and, in some cases, significant consequences for citizens.

Soundproof generator by Genesal Energy during installation.

Genesal Energy installed three generator sets of 330 kVA each, specifically designed to meet the hospital’s needs. The units, insulated not to exceed 75 dB(A) at 1 metre, were manufactured in specially dimensioned canopies and finished with C5M environmentally resistant paint. In addition, they are synchronised with each other by means of a DeepSea DSE8610 control system, which ensures perfect operability between the units.

Each generator has a 650 litre fuel tank and a transfer system that allows continuous fuel supply from an external tank at ground level. Anti-condensation heaters on the alternators and anti-corrosion treatment on the windings have also been added to ensure their operability in all climate conditions.

The careful design of this project not only responds to the high technical standards that these buildings require, but also to the importance of maintaining a safe environment for users and workers.

Soundproof generators installed by Genesal Energy at Blackpool Hospital.

Our Engineering Solution

Supply of an emergency network with the design, manufacture and commissioning of soundproofed generator sets which guarantee the operation and safety of the centre’s activities at all times.

Features

  • 3 x 330kVA Specially oversized soundproofed canopy 75db(A) @ 1m, C5M surface treatment in customised RAL.
  • DeepSea DES8610 Control panel for synchronisation between units.
  • 650 litres Integrated fuel tanks.
  • External fuel filling point with 3 x transfer pumps, solenoid valves, leakage sensors, fuel polishing systems, and connection boxes.
  • Anti-condensation heaters on alternator.
  • Anti-corrosion treatment on alternator windings, PMG and neutral contactors.

General view of the generators installed by Genesal.

Genesal Energy takes part in the construction of the world’s longest underwater tunnel

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Linking Northern and Southern Europe through new communication routes is one of the major engineering goals currently being realised.

Strong investments are being made in the development of infrastructures designed to reduce travel times and facilitate the movement of goods between countries.

One of them is the Fehmarnbelt tunnel, a mega construction that is pushing the boundaries of engineering. This unique $8 billion project will transform travel between Central Europe and the Scandinavian countries. Once completed, it will become the longest combined road and rail immersed tunnel in the world, spanning almost 20 km, crossing the Fehmarn Strait in the Baltic Sea and providing a direct connection between Northern Germany and the Danish island of Lolland.

It is a key component of the Scan-Med corridor, a transport network of more than 5,000 km, stretching from Malta in the south to Finland in the north.

A project of this scale demands the most reliable equipment to ensure its successful completion on time. To provide back-up power for the machinery involved in the tunnel’s construction, Genesal Energy’s engineering team designed and manufactured 16 generator sets, delivered in two phases.

These soundproofed units were customised with canopies of 3,800 mm and 2,900 mm, and fitted with fuel tanks of 630 and 350 litres, offering an autonomy of more than 17 hours at 100% load.

Due to the harsh environmental conditions, and in order to protect the alternators, a special marinisation treatment was applied to increase their resistance to highly corrosive atmospheres.

The generator sets were designed to operate in AMF mode, and are equipped with 3-way double valves to allow manual selection between the integrated tank or an external one for fuel supply.
This ensures a reliable energy supply throughout the construction phase, helping to keep the project on schedule.

Commitment and rigour

At Genesal Energy, we have built a solid reputation in the generator set sector, offering our customers products that stand out for their reliability, performance and quality.

We design and manufacture custom-made solutions tailored to each project’s technical requirements, delivering turnkey systems in which we take care of every stage.

This commitment has allowed us to take part in high-demand projects such as the Fehmarnbelt tunnel, where a reliable power supply is key to the project’s success.

Features

  • 16 soundproofed canopied generator sets: 16 with 3,800 mm length and 2 with 2,900 mm length
  • Integrated fuel tanks of 630 and 350 L, providing more than 17 hours of autonomy at 100% load
  • Fuel tanks fitted with liquid retention trays and leak detection systems
  • Exhaust gas silencers installed inside the canopy, achieving a -30 dB reduction
  • Cyclonic filters for engine air intake
  • Motorised louvres at air inlet and outlet, which open only during operation
  • 3-way double valves to manually switch between integrated and external fuel tanks
  • Quick external connectors for fuel supply and return
  • C5-scheme paint surface treatment, compliant with ISO 12944:2018
  • ComAp InteliLite AMF 25 IL4 control panel
  • Alternators with anti-condensation resistors and special marinisation treatment
  • Powerlock switchboards for power output

 

Genesal Energy designs a new set to guarantee supply to supermarkets

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Genesal Energy provides innovative solutions adapted to the needs of any sector, including large food & drink companies.

In their premises, maintaining the flow of electricity is crucial to guarantee the good quality of the products and service.

Firstly, the preservation of perishable goods requires constant refrigeration to ensure their safety for consumption and, secondly, the support of the operation of critical systems such as computer systems, lighting systems or security cameras. If a supermarket suffers a power outage, the financial and reputational losses can be considerable, as well as causing serious disruption to customers and employees.

To avoid this type of situation, Genesal Energy’s team of engineers designed a solution for one of these in Getafe, Spain. In addition to guaranteeing the supply, it was also adapted to the needs and measurements of the dedicated space. The energy autonomy of the establishment was secured ensuring that it remains operational in events such as overloads or short-circuits.

Our solution

Our engineering department developed a soundproof generator set, with a 450-litre tank and a liquid collection container designed to hold all the fluids that could be leaked (oil, coolant, diesel…).

In addition, a trip coil was fitted in the circuit breaker which acts when there is a power cut, activating the automatic immediately.

Features

  • Calculation of necessary cross-sections for air inlet and outlet in the room.
  • Circuit breaker with minimum voltage trip coil for possible overload, short circuit or earth fault events.
  • Exhaust gas silencer -30dB.
  • 1000W preheating system.
  • Leak tray for liquid collection.

 

An engineering feat to ensure power supply to a data center in Northern Europe

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We design five unique gensets capable of providing a DCP output of 3,000 kVA each.

In an innovative and technological implementation, our engineering team has designed five generator sets that have been installed in a Data Center in Northern Europe. These are ad hoc machines designed to provide a DCP power of 3,000 kVA and meet the stringent technical and regulatory requirements of the project.
We have reached this milestone hand in hand with manufacturers Baudouin, ComAp and Friga-Bohn. The generators were designed to ensure continuous uptime and data security in one of the world’s most critical and demanding environments, protecting the infrastructure against grid outages.
The integration of advanced technologies, customisation to detail and compliance with the highest standards of security and efficiency, consolidate this installation as a model to follow in the industry.

The importance of investing in emergency power generators

The installation of these generators responds to the critical need to ensure operational continuity in data centres, essential for the IT infrastructures of global companies. The benefits include:

  • Data Loss Protection: They provide an alternative power source to protect unsaved data and prevent damage to storage systems.
  • Cooling Maintenance: Enable continuous operation of cooling systems, preventing equipment from overheating.
  • Prevention of Costly Downtime: Minimise downtime that can result in significant financial loss.
  • Regulatory Compliance: Help companies comply with regulations that require robust contingency plans.

Innovation and security in every detail

This completely customised solution exceeded the customer’s most demanding specifications. The design of the container – with special dimensions of 13.5 x 3 x 3 m – includes a structurally reinforced base with pipes running underneath to facilitate connections to the fuel tank and a liquid collection tray that guarantees total containment in case of spills.
In addition, the container was given a C5 type surface treatment in accordance with UNE-EN ISO 12944-2:2018 – ideal for marine environments – guaranteeing exceptional durability and resistance.
To ensure that noise requirements were met the exhaust system was optimised including a thermally insulated (rock wool and aluminium) -30 dB silencer, maximising safety and minimising environmental impact.
In terms of equipment protection, 5,000 A circuit breakers and Power locks were installed, as well as an oversized busbar, specially designed to facilitate the customer’s electrical connection of the system.
Our engineering team also developed an independent cooling system with motorised louvres and a fully integrated & automated fire suppression system to ensure a fast and efficient response in case of an emergency. The incorporation of wide accesses, advanced control systems, fire protection and adverse environment features completed this project and made it a benchmark in the industry.

Requirements and Customised Solutions

  • Non-full-flow: In terms of the cooling system, V-arranged Friga-Bohn air-coolers were installed in a room separated from the generator room. They were sized for a maximum ambient temperature of 38ºC at 100% load. This configuration allowed outside operation of a full flow system, significantly reducing air interference in the operating area.
  • Low noise level: The generators were required to operate at a sound pressure level of no more than 85 dB at 1 metre, at 100% load.
  • Fire protection: A Novec fire detection and gas extinguishing system and sectorisation panels were integrated, ensuring EI60 fire resistance standards.
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Business collaboration

After a thorough analysis of the customer’s specific power requirements, generator set models and capacities were selected based on a detailed list of electrical loads. The choice of Baudouin’s 3,000 kVA DCP engines was not a gamble; these engines have been specially designed for critical applications and meet the highest standards of reliability and performance.
Regarding the control system – and as it was essential to ensure the highest availability of the equipment – redundant systems were installed. Namely, a redundant battery rack of eight units in total, separated into two groups of four. Also, a redundant two-stage starting system. First stage fitting two starter motors and managed by the engine ECU and a second stage with one starter motor managed by an ComAp controller. This particular control centre allows, in addition to real-time management and monitoring of the status of the generators, a flexibility that traditional control systems do not provide.

Features

  • V-arranged air-coolers were installed in a room separated from the generator room. They were sized for a maximum ambient temperature of 38ºC at 100% load. This configuration allowed outside operation of a full flow system, significantly reducing air interference in the operating area.
  • The generators were required to operate at a sound pressure level of no more than 85 dB at 1 metre, at 100% load.
  • A Novec fire detection and gas extinguishing system and sectorisation panels were integrated, ensuring EI60 fire resistance standards.

Genesal Energy takes part in the undersea Greenlink highway project that will bring green energy to Great Britain and Ireland

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Greenlink: A huge HVDC interconnector will link Ireland and Great Britain to bring electricity to 350,000 homes.

Greenlink, the colossal engineering project designed to bring clean energy to thousands of people.

The Greenlink HVDC interconnector is an immense undersea highway which features are as spectacular as its construction. The interconnector will have a capacity of 500 MW and a length of 160 kilometres, the distance separating the counties of Wexford in Ireland and Pembrokeshire in Wales. Its entry into service, scheduled for this year, will enable the supply of clean electricity pursuing the aim of achieving zero emissions. This project has been declared a Project of Common Interest by the EU).

Our involvement in the project

For this mega project, delivered by Siemens Energy and Sumitomo Electric, Genesal Energy designed three generator sets to provide emergency power at both ends of the giant interconnector. Three special units developed at our HQ in Northern Spain to guarantee the supply of the two vital facilities in the connection of the electricity grid of Great Britain and Ireland.
“If for any reason there were to be a lack of supply, it would cause a major grid failure”, explains our engineering team, highlighting the importance of having precise, robust and extremely reliable contingency gensets.

Making a difference

For the Greenlink project, our client Siemens Energy requested the generators to be fully operated, controlled and monitored from the genset control panel. The solution we provided consisted of bespoke generators including the following features:

  • Bespoke soundproofing.
  • Great Britain and Ireland Regulations compliant in terms of air conditioning, motorised grilles or liquid retention systems. These latter trays fitted with sensors monitored from the control panel.
  • Integrated into the container Load-Banks so that the generator sets are always in the optimum working load range.

 

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Smart Grids

The Greenlink subsea interconnector project is perfectly in line with our policy of putting innovation at the service of sustainability and the environment. It is also a clear example of a Smart grid or intelligent electrical network that has been conceived to facilitate the transport and distribution of green energy.

2xGEN1100YC Features

  • Power output panel integrated in the same soundproofed container as the genset.
  • Engine coolant recirculation and heating system to provide the right temperature when starting the unit.
  • Air conditioning system in the genset control room.
  • Motorised louvers.
  • Liquids collection tray.
  • Integrated load bank.
  • Surface treatment of the container according to ISO 12944 standard, in C5I finish.

GEN175YI Features

  • 160/175 kVA soundproofed unit. 730 L tank (17 hours autonomy at 100% load) and liquid collection tray integrated in the canopy.
  • Canopy adapted to the customer’s room.
  • Reduced dimensions due to space limitations.
  • Canopy designed to be attached to the wall. The doors on the side were sized to open accordingly.
  • -30 dB(A) Exhaust gas silencer.
  • 80 kW Resistor Load Bank, with 4 automatic steps of 20 kW each, integrated in the Canopy.
  • Interior Space Lighting.
  • C5M Surface treatment in accordance with the ISO12944 standard.