Tag Archive for: Genesal Energy

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.

We supply power to CECOEL, the Big Brother of Spain’s grid.

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The CECOEL (Electricity Control Centre) controls every inch of the national electricity grid to ensure that the supply is perfect.

This organisation, dependent on Red Eléctrica, has its headquarters in Alcobendas (Madrid).

This operations centre performs real-time supervision of all the generation and transmission facilities of the national electricity system. The CECOEL operates 24/7, 365 days a year.

All the instructions for the correct programming of national electricity production and international exchanges to meet variations in electricity demand are issued from its offices. It also issues the operating instructions for the elements of the transmission grid to ensure that the control variables remain within the established parameters.

CECOEL secures the quality of supply and restores service when an incident occurs. Its maintenance must be optimal, and this is where generators come into play. In the event of a power failure in the grid and the hypothetical risk of a nationwide system outage, emergency power is crucial as part of the safety protocols.

Project development

As part of the organisation’s maintenance and modernisation plan, Genesal Energy replaced the existing generator set with a last-generation unit in a new location, further away from the main CECOEL offices. This way, the operation of the generator set would not alter the normal activity of the different departments in the slightest.

Extra fuel tank

Genesal Energy designed, manufactured and supplied this genset and also an additional tank – for which a large crane was required – in order to provide the genset with a high level of autonomy. Transfer pumps and the installation of connecting pipes between the unit and the tank completed the project.

Features

Special soundproofed Canopy. The unit starts by external command.

  • Internal tank with liquid collection tray.
  • 4000 litres Certified External tank double-walled (steel-steel).
  • Redundant automatic fuel transfer system between both tanks.
  • Automatic start-up control panel manufactured to customer specification.
  • Fuel consumption meter for carbon footprint calculation.
  • FATs were carried out with a load bank and in the presence of the client to verify compliance with all the requirements.

Genesal Energy emergency power for a mobile water-generation plant

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Water-generation plants extract water from the environment, concentrating and purifying it inside the equipment.

This type of mobile infrastructure makes it possible to bring drinking water to remote areas where access to it is very scarce or even non-existent.

Genesal Energy has just supplied a custom generator set for one of these plants. These devices operate in emergencies or natural catastrophes. They also play a fundamental role in places where there is a lack of water infrastructures.

Among other projects we have designed for this sector, we have manufactured and supplied a tailor-made 20ft DV container generator set.

What was the objective?

The solution developed by our engineers focused on powering the entire series of elements that are installed inside the container itself. The Engineering Department also points out the specific characteristics of the place, e.g. the humidity conditions, where the generator set is going to operate.

Importance of a generator set.

A genset is the main source of power for these plants, which are often installed in remote locations where the infrastructure is very poor. They are often commissioned in areas where there is not even access to a conventional power grid.

Customer need

The client needed a generator set with a great autonomy and the necessary robustness to be able to be transported through unconventional places where cargos are subjected to high stresses due to the shakings.

The small area available was also a handicap. It “forced us to build a fairly high base frame for generators of this power rate in order to reach the fuel capacity required for the requested operating hours”, our technicians explain. “We had to make reinforcements and frames for the container, completely different elements from the standard ones”, they underline.

Eventually, the engineering department was able to design the container as required by the customer in order to be able to install the rest of the elements.

Features:

  • Specially designed container meeting customer’s requirements.
  • Custom-designed base frame, adapted to the location and space reserved by the customer inside the container.
  • 1000 L base frame integrated fuel tank.
  • RAL colour required by the customer.

Genesal Energy increases its presence in the UK generator healthcare industry providing the Eastbourne hospital

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The design of generator sets for the healthcare sector must meet many criteria, but there are two without which achieving optimum performance would be virtually impossible: power and silence.

Genesal Energy Health generator sets complies with both – high power and soundproofing – ensuring normal operation in the event of any power failure or incident.

One of our latest projects has been delivered for the United Kingdom, reinforcing the power supply for Eastbourne Hospital, in the Southeastern County of East Sussex.

Power

The town of Eastbourne has a population of almost 100,000 and its hospital is a speciality centre that covers the demand of not only the city but also the small surrounding towns, making it one of the main health facilities in the county.

The project developed by our engineering department consisted of extending the emergency network designing, manufacturing and commissioning two new powerful and silent hospital generators, guaranteeing an average sound pressure level of 75 decibels at one metre at all times.

As with other special turnkey projects, the generator sets at Eastbourne Hospital have a number of features that set them apart. These are the main ones:

FEATURES:

  • Walls fitted with high-thickness acoustic panels and a synthetic foil for special soundproofing, guaranteeing also EI120 fire resistance.
  • Outlet Air silencers fitted to the container and Inlet Air silencers integrated into the container.
  • Mitsubishi engine fitted with a Mecc Alte alternator on a base frame.
  • Certified 1000-litre double-walled (steel-steel) tank inside the container.
  • Exhaust gas silencers providing -40 dB attenuation.
  • C5 paint surface treatment, according to ISO12944.
  • Automatic fuel transfer system.
  • Special power outlet busbars for coupling to the busbar trunking system.
  • Motorised air inlet and outlet louvers and indoor space heaters.
News - Emergency generators for stadiums

Power Solutions for Stadium Emergencies

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Emergency power generating sets are a must in any stadium where competitions or tournaments are held.
Virtual image of soccer stadium

The lighting in stadiums is special since it must be uninterrupted during the matches, therefore, high reliability is essential. In addition, the design and manufacturing processes is carried out according to a series of parameters related to the particularities and dimensions of the facility, i.e. the seating capacity of the venue. Emergency generators for stadiums are a must.

In stadiums, emergency power is not only necessary to allow the sports competition to run smoothly in case of a power cut, but also, and most importantly, it is essential for safety, providing lighting and guaranteeing the operation of basic services in circumstances such as an evacuation.

The stadiums of Mendizorroza in Vitoria, Anduva in Burgos or Manuel Martínez Valero in the city of Elche, are some of the projects we have developed ensuring this type of facilities are always lit. Nevertheless, these are all customised solutions where the previous in-site work is of great importance to obtain the best results.

 

Oversized generator sets

In Mendizorroza, the Deportivo Alavés stadium, Genesal Energy opted for a 650 kVA High-Capacity emergency generator set ready to start automatically in the event of a power failure.

This upgrade was part of the stadium major refurbishment plan. An investment of more than 50 million euros that involved, among other works, increasing the seating capacity of the stadium by 60%, as in addition to football matches, it will be used to hold other recreational events.

The solution designed by our engineers included an oversized alternator to power the lighting of the football pitch; mainly metal-halide lamps. This type of luminaire has high performance – both in terms of light and colour – but also a drawback: they have a high peak start-up voltage & start-up and restart times of between five and ten minutes.

The Genesal Energy generating set is capable of powering this type of load and restoring the lighting in the stadium in the shortest possible time. Likewise, its electronic engine management allows maintaining a constant value in the frequency during continuous power supply and has a very fast recovery when faced with the load impacts at start-up.

Emergency generators for stadiums Mendizorroza

 

Emergency lighting at the Mirandés stadium

Four 42-metre-high towers and 120 LED spotlights illuminate the Estadio Municipal Anduva, With a seating-capacity of 6.000, it’s home to Club Deportivo Mirandés, the football team from Burgos. Genesal Energy has supplied it with a high-capacity, soundproofed emergency generator. To achieve maximum precision, we took care of the load calculation, designing a 900 kVA group with a highly reliable engine and sized to feed large peak loads.

Generator installed in Mirandés

Prioritising power and reliability in the development of the project, we also supplied continuous energy to guarantee the special lighting for the broadcasting of the matches in 4K HD quality, at the football stadium in the city of Elche.

Soccer field generator for the city of Elche

Infallible power for extreme security at a hospital in Germany

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Hospitals are critical infrastructures because of their great importance to society.

They require special security measures in areas such as the power supply, key in the operation of these buildings. Electricity can never fail.

Genesal Energy specialises in offering the healthcare sector highly innovative energy solutions with all the warranties in terms of design, manufacture and maintenance. Machines capable of starting up in record time – in the event of a failure in the network – securing the operation of ORs, ICUs and other equipment.

The high quality and innovation of our own-manufactured generator sets has led us to design projects for hospitals all over the world and one of the latest orders has been for the Lukas Neuss one in Germany.

With 13 specialities and a staff of almost 1,000 professionals, this leading hospital is located in Neuss, a city of more than 150,000 inhabitants in the Westphalia region. Genesal Energy has reinforced the safety of the facilities designing, manufacturing and commissioning an emergency power unit. Among many other features, it complies with local emissions’ standards for combustion engines and water protection and is suitable for operation at low temperatures.

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What makes it so special? Stage V generators

The generator set designed for the Neuss hospital has a latest-generation Stage V engine with particles filter, catalytic converter and urea system to comply with the demanding German emissions regulations. The machine must also be fitted with trays to collect any type of polluting liquid such as fuel, oil, coolants, etc.

In addition, it is equipped with leak detection systems to prevent spillage and motorised louvers and interior heating to ensure start-up in adverse weather conditions.

Technical Data

  • Power panel integrated in the container.
  • WHG compliant.
  • Leak detector in the container rooms and in the double-walled tank.
  • Motorised air inlet and outlet louvres.
  • Interior space heaters.

Generator set for a hangar at Barajas airport with a surface area equivalent to three football pitches.

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Adolfo Suárez Madrid-Barajas airport leads the ranking of air traffic in Spain. It closed the 2023 financial year with a passenger volume of more than 60 million and more than 380,000 operations carried out.

The figures reflect the importance of this airfield which, due to its colossal dimensions, needs to have many hangars where aircraft can “rest”. Premises equipped to carry out repairs and maintenance operations inside.

They are normally designed to house more than one aircraft and emergency power is key to their operation. With a surface area of more than 22,400 square metres, the equivalent of almost three football pitches, one of these airport hangars needed a special generator. Genesal Energy has just supplied contingency power to prevent a significant loss of time and money with a special genset for airports.

Tailor-made: generator set for a hangar

“The client required the customised manufacture of hoppers and bellows for the generator’s cooling air outlet, as well as a gas duct with 90° bends to adapt to the layout of the hangar’s generator room“, explain the engineering staff which developed this project. 

Our engineering team’s solution consisted of a highly customised generator set, which was manufactured according to the customer’s requests, seeking the best options for a special site with such particular dimensions.

Technical Data

  • Power panel integrated in the alternator, allowing the intake of two cables per phase.
  • Calculation of the necessary cross-sections for the inlet and outlet of gases in the room, tailor-made hopper and bellows.
  • Oversized exhaust silencer model.
  • Multicolour control panel.
  • Heating system.
  • Integrated 350 L tank.