Tag Archive for: Genesal Energy

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 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