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Gas generator in natural environment

We bring our energy to the Montseny Natural Park, World Biosphere Reserve

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The southernmost fir forest in Europe is located in the Montseny Natural Park (Barcelona), declared a World Biosphere Reserve by UNESCO in 1978.

A privileged environment that extends over more than 30,000 hectares. There, in the heart of nature, you can find holiday camps & farmhouses where vulnerable families’ children can enjoy unforgettable summers in a film-like area.

The challenge: installing a generating set in a protected place

Genesal Energy has provided emergency power to guarantee the electricity supply in one of these holiday homes located in Sant Pere de Vilamajor. In such a special and protected place, from an environmental point of view, the care taken when developing the project was of the utmost importance.

Gas generator in natural environment

Genesal Energy’s engineering department paid utmost attention to the location of the generator set, which had to operate in a natural park protected by UNESCO. So, from the very beginning one of the objectives was to reduce the acoustic and visual impact of the generator set so as not to spoil the beauty of the site.

The project included the installation of a gas generator, which is more environmentally friendly in terms of CO2 emissions than a diesel generator. The generator set was manufactured in a soundproof cabin to lower the noise levels of the machine as much as possible.

Technical Data

These are its main features:

  • LPG gas engine.
  • Alternator with auxiliary winding.
  • No fuel tank on the base frame, which functions as a tray for liquid collection.

We’ve supplied 18 new super-soundproofed generator sets to the Chilean market

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In Latin America, as well as in Europe, there are many countries with a growing demand for gensets providing low sound levels (therefore contributing to a greater social well-being), which are also guaranteed to be able to cover power requirements, whether it be for continuous use or in emergency situations.

One of these countries is Chile, a market with great possibilities and in constant expansion in the energy sector (especially in the field of renewable energy), for which we’ve designed, manufactured and supplied a total of 18 super-soundproof gensets.

The generator sets were tailor-made according to the client’s needs, and two different models were designed (five gensets of 500/550 kVA and 12 of 1000/1100 kVA), but with a common denominator: their great level of sound attenuation: 65 dB at seven metres distance at the point of maximum emission.

To achieve this, the engineering team and the sales department, which at Genesal Energy always work hand in hand, kept the basic cooling requirements into account, without surpassing the length and width of the 40’HC shipping container which encases the generator sets.

Double-walled fuel tank

Specifically in the 550kVA unit, we also installed a medium voltage step-up transformer, and in the 1.100 kVA, a 3.000 litre double-walled fuel tank inside the container, as well as control cabinets, silencers, etc.

On the other hand, to achieve a sound level of 65dB it was necessary to decrease the sound levels by 43’5 and 48 dB respectively. To reach this goal, we selected different materials and solutions, some applied in exactly the same way in both models, but others had to be adapted due to the unique characteristics of each unit, which went beyond their engine’s respective power ratings, to be able to comply with the technical specifications requested by the client.

Finally, once the open-field tests of the prototypes had been carried out following the indications and procedure set by the applicable regulations, the results were as follows:

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  • GEN1100TC: 64.5dB (A) at 7m distance
  • GEN550TC: 64.5dB (A) at 7m distance

These are the main features of both models manufactured for Chile by Genesal

GEN550TCGEN1100TC
PRP power500 kVA.
1000 kVA.
STP power500 kVA.
1100 kVA.
Voltage400/230 V + 23kV transformer.
400/230 V
Frequency50 Hz.50 Hz
RPM1.5001.500
Engine brandMTUMTU
Alternator brandMECCALTE WITH PMG.MECCALTE WITH PMG.
TypeSoundproof in 40 HC container.
Soundproof in 40 HC container.
Specific installation roomsThree independent areas
Two independent areas
Fuel tank1.500 L integrated in the base frame.3.000 L double-walled and approved according to Chilean regulations
Sound emission level56,3dB (A) 7m64,5dB (A) 7m.
PaintISO 12944 C5M.ISO 12944 C5M.
CouplingElastic between engine-alternator.
Elastic between engine-alternator.
Control systemCOMAP (possibility for parallel operation).DEIF (possibility for parallel operation).
Circuit breakerSchneider, removable and motorized.Schneider, removable and motorized.
Cooling systemRemovable for maintenance.
Removable for maintenance.

Genesal Energy consolidates its growth

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The company expands its headquarters by 3,000 square meters in order to increase its production capacity.

Genesal consolida su crecimiento en 2019

Genesal Energy consolidates its growth in order to tackle a 2020 full of projects in Spain and in the demanding international market

The company continues its international expansion in strategic sectors and countries with personalized customer service as well as services like the Technical Assistance Service

Power plants, electric substations, DPCs, hospitals, airports, food and telecommunication sectors. Genesal Energy is present in all of these industries thanks to the versatility and high specialization of its equipment. With more than 25 years’ experience (this year the Galician company celebrates its anniversary) and with branch offices in Mexico and Peru, the company is closing 2019 with constant and controlled growth and with its mind on a new year full of projects. Because Genesal Energy’s objective is to continue growing internationally with a presence in new markets like the Asian giant Taiwan, but also nationally by increasing its production capacity with new installations adding up to 3,300 square meters at its central headquarters in Bergondo (province of A Coruña).

Here are some success stories and challenges for the future.

New rental product lines:

The search for new lines of business within an increasingly competitive market is one of Genesal’s commitments, and the rental line, with some excellent results at the end of the first year of its launch by the company is an excellent example. Reliability and robustness define these gensets destined for the rental market. Following the success of this product line and the official presentation in Mexico, where four generators were subsequently delivered, the company will continue its commitment to these rental products throughout the 2020 fiscal year. They are special products, custom made so as to make maintenance easier, and fitted with state of the art GPS systems for their immediate geolocation in case of theft.

Emergency energy for large health centers: Toledo Hospital (Spain) and Montero Hospital (Bolivia)

Electricity is vital in hospitals and its absence can have fatal consequences, which is why it is necessary to have state-of-the-art emergency generator systems. Among the projects carried out by Genesal in 2019, a special mention should be given to the supplying of four generators to the new hospital in Toledo which will open in the first semester of the year. They are four generators of 2250 and 2500 kVA which will function in parallel. Outside Spain, Genesal Energy offers a turnkey service to Montero Hospital (Bolivia): three 410-450 kVA generators, which are soundproof, one of them automatic, the other two in parallel with the air outlet on the upper side in order to fit in with the installation.

Gaining ground in the wind energy sector: from Los Llanos to Monte Cristi

This year Genesal has strengthened its presence in the field of renewable energy with a good number of wind farms in its portfolio. For example, in 2019, the company supplied emergency equipment for the substations in Oriche and Venta Vieja, in the province of Teruel, Montilla del Palancar (province of Cuenca) and in Serra das Penas (province of Lugo), and also for the wind farm in Los Llanos (province of Málaga), an installation for which we manufactured and delivered turnkey equipment. Internationally, we delivered a 100% personalized generator for the wind farm in Monte Cristi (Dominican Republic), whereas for the Agua Clara wind farm on the same Caribbean island, Genesal’s Engineering Department designed and manufactured a hurricane-proof generator for the whole park, which has 25 air generators, supplying power for 250,000 persons.

Biomass plants: the Viseu and Fundão stations

In Portugal there are two stations considered prime examples in the production of clean and renewable energy. They are the biomass plants located in Viseu and Fundão, repectively. Genesal installed special tailor-made equipment in both of these facilities.

More projects in Mexico: the combined-cycle power facility Topolobampo III

Genesal Energy’s strong presence in Mexico results in numerous projects, some of which are on a very large scale. Such is the case of the Topolobampo III combined-cycle power facility, whose founding in the municipality of Ahome was encouraged by the Mexican Federal Electricity Commission (CFE), and which will supply power to more than 2.5 million people. It will start operating in 2020 and the emergency power for it will be supplied by Genesal.

Tailor-made generators for the Saudi Embassy in Chad

The embassy of Saudi Arabia in Chad also uses emergency power from this Spanish brand. Concretely, the order consisted of three sets of tailor-made generators of two different powers: of 2 x 1.000/1.100 (ojo, en español, también está mal, sobra un 0) kVA, 2 x 1.500/1.650 kVA and 2 x 25-27 kVA respectively, supposed to work in parallel.

Bigger presence in Asia: entry into Taiwan

The growth witnessed in Southeast Asia over the last two years was strengthened in 2019 with the addition of a new market: Taiwan. Said country is one of the most powerful economies in the world and Genesal entered its market through several projects. In total, we have supplied the Government 13 generators. It’s our aim to continue to expand the market with new operations.

New year, new challenges

The good results obtained in the 2019 fiscal year, which has seen a constant growth, induces optimism once again. The company, after 25 years of presence in the energy sector, has now grown up and expanded its central installations in Bergondo (province of A Coruña) by 3000 square meters. The new space is meant to provide the necessary production capacity in order to tackle the new challenges by an orderly growth, given that Genesal Energy’s main aim is always the customer, who should never feel unsupported, the company states.

An example of this commitment to close attention and personalized projects -a hallmark of our company- is the boost received by the Technical Assistance Service (SAT) Department -now an indisputable benchmark in matters of remote management and multi-branding- a section which is closing the year with a steady growth and the modernization of its vehicle fleet, a process which takes into account the latest developments in ergonomics.

As far as the expansion plans are concerned, Genesal Energy will maintain its international vocation. In this regard, although Europe and Latin America are its main markets, the company pays very special attention to others, such as Qatar and Taiwan, as well as the African market, a real challenge for the energy sector.

 

Get to know our 2019 projects

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Remote management, added value in Genesal Energy’s Technical Support Service

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Remote management and SAT

Our Technical Support Service closed 2019 with sustained growth and the modernization of its vehicle fleet, which incorporates the latest ergonomic improvements.

Guaranteeing the reliability of our gensets and offering the best customer service are the pillars of Genesal Energy’s Techical Support Service, which in the last years has grown spectacularly. Our Technical Support Service is our maintenance, installation and reparation service which offers specialized attention with a clear objective: to achieve the best performance of the equipment to fully comply with the client’s needs.

“We’re a reference company when it comes to remote management and multi-brand service”, Marga González, Technical Support Manager, explains, adding that predictive maintenance (remote management and supervision system) has turned the Galician company in a reference company, both nationally and internationally, in the detection of possible breakdowns as well as the status of any unit through a stationary or mobile internet connection. Adjustments are also carried out remotely, impacting action time directly “as it is reduced considerably”, the area manager points out.

Comfort and security

More than 30 professionals form this business line which last year closed its accounts with a sustained growth in maintenance and has modernized its vehicle fleet through the incorporation of the market’s latest ergonomic improvements in order to avoid staff fatigue and make their job more comfortable. “We don’t consider it an expense, but an investment in quality for the peace of mind of our clients and employees. It’s a win-win”, says Marga González.

Their own load banks and a 24 hour service are the hallmark of Genesal Energy’s Technical Support Service. “Knowledge and innovation allow us to provide exclusive and personalized solutions, tailor-made for our clients”, says González.

Case Studies

The update of four gensets for an important television network has been one of Genesal Energy’s Technical Support Service’s latest projects. In this case, the existing controllers for parallel operation were substituted for three state-of-the-art control panels, and new circuit breakers were installed.

Our Technical Support team also carried out the update of the genset fleet of the substations of an important global electrical company in order to carry out predictive maintenance works. For this project, the substitution of more that 30 control panels, communication cards, pressure, temperature and fuel sensors were carried out in record time in order to comply with the client’s needs.

Another succesful project consisted in the study of the Modbus mapping of the genset fleet of an important telecommunications company to integrate the predictive maintenance of its units into its management and remote control system. For its execution, Genesal Energy analyzed almost a hundred mappings according to the features of each piece of equipment, their operation, environmental factors, climate…

Find out more about our maintenance service

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Supply of a generator set in the hotel sector

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Once again, GENESAL ENERGY is the chosen brand for the supply of a generator set in the hotel sector, specifically in such a tourist-dense destination as Santa Cruz de Tenerife.

This 440 kVA genset has been designed and prepared to guarantee the correct operation of the hotel should a mains failure ever occur on the island.

Features

  • 400 kVA PRP & 440 kVA STP generator set, with VOLVO engine and MECC ALTE alternator.

We’ve reinforced our presence in Asia through a new market: Taiwan, the ever-expanding Asian Tiger

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At Genesal Energy we’ve opened up a new market in Taiwan through the supply of a 500 kVA generator set designed to supply power in mains failure situations.

Our arrival to the Taiwanese market marks a turning point in Genesal’s internationalization plan in South East Asia. Taiwan is a strategic market, due both to its economic importance as the 28th wealthiest country worldwide and the 6th wealthiest in Asia, and to its potential for companies in the energy industry.

With a GDP that grows at a dizzying rate year by year, the power distribution sector is in constant evolution and with an increasingly strong focus on sustainability. As such, the first project we’ve carried out in the country, a stationary genset of 450-500 kVA, complies with Tier III emission standards. We delivered a genset which was completely adapted to the client’s requirements, providing the adaptability and flexibility needed for a correct integration of all components, with the following features:

  • Stationary, open type genset of 450-500 kVA at 60Hz, 380/220V.
  • DSE 7320 MKII control panel for automatic start at mains failure, with an Ethernet communication module to monitor the genset’s status remotely from a linked-up computer.

12 gensets for the Administration

Furthermore, our entry into the Taiwanese energy market has been consolidated through the supply of 12 gensets of 200/220 kVA for the Taiwanese Administration. The units, all customised, are designed to enter into operation should a mains failure ever occur. The gensets are stationary and were personalized according to the client’s requirements to be adapted to the modifications that would be carried out at a later date in their facilities. All of them comply with Tier III emission standards.

Main features

  • Open type stationary units of 200/220 kVA at 60Hz, 220/127 V.
  • DSE 7320 MKII control panel for start-up upon mains failure.
  • Engine with EGR valve for exhaust gas recirculation.
  • Alternator anti-condensation heaters.

We designed an ‘anti-hurricane’ generator set for a great wind farm in the Dominican Republic

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Our engineering team has designed and supplied emergency power to the Agua Clara wind farm in the Dominican Republic, a large power station capable of providing power to 250.000 citizens.

The wind farm, whose first phase has already come to a close, has 25 wind turbines, of two megawatts (MW) each, which represents an estimated annual production of 170.000 MW/hour. 

With an initial investment of 100 million dollars, the project produces 50 MW of renewable power and the objective is to install up to 200 MW once the four phases of the project have concluded. Genesal Energy has designed and supplied a special generator set, adapted to face the complicated climate of the región of Monte Cristi, where the wind farm is located.

Agua Clara is in a hurricane-prone area, which means the wind farm’s infrastructure requires special equipment capable of facing this type of phenomena. In order to reduce the pressure exerted on a wind turbine by a potential hurricane, it must direct its nacelle and blades with the help of electric and hydraulic motors in such a way that the wind exerts the least force possible on the structure, avoiding harm.

One hundred percent personalized

At the windfarm, the client needed that, in the event of a hurricane or a cyclone and in consecuence, a mains failure, the wind turbines could position themselves correctly and avoid serious damage through the use o fan alternative source of energy. To achieve this, we manufactured a generator set capable of powering the auxiliary services which drive the positioning of the windmills.

The generator which we’ve designed is 100% customised and can be completely managed, controlled and monitored from the wind park’s control centre (SCADA). Inside the actual container, the local control system was installed, along with a PLC to manage communication with the farm’s SCADA through fiber optics, and a protection relay.

Genesal Energy ha diseñado y suministrado un equipo especial, adaptado para hacer frente a la complicada climatología de Monte Cristi.

The Genesal Energy unit will receive start-up and shut-down commands from the wind farm’s control centre and will start-up and energize a step-up transformer. From that momento onwards, the genset will power the whole wind farm and, therefore, the auxiliary systems needed to position each one of the wind turbines to avoid damages in the event of a hurricane.

To compensate the capacitance of the medium-voltage cable runs to the turbines, of hundreds of metres of height, an inductor bank was also installed in the wind farm’s substation. The generator set must power the bank during the first seconds after the hurricane, while the wind turbines and the medium-voltage cable runs aren’t being powered. In order for the generator set to be able to support this strong inductive load, its alternator was oversized, through the installation of a top of the range 3.000 kVA alternator.

Features

  • Engine and alternator pre-heaters.
  • ModBus TCP/IP communicaition.
  • Tailor-made control logic carried out through PLC & DEIF AGC4 controller.
  • Dedicated electrical protection relay.
  • Oversized alternator to support high inductive currents.
  • Automatic fuel transfer system.
  • Special application for an anti-hurricane system in a wind farm.

 

In a generator set, reliability is key

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We’re in Austria, the demanding Central European market

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100-110 kVA genset to be mounted on a trailer in Austria, for the genset fleet of an important telecommunications company.

Features

  • Engine compliant with mobile genset exhaust gas emission standards.
  • Prepared to operate in island mode as well as in parallel with mains.
  • 425L baseframe fuel tank integrated into the soundproof canopy, with leakage collection tray.
  • Air and exhaust gas outlets adapted to the client’s needs to fit with the genset room’s layout.
  • Mains breaker (ATS system) integrated into the genset’s control panel.

Supply of two generator sets for a solar power plant

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Another achievement by our distributors.

We’ve supplied two gensets of 220 and 462 kVA, 220-127Vac at 60Hz, prepared to operate under CFE norms according to the degree of seismicity in Mexico as well as the area’s semitropical characteristics.

With a capacity of 170 MW, the Santiago photovoltaic power plant is located in the state of San Luis Potosí (México). It’s a large complex, whose construction began in 2017 with the participation of 1.000 workers. The power plant was built with the idea of supplying enough electricity to power 138.000 homes.  

Its 672.000 solar panels turn the Santiago power plant into one of the largest renewable energy installations in terms of investment (250 million dollars) and also one of the most spectacular, not only in regards to its size (it occupies 750 hectares), but also to the results its expected to achieve: it was built with the objective of preventing the emission of 340.000 tons of CO2 into the atmosphere each year.

The Galician company Genesal Energy participated in this megaproject through the design and supply of two generator sets of 220 and 462 kVA, 220-127 Vac at 60 Hz, prepared to operate in the area’s special conditions, such as the semitropical climate.

Both units were manufactured in Genesal Energy’s headquarters, located in the town of Bergondo, in A Coruña (Spain), with the goal of guaranteeing the correct operation of the booster and switching substations during emergency situations, providing the power necessary for the auxiliary services, emergency lighting, etc.

Genesal Generator in a solar power plant

High precision

Both gensets are high precision units, whose design has been thought out to the very last detail to comply with the client’s requests. They have the following features:

The first unit (GEN220FC) is soundproof type and has a 500 L fuel tank integrated in its baseframe, while the second (GEN462F) has a 1.000 L fuel tank. Both special gensets comply with all technical requirements established by CFE (Comisión Federal de Electricidad or Federal Electricity Commission) norms, the prestigious certification that the CFE awards and which elevates the company to the category of trusted supplier.

The CFE-LAPEM certification is granted by the LAPEM (Laboratory for Equipment and Materials Testing), an organization dependent on the CFE, and Genesal Energy received said distinction last year upon passing the audit process carried out by LAPEM in the company’s headquarters, thus becoming part of the select group of companies which have been awarded this certification, a true symbol of excellence.

Features

  • GEN220FC 500L fuel tank integrated into the base frame, Soundproof type, and with technical features following CFE (Federal Electricity Commission of Mexico) standards, painting with finish according to CFE norms.
  • GEN462F Approved 1000L double-wall fuel tank for external installation, with technical features following CFE (Federal Electricity Commission of Mexico) standards, painting with finish according to CFE norms.