Genset Roundup

Volvo launch strongest industrial engine range

Volvo Penta’s has a launched a 16 l engine. It is based on Volvo’s six-cylinder design, but contains several features including an electronic control system that provides added operational reliability and optimal combustion.

The new high-efficiency engine has a displacement of 16.1 l and is available in several configurations for generator sets as well as stationary industrial applications. It offers more power than its predecessor, with improved characteristics at low r/min and up to 57 per cent more torque.

The launch of Volvo’s 16 l engine
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Power levels ” up to 604 kW ” are also significantly greater than its predecessor. Improved fuel efficiency and more complete combustion are two reasons for this higher capacity. An injection pressure of up to 2000 bar creates the requisite environment for optimal fuel combustion and results not only in lower fuel consumption, but also lower nitrogen oxide and particle emissions.

The engine meets all existing emission requirements, and the new technology will allow for adaptations to meet future legislation.

The engine’s fuel needs are analyzed up to 100 times/s. By controlling injection levels and timing through fuel valves in the unit injectors, the engine always receives the amount of fuel that operating conditions demand. The result is lower fuel consumption and cleaner exhaust emissions, as well as a more responsive engine at increased loads.

Deutz widens product series

Deutz has added two new series of compact diesel engines. The engines are water-cooled and their designations, 2008 and 2009, cover a total of five different engine types in the high-volume output range from 9 to 50 kW.

The Deutz engines have been designed for the particularly heavy demands made by mobile working machines, agricultural machines, and pumps and generators. Their development also took account of the more stringent requirements the market is now making in terms of the lowest possible exhaust and noise emissions, low vibrations, compact dimensions, and the assurance that they will not quickly become obsolete.

The engine series D 2008 with a power range from 9 to 25 kW at 3000 r/min
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The five new Deutz engines meet the strict exhaust emission limits of Stage II in Europe and the USA and are also readily equipped for the next exhaust emission limit stage, which will take effect in 2008. With the new Deutz 2008 and 2009 series, original equipment manufacturers will have suitable and durable drive systems available to them. Series production will start in January 2005 at the Deutz engine factory in the Porz suburb of Cologne.

Wärtsilä wins largest power plant order

Luz y Fuerza de San Lorenzo (Lufussa) has awarded a contract to Wärtsilä to supply a 250.7 MW base load diesel engine power plant in Pavana, Honduras, Central America. This will be Wärtsilä’s largest power plant to date.

The Pavana III Power Plant will be powered by 15 Wärtsilä 18V46 engines, operating on heavy fuel oil (HFO). The scope of Wärtsilä’s contract covers power plant engineering, supply, construction and start-up. The plant will enter commercial operation in two phases: the first phase in 12 months will provide 133 MW and the second phase three months later, will bring the plant to its full capacity of 250.7 MW.

During 2001, due to the country’s increasing energy demand and the need to replace inefficient generating facilities, the Honduras national utility Empresa Nacional de Energia Eléctrica (ENEE) entered into an international tender to purchase 210 MW for 12 years. The tender concluded in July 2002 with six bidders submitting proposals.

In November 2002, ENEE awarded the 210 MW PPA contract to Lufussa, as the company offering the lowest selling price and including a 120 km transmission line and substation for ENEE.

The Pavana III Power Plant powered by 15 Wärtsilä 18V46 engines
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The project at Pavana site also includes a new substation named Aguas Caliente on the site together with a 120 km, 230 kV transmission line, and additional storage tanks at its port fuel depot and at Pavana site, plus a 13 km fuel pipeline from the fuel depot to the plants. The transmission line will deliver the power generated by the Plant to the Amarateca substation, located on the perimeter of the Honduran capital Tegucigalpa, where the power is urgently needed.

Cummins gives quick-fix emergency power

Cummins Power Generation commissioned a 170 MW emergency power station in 41 days ” its largest single power site to date.

The Cummins plant in Mexico provides 170 MW of emergency power
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Built at two sites near the city of Zacatecas, Mexico, the project was the result of a contract awarded by the Comision Federal de Electricidad (CFE), the state-owned power company. The water levels in major hydroelectric dams in Mexico were at record lows, and the amount of rainfall expected was not likely to be enough to permit the country’s electricity demand to be met through hydroelectric power generation. For this reason, the CFE requested quotations for bid proposals for emergency power totaling 500 MW. Cummins was able to complete the project in the limited timeframe by utilizing its large North American fleet of rental generators. Diesel generators offered immediate availability, high fuel efficiency and excellent reliability.

The 170 MW prime power facilities at the Zacatecas sites consisted of 150 trailerized generating units: 75 – 2 MW generator sets; and 75 – 1.5 MW generator sets, manufactured by Cummins. Each individual generating unit was a stand-alone power station that included a diesel-powered generator, PowerCommand digital controls, cooling system, fuel tank, paralleling equipment, and the necessary step-up transformers to connect to the grid. This gave plant operators the flexibility to operate just a few units in parallel with the grid, or all 150, depending on power needs.

Wärtsilä to install gas-fired plant for Bangladesh

Wärtsilä Corp. has won a contract from Surma Energy, a Larfarge Surma Cement company, to deliver a 30 MWe power plant for a new cement plant.

The engineering procurement and construction (EPC) contract worth G15m includes the supply of four Wärtsilä 18V34SG gas engines and two 18V200 diesel engines. The 18V34SG engine sets will each deliver 5990 kWe at 750 r/min and the 18V200 sets 3450 kWe at 1500 r/min.

CAD drawing of the Wärtsilä 30 MW power plant in Bangladesh
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The gas engines will be for normal baseload operation on natural gas while the 18V200-engined sets will be for peak load operation during the starting of main motors in the cement plant. The plant will operate independently of any external network and is situated in north east Bangladesh.

Briggs introduce V-Twin

Briggs & Stratton Commercial Power has launched a powerful new range of 18.65 – 26.1kW (25-35HP) V-Twin engines available in two displacements with six different horse power options. Robust, powerful and environmentally friendly, the application engineered V-Twins are available as both air- and liquid-cooled models.

The 25-35 Vanguard air-cooled V-Twin engine
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The air-cooled V-Twin engines have been developed with ‘cooler cleaner’ technology, including an advanced debris management system, allowing them to run between 25 ” 35 à‚°F cooler than traditional air-cooled V Twin engines. This not only extends the life of the machine and lowers engine maintenance costs, but also ensures the engines comply with all European noise and emissions regulations.

The liquid-cooled V-Twins feature a 360 à‚°F cooling water jacket, efficiently cutting oil and engine temperatures. All engines feature a large volume muffler, which helps to provide a quieter engine.

Cummins selected by Estonia company

Cummins Power Generation (CPG) is helping to keep the Estonian economy moving by ensuring the production of asphalt concrete for construction specialist company Tallinna Teede AS (TTAS).

TTAS has won a contract to upgrade nearly 60 000 km of road using mobile asphalting units. These units require a constant power supply for the continuous production of asphalt throughout the day and to maintain the asphalt’s temperature overnight.

Cummins supplied the above gensets housed in its 12 m container, including a 3000 l fuel tank
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CPG, working together with local distributor JCS Tallmac, provided the solution to this problem by supplying two gensets, housed in a 12 m container, including a 3000 l fuel tank – thus allowing the variable power requirements to be met whilst ensuring noise levels of less than 75dB(A) at 7 m.

Also fitted with fire alarms and internal lighting, the solution meets all EU regulations ahead of Estonia joining in May 2004.

As the larger 460 kVA genset, used for production, powers down at the end of each day, the smaller genset (60 kVA) is set to start automatically, ensuring a smooth power transfer and correct overnight maintenance of the asphalt.

BBC orders standby power generation

The British Broadcasting Corporation (BBC), the world’s most respected media organization, has ordered the redevelopement of its broadcasting house in London’s west end. The order with Bovis Lend Lease for à‚£252m is the first phase of a five year project to create the world’s largest media centre.

In conjunction with T.Clarke, the nominated mechanical and electrical contractor for the first phase, and Faber Maunsell overall infrastructure consultants; Northern Ireland based FG Wilson (Engineering), a diesel generating equipment manufacturer, has been awarded an order to provide the standby power generation equipment including 2 x 18VP185 generating sets.

The selection of the VP185 for this application has been made because of the reqiurement for a high power to weight ratio and the need to achieve a compact installation without compromising sytem integrity and overall reliability.

The 18VP185 generating set
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The 18VP185 operating at 1500 r/min will produce 3250 kW with a ten per cent overload for 1 h in any 12 h operation and will be integrated into the generating sets by FG Wilson (Engineering). Once installed on site the sets will be controlled and operated through a building management system in conjunction with the sets own sophisticated control and monitoring package. Installation of the first phase engines is programmed for spring of 2004.

GE Jenbacher to supply genset to Pakistan

GE Jenbacher has been awarded a contract to supply power generation equipment to a textiles factory near Karachi, Pakistan’s largest city.

Austria-based GE Jenbacher, which is part of GE Energy, announced that it will supply Yousuf Textile Mills Ltd. with a 1 MW, JGS 320 GS-N.L generator set. The low-emission unit, which features the DIA.NEXT management system, will use natural gas as its primary fuel source.

The generator set is designed to create more power for Yousuf Textile’s factory, which is being expanded. The company manufactures and exports various products including cotton yarn. The plant is located in the 13-acre Korangi Industrial Area, southeast of Karachi.

Karachi is the capital of the province of Sindh in southeastern Pakistan. The city is Pakistan’s largest, with more than 10 m people, and serves as the country’s manufacturing centre.

The new generator set will be manufactured at GE Jenbacher’s facilities in Jenbach, Austria and shipped to Karachi in July 2004. The equipment is expected to be installed and to begin commercial operation in September 2004.

GE Jenbacher will also provide technical services and spare parts for the project. The new contract marks GE Jenbacher’s second order from Yousuf Textile, which purchased a similar generator set in 2001.

Power generation with mechanical drive

GE Marine & Stationary power (M&SP) now offers three medium speed diesel engines that are ideal for power generation and mechanical drive applications.

These engines are available for applications in the 1.2 to 3 MW range. The three cylinder engines, each rated as 2.8 MW, will go into continuous power operation in the Middle East this year.

GE’s diesel range of medium speed engines are designated to the 7FDS engine series for power generation applications. They are available in power ranges between 1193 kW/1600 bhp to 3057 kW/4100 bhp for continuous operation and 1312 kW/1760 bhp to 3356 kW/4500 bhp for maximum power in 8, 12 and 16 cylinder V configurations.

The 16-cylinder GE 7FDS diesel engine series
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GE claims that when it comes to maintenance and operating costs, an advantage to its customers is that medium speed diesel engines can go three times as long between overhauls, nine times longer between schedule maintenance and are one and a half times cheaper to operate on a per kWh basis compared to high-speed diesels.

For example, the typical maintenance cycle for GE’s diesel engines running in continuous operation is 24 months between overhauls. The engines also offer NOx below 8.6 g/hph.

Genset orders on a high

A boom in orders is currently being experienced for diesel generating sets world according to Indamex, a UK genset manufacturer.

The Middle East, Africa and the Far East are all producing record orders well above the same period as last year. Orders are mainly for the larger size of generating sets ranging in outputs from 500 to 2000 kVA suggesting a rise in power demand from the major type of civil engineering projects, factory and industrial expansion coupled to power shortages, an increase in multi-story office premises and the continuing development of mobile phone networks.

Indamex and part of the VibroPower Corporation of Singapore, are currently dealing with a greater than 200 per cent increase in orders for the Middle East and Africa compared to last year. This includes a contract for over 170 generating sets ranging in sizes from 100 to 1000 kVA in a fully silenced configuration which have had to be air freighted to meet the customers demands for short deliveries. The smallest set weighs 2 t and the largest 12 t.

Several 90 kVA sets have been supplied to a plant hire company for use at Bedouin style traditional weddings held in tents in the desert. Orders from Iran, Egypt, Qatar, Kuwait, Yemen, Saudi Arabia and the UAE include a number of generating sets for marine purposes, ranging in sizes from 80 to 600 kVA.

Orders for the diesel Indamex gensets range from 500 to 2000 kVA
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Meanwhile, parent Company VibroPower in Singapore has won orders in excess of $15m from China as a surge in demand for diesel generating sets has been experienced due to power shortages from the public supply. The power shortage in China has badly affected a large number of small and medium enterprises as many factories are only permitted to operate three-day weeks. Most of the generators are in the 500 to 2000 kVA sizes.

Weg bags Brazil deal

Weg is partnering with the largest alcohol plant in the world to provide electrical power from sugar cane waste.

The project involves doubling the generation capacity of the Santa Elisa power plant in Sàƒ£o Paulo, Brazil from 30 MW to 60 MW. Weg is providing a complete electrical package including 2 x 15 MW gensets, 3 x 15 MW transformers, panels cabinets and the complete automation system for the generation and distribution of energy. The new investment allows the Santa Elisa plant to produce enough energy to supply 110 000 people.

Half the 60 MW capacity is used to process 35 000 t/day of sugar cane. The other half is sold to the local utility CPFL.

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