Peaking power for the Port of Pecém

As one of the largest ports in Brazil, the Port of Pecém sees 60 per cent of the products exported from the Ceará region flow through its waters. Providing power for a facility as large this is a complicated task. In order to help power the electrical infrastructure required to operate, the Port relies on an on-site power system from Cummins Power Generation for both peaking and standby power. The power generation equipment provides peaking energy to save money on electric bills as well as backup power should there be a utility outage due to unreliable power supply, terrorism or a natural disaster.

Located on the Atlantic Ocean, near the city of Fortaleza, the Port of Pecém is primarily used for the export of shipping containers to Europe and the US. The main products exported are steel and fruits, with an additional pier for loading and unloading petroleum derivatives.

In 2004 the Port of Pecém loaded and unloaded almost one million tons of cargo, a 35 per cent increase over 2003. With further expansion expected, the port needed to find a way to effectively and economically meet its power demands.

The Port of Pécem, one of the largest ports in Brazil, relies on an on-site power system from Cummins Power Generation for peaking and standby power
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“In Brazil the power isn’t always very reliable. There are often random power outages that can seriously interrupt international shipping,” explained Marcilio Rocha, coordinator of the secretary of infrastructure of the State of Ceará. With that in mind, Rocha contacted Distribuidora Cummins Diesel Nordeste (DCDN) about finding a reliable power alternative. “DCDN and Cummins Power Generation worked together to install a system that has significantly improved the reliability of electricity supply to the port,” said Rocha.

The port’s on-site system consists of three 1750GQPB lean-burn natural gas generators with a total generating capacity of 5.25 MW. The load on the generators varies depending on the level of activity of the port; however, it currently rarely exceeds 2 MW. “We use the generators to provide electricity for all the equipment at the port. By far the largest load on the generators comes from the refrigeration for all the fruit, but we have the ability to power the entire load of the port should the situation arise,” explained Rocha.

In addition to the three gas generator sets, Cummins Power Generation installed a “black start” diesel generator set with the ability to start and run even when there is no outside power available. Additional Cummins Power Generation equipment at the Port of Pecém includes a DMC300 digital master control for controlling the power plant, transformers and automatic transfer switches.

In addition to providing reliable power, the generator sets installed by Cummins Power Generation help lower operational costs by reducing the Port of Pecém’s dependency on the local utility during certain times of the day. The lean-burn gas generator sets run at peak times, from 5:30 to 8:30 PM, on Monday through Friday. “Power is very expensive in Brazil at those times,” said Rocha. “The electricity produced with the generator sets costs about one-third of that charged by the local utility company.”

“We have been nothing but impressed with the way the generator sets from Cummins Power Generation have performed,” said Rocha. “More generators will be needed as the port continues to expand. When the expansion is complete in two years, five more generator sets will be added, bringing the total generating capacity to 14 MW.”

The additional generator sets will continue to reduce operating costs for the Port of Pecém as it expands by providing cheaper and more reliable power during peak hours, as well as ensuring the port remains in operation in the event of terrorism or a natural disaster.

Spanish launch for big Cat

Caterpillar chose its Demonstration and Learning Centre near Malaga in the south of Spain as the venue for the European launch of its new Cat C175 large diesel engine family. The new genset will be available in the 2-4 MW range, each incorporating the C175 centerline engine and are designed for standby, prime, continuous and load management applications.

The C175 has been designed to Six Sigma standards and is the first genset to incorporate Caterpillar’s ACERT technology, which has already been rolled out across a number of other Caterpillar products. ACERT technology was developed in 2005 and combines advances in electronics, air management and fuel delivery to improve engine response and fuel efficiency, plus lowering NOx emissions. Research and development costs for the ACERT emissions compliance technology were more than $0.5 billion and the technology is now running in 330 000 engines. The total cost of development for the C175 including ACERT was put at around $1 billion.

The new genset will be available in the 2-4 MW range, each incorporating the C175 centerline engine, and are designed for standby, prime, continuous and load management applications
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Bill Barber, product manager for Caterpillar’s Electric Power Division said at the launch, “The market is currently served by heavier and more expensive engines. The introduction of the C175 represents a landmark in the reciprocating engine sector.”

The Cat C175 is much smaller and less than half the weight of its predecessor high-speed gensets and has a greater power density. Its size and weight makes it suited to both stationary and in transportation applications. Caterpillar says that the new models are able to deliver high efficiency and low emissions without sacrificing performance. Caterpillar declined to comment on how the price of the C175 would compare to other engines in its current range.

“More power, Gromit!!”

In scenes reminiscent of Wallace and Gromit’s latest caper, “The Curse of the Wererabbit”, power supply problems were rapidly solved when Western Power Distribution called in Power Electronics, one of the UK’s leading suppliers of generating systems.

A major fire at the Bristol, UK, warehouse used by the Wallace and Gromit creators Aardman Animations tripped out circuits in Western Power Distribution’s grid, and the utility immediately sent engineers to the site to assess the situation. The fire caused the roof of the Victorian warehouse building to collapse, and much of the Oscar-winning studio’s past works, including models, memorabilia and awards were lost.

When Western Power Distribution’s engineers realised that it would not be possible to restore mains supply to the area, they called in Power Electrics, which has been contracted since 2002 to supply generators in the event of a power failure.

Almost 30 m of power cables running up the building were destroyed in the fire making it unsafe to restore mains power.

Power Electrics operates a 24 hour dedicated helpline to its customers to respond to situations like this and within an hour four generators were dispatched to the scene from the Bristol depot. The sets supplied ranged in size from 200 kVA to 350 kVA.

LSLN technology secures data centre

AVK|SEG recently completed a major data centre project in London, UK, using its Low Space Low Noise containerised generators. The low space is achieved using the 12 m standard ISO footprint, this gives 5 m centres between containers, providing suitable access space. The water jacket and turbo heat is removed using roof-mounted radiators with slow variable speed fans, to reduce operating noise. The ambient heat is removed using fixed speed fans and attenuation. The exhaust system is part mounted within the container. All these design features provide a low noise level at the boundary of the site compound.

AVK|SEG has completed a major data centre project in London, UK, using its Low Space Low Noise containerised generators
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Another project requirement was the complete testing of the 4 x 2 MVA N+1 generators with the generator switchboard. The eight-position containerised test bay allowed this using only half of its capacity. This testing provided complete confidence that the system would function as designed once on site.

All generator control panels and the command PLC use the ‘Kerys’ man machine interface touch control colour screen. Couple this with the special relationship with the MTU and its MDEC engine management system incorporating electronic governing results in predictive load step monitoring providing increased performance.

JCB powers up

JCB has entered the generator market with a brand new range of 42 diesel-powered generators. Aimed at the UK market, the range has been designed to meet the requirements of a very demanding market for both prime power and standby power applications.

The new range is available in 18 power nodes from 15 to 500 kVA, available as single or three phase at 50 Hz. All power sizes are available as open units or with sound attenuated canopies.

JCB’s own 444 engine is the main platform for the new range of generators
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Included in the range are six models specifically designed for the rental market. Standard features include: 24-hour fuel tank; 110 per cent bunded base; fork sockets; single point lift; Racor fuel/water filter; 4-pole circuit breaker with earth leakage; fuel tank level gauge; three-way fuel valve; connection box with copper busbar; earth leakage protection and multiple sockets.

JCB’s own 444 diesel engine is the platform for this development and it will power the mid-range generators, which account for 40 per cent of UK generator demand. The smaller generators will use Deutz diesel engines while the larger ones will be powered by Sisu and Scania diesels.

Generators are flavour of the month

LCH Generators of the UK recently supplied a total of three diesel generator sets to international construction group UK GSE Limited to provide temporary mains-independent power for a £10 million redevelopment project at a former flavourings factory in Milton Keynes.

The project involved the conversion and redevelopment of the flavourings production facility at Milton Keynes of Swiss-based Givaudan, the international flavourings and fragrances manufacturing group. Following the consolidation by the company of its manufacturing activities within the Givaudan facility at Dortmund in Germany, a major proportion of the company’s UK site was released for redevelopment. The former production unit was subsequently acquired by Volume Developments Ltd. for demolition and rebuilding as warehouse units. The remaining areas were retained by Givaudan to provide continuing research and development facilities for the group.

The redevelopment project was carried out by UK GSE, the UK arm of the Avignon, French-based international construction group. In addition to the redundant production facilities, the former production buildings scheduled for demolition also housed the main energy centre, including the high voltage incomer and substation, distributing power to the areas and facilities retained and in current use by Givaudan.

LCH Generators’ diesel units enabled uninterrupted power to be maintained while demolition and site clearance proceeded
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To maintain uninterrupted power to Givaudan’s facilities while enabling demolition and site clearance to proceed, UK GSE arranged with LCH Generators to supply and install an 800 kVA diesel generator from the genset specialist’s Coventry depot. A second 800 kVA standby unit was also supplied together with automatic changeover switching controls, to provide continuous, uninterruptible power over a seven-month period until a new public mains supply could be installed and connected by Central Networks.

In addition to providing a comprehensive fuel service, including the installation of a 3000 litre bunded fuel tank, LCH Generators also supplied a further 100 kVA generator. This is currently providing temporary mains-independent power for plant, equipment and site-office requirements for the construction company.

GE expands Type 4

GE Energy has introduced two additions to its Jenbacher Type 4 engine series: the J412 GS and J416 GS models.

GE developed the J412 and J416 models to address a growing demand for higher efficiency engines in the output range of 800 kW to 1.2 MW. The original Type 4 engine – the J420 GS – was developed to serve the 1.5 MW segment. Since 2002, more than 250 J420 engines have been installed worldwide.

The J412 and J416 began field trials in 2003. In total, seven field test engines accumulated more than 60 000 operating hours, while demonstrating high levels of efficiency and reliability.

Features of the J412 and J416 include enhanced ignition technology and Jenbacher-developed spark plugs; the TecJet gas-dosing valve, which offers a high degree of control accuracy; and a newly developed, high-efficiency combustion system with Miller LIVC technology. This technology system results in higher mechanical efficiency and improved fuel flexibility.

There’s mileage in CHP

The campus of American Honda Motor Company’s headquarters covers more than 40 ha and includes 12 buildings with nearly 139 400 m2 of mixed-use office space for 3000 workers. Known worldwide for environmentally-conscious products, American Honda established the ability to generate its own electricity for its campus at a lower cost, both fiscally and environmentally, using natural gas, and selected a combined heat and power (CHP) system from Cummins Power Generation. Based on projections, it is estimated that American Honda will save more than 30 per cent in on-campus energy expenditures each year.

Cummins Power Generation’s distributor analysed American Honda’s needs and recommended a CHP system based on one of its most popular natural gas engine generator systems
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Garth Sellers, American Honda’s manager, National Facility Management, says that beyond saving money on its electric bill, American Honda approached the CHP project as part of its commitment to the environment through developing and implementing industry-leading technologies. “We make every effort to contribute to human health and the preservation of the global environment in each phase of the company’s corporate activities, products, manufacturing and business practices,” says Sellers. “Our decision to install cogeneration was an entirely logical one – it took our environmental commitment a step further.”

The CHP system for American Honda consists of a 1250 kW PowerCommand QSV91G gas engine generator from Cummins Power Generation, plus three Mueller heat exchangers that capture over 10 550 MJ/hour of waste heat in the form of hot water from the engine exhaust, engine coolant and oil systems. The hot water is used to run a 250 t Trane absorption chiller for the campus’ air conditioning system.

New four-stroke launched

The MAN B&W Diesel Group is launching a new four-stroke engine onto the market that not only burns both gas and MDO (Marine Diesel Oil), but can also run long-term on pure HFO (Heavy Fuel Oil). This flexibility meets and even exceeds all requirements from the marine as well as the stationary market.

The 51/60DF (Dual Fuel) engine is based on the well-known 48/60B range, tried and tested in both marine and stationary applications. Its technology benefits from the experience that MAN B&W Diesel has gained over decades of working with smaller dual-fuel engines, most recently with the 32/40DF range.

The 51/60 DF is ideal for baseload power generation and will be dispatched from mid-2007
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The 51/60DF is currently the largest four-stroke gas engine on the market and is to be incorporated in all its versions into the MAN B&W Diesel product portfolio in a spectrum ranging from the 6-cylinder in-line engine to the 18-cylinder V-engine. A special common rail pilot oil injection system makes the engine exceptionally environmentally friendly. The available engine power ranges from 6000 to 18 000 kW.

Being the most powerful dual-fuel four-stroke engine in its class, the 51/60DF is not only aimed at the LNG tanker market, but is also ideal for base load electricity generation in power stations with a good gas connection. After extensive tests on the test bed, the first series-produced engines will be dispatched from mid-2007.

Generators tee off for a new resort

GE Transportation’s marine and stationary power business has delivered to Power Quality Engineering, Inc. (PQE), of Cedar Park, Texas, USA one 2.5 MW containerized 7FDS16 diesel generator set.

The medium speed generator set is being used as part of the first phase of development at the La Vallee Greens Golf Course and Resort in Sandy Point, the Federation of St. Kitts and Nevis, West Indies. PQE purchased the first of four GE diesel generator sets for this project. When PQE receives the three additional GE units, power output at the site will eventually be increased to 10 MW.

“We are delighted to be part of this new resort that is currently under construction,” said John Manison, manager of GE Transportation’s marine and stationary power business in Erie, Pa, USA.

The 16-cylinder generator set provides 2.5 MW of continuous power for the La Vallee Greens hotel, golf course, marina and villa resort. The diesel generator set is electronic fuel injected, and offers NOx emissions of below 8.6 g/hp-hour.

The medium speed generator set is being used as part of the first phase of development at the La Vallee Greens Golf Course and Resort in Sandy Point, St. Kitts and Nevis
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The La Vallee development is part of a major strategic initiative that focuses on the construction of a number of golf courses and tourism facilities throughout St. Kitts. The new projects are designed to generate economic activity and employment opportunities particularly in rural areas, and at the same time establish a market niche in golf tourism, one of fastest growth sectors of the international tourism market.

The GE diesel generator set for the La Vallee project is designed to operate well in rugged, harsh environments, and is particularly well suited for continuous generation applications. The engine was built at GE’s Grove City, Pa. manufacturing facility.

GE engines also can be used for standby and peaking service, as well as for mechanical drive applications such as pipeline pumping and gas re-injection. GE’s 7FDS family of power generation diesel engines are available in power ranges between 1004 kW/1403 bhp to 3355 kW/4500 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 generator set is self contained and portable, making it easier to relocate it to where power is needed the most. The GE engine helps lower life cycle costs associated with fuel consumption and offers less mechanical wear on parts. These improvements extend into ease of maintenance and increased reliability for GE’s engines.