Category Archives: Peak Shaving

Cummins Power Generation provides complete build-install-operate solution for another Australian peaking power plant

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Infratil Energy Australia (IEA) already has three peaking power plants in operation comprising some 100 MW of capacity. The company wanted to add another peaking power plant at the Port Stanvac Power Station in Lonsdale, near Adelaide. Once again Cummins Power Generation, through Cummins Energy Solutions Business South Pacific, was chosen to design, build and operate the plant. Its construction, which met more than the usual requirements, is the subject of a new case history.

The first challenge: The site was already occupied by the 20 MW Lonsdale Power Station, which had to be decommissioned, refurbished and moved to adjacent land. Then, as with the other IEA peaking power plants, there were strict environmental standards for noise and emissions. At the same time, the new plant had to be able to meet short-term demands for electricity by starting within five minutes.

The result is 57 MW of peaking power, delivered by 36 diesel-fueled generator sets managed by a DMC300 Master Controller. The case history is here.

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Hotel Holiday Inn in Cuiabá ensures safety for guests with Cummins energy.

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Holiday Inn, the “Nation’s Innkeeper”, is recognized as one of fastest growing hotel brands. One of its latest editions is the new operation in Cuiabá, one of the 12 host-cities for the 2014 Soccer World Cup. To ensure a peaceful stay for its customers, Holiday Inn also needed to ensure reliable power, in the case of a blackout or failure of the public grid.

The power solution at the Cuiabá facility includes one Cummins Power Generation model C200 D6, 60 Hz, 260 kVA generator set which operates in standby/emergency mode. The generator set is fitted with a Cummins PowerCommandTM DMC 1000 parallel panel, equipped for operation in prime-power/peak-hour mode.

With our energy, the Holiday Inn guests’ comfort and safety are thus ensured! For additional information and more details on this case, please, click here.

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Check out these tips designed to help you understand Cummins generator sets and their applications.

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We prepared some tips to help you understand Cummins generator sets and their potential applications.

Power generation systems and equipment are classified by type, or class. For example, it can be classified as standby / emergency, Power Prime / Peak Hour, or continuous. It is very important to understand that the type of generation system and classification depend on the application.

Emergency system: This type of equipment and system is designed to supply power and lighting for short periods. It will allow for the safe evacuation of buildings, the continued operation of emergency communications systems used for public safety, and for the continued operation of life support, and other medical equipment needed by people requiring special care.

Legally required: These systems are typically designed to supply power and lighting for short periods, as a means to prevent accidents or facilitate firefighting operations.

Optional standby: Optional standby systems are installed where safety is not a critical factor, but rather where a power outage can cause inconvenience or loss of business. Such systems are typically installed in data processing centers, farms, commercial or industrial buildings and residences.

In addition to providing a standby/emergency resource in case of power failure, localized (direct) power generation systems are also used for the following purposes:

Prime Power: Prime power installations use generator sets to produce localized power so the need or application need not rely on energy supplied by the public utility. A simple prime power system uses at least two generator sets and a commuting switch to transfer energy loads between them. Typically, one of the generator sets handles a variable load, while the other serves as a reserve.

Peaking Power: Peaking-power facilities use localized power generation to reduce utility energy usage or stabilize electricity usage during peak hours, as a means to save money on energy costs. Power generation equipment installed for standby purposes can also be used for peak power needs.

Cost reduction (seasonal use): Peak-time systems provide power using generator sets to reduce electricity costs. With the operation of generator sets during seasonal peak periods, users can save up to 30% of their total energy costs at the end of the month.

Continuous basic load: Facilities for continuous basic loads use local generation to supply ongoing energy (kW), usually by using equipment for interconnection with the power utility grid.

Cogeneration: Cogeneration is the use of directly generated electricity and the use of radiated exhaust heat to replace energy provided by the utility. The radiated heat is recaptured and used directly for heating, or otherwise converted back into electricity.

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Yet another success story: Cummins energy working for Sony in Brazil.

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Exhibiting the technical competence of our generator sets, we have just consolidated the supply of our energy to Sony, one of the world’s largest manufacturers of electronic products. The corporation now relies on model C500 D6 60Hz diesel Generator Sets producing 625kVA and model C400 D6 60Hz diesel Generator Sets producing 500kVA. Both types are fitted with PC3.3 controls and are intended for peak-hour use.

To put this application in place, we enjoyed the support of our local distributor, Powertech. Sony’s energy is now ensured, and the company will be able to save up to 30% on its current bills. The savings is due in part due to Cummins’ total solutions focus.

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Fishers Island, New York, gets emergency and peaking power from Connecticut utility and Cummins Power Generation

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Because Fishers Island, New York, is close to Connecticut, it is served by the Connecticut Municipal Electrical Energy Co-op, or CMEEC. Recently, CMEEC installed a 2.5 MW generator set from Cummins Power Generation to provide emergency and peaking power for the island’s residents.

Before that, power was provided by means of a cable running from a utility generating facility in Connecticut — along the floor of Long Island Sound — two miles out to the island. This cable is susceptible to getting snagged by ships’ anchors, and if the cable did break, power to the island would be knocked out for some time. It would take months to repair or replace the cable, and several days just to get some form of portable power generation set up and connected to the distribution system on the island. With the new system, Fishers Island will be able to start the generator set and supply power within an hour of a mainland power interruption.

Beyond supplying standby power, CMEEC also wanted to reduce the amount of electricity imported to the island during periods of peak usage. So the Cummins Power Generation system will also be used to handle peak energy demands, which typically occur during summer weekends. The new generator set is capable of providing sufficient energy to power the whole island, even during the summer, when the population swells from about 300 year-round residents to 2,000 people and demand for power reaches 2 MW.

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Energy Company Expands its Operations with Cummins Power Generation

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The Lonsdale 20MW non-scheduled peaking power generation facility has been relocated; fully operational and now installed with new emissions technology to satisfy the current regulation that the plant has been commissioned to by Environmental Protection Agency (EPA).

Relocated 20MW Lonsdale Peaking Plant

New 65MW Port Stanvac Site

With Adelaide experiencing its wettest winter yet in eighteen years, Cummins Power Generation have worked through the adversity with the new 65MW Port Stanvac project as it continues its advancement with commissioning planned to commence in early December 2010.

Following up with my previous article on this project, the 12 X QSK60G4 generator sets have been placed with the second of the three power houses – with power house one and two cooling towers installed, the two elevated 11KV switchrooms installed onto their footings and the two 66KV transformers placed within their containment areas.

Development is on the way as installing and connecting the kilometres of medium voltage cabling and control calling which is required throughout the site, footings for the control room and 11KV/415V station power transformers, the building of the third power house- all of which have already commenced.

Cooling towers power house one and two

QSK60G4 Gensets

11KV Switchboard contained within one of the elevated switchrooms

Keep your eyes peeled for further updates in months to come on this exciting Cummins Power Generation project.

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Mexican retail food chain selects Cummins Power Generation for peak shaving power

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Calimax is a popular Mexican grocery store chain with more than 50 stores that vary in size from 1,000 to 4,500 square meters. Calimax selected Cummins Power Generation equipment to provide prime power for its giant distribution center to reduce operating costs during peak hours.

Headquartered in Tijuana, Calimax has a strong presence in Mexico’s northwest region, including Tijuana, Mexicali, Ensenada, Rosarito and Tecate in the State of Baja California, as well as San Luis Rio Colorado in the state of Sonora. Both of these Mexican states share a border with the United States.

The entire chain of Calimax stores is supplied from a large distribution center in suburban Tijuana. The center covers 48,000 square meters and is capable of storing 16,000 different products.

Calimax wanted to reduce the energy costs of running this large facility. The local Cummins distributor, Cummins de Baja, developed a solution that reduces the cost of electricity at peak times by allowing the company to generate its own power with seven Model DQDAC high range generator sets.

Seven DQDAC model generator sets were installed at the Calimax distribution facility. This model is rated at 300 kW standby and has a 270 kW prime power rating. When the cost of power from the local utility is high, Calimax can run these generator sets to produce their own electricity and save money.

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SuperFrango builds modern incubator with help from Cummins Power Generation

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Brazil has one of the world’s most modern and efficient poultry industries. The São Salvador Poultry Processing Plant, better known as SuperFrango (SuperChicken), is a pioneer in modern poultry-raising systems in the country’s central region. The company, headquartered in Itaberaí, Brazil, was founded in 1970 through a partnership between friends Carlos Vieira da Cunha and José Carlos de Souza.
SuperFrango continually invests in new technology to improve operational stability and performance, while complying with all required health and sanitation standards. Their commitment to these practices is demonstrated in their latest project: the Pintos de Corte incubator.

Prime technology
After five years of planning, design aFive Cummins Power Generation model C400 D6 456 kVA generator sets  paralleled to provide 2280 kVA of power to the facility.nd construction, and a $12.6 million investment,  SuperFrango opened its new 14,000-square meter plant on a 100,000-square meter site. The plant provides jobs for about 1,400 employees.
The plant currently processes 180,000 chickens daily, and it is sized to reach a volume of 320,000 chickens by 2012. The plant will also provide up to 10.7 million eggs monthly. SuperFrango exports to Asia, Eastern Europe and Africa, as well as serving the Brazilian market.
As with most industrial facilities in Brazil, SuperFrango needs reliable, economical power. Utility power at the site is provided based on a “time of day” rate, so economics dictate a design that provides a seamless transfer between utility and generator plant. A prime power generation and ramping power transfer system was the answer. After a market study to determine the best equipment available in Brazil and internationally, SuperFrango teamed up with Cummins Power Generation to provide a cutting-edge peaking power solution for the entire complex. The installation work began in April 2006, and delivery was made in November 2008, three months ahead of schedule.

Power for growth
The system includes five Cummins model C400D6 456 kVA diesel generator sets driven by Cummins NTA855G5 engines, which are manufactured in Brazil. The generator sets also include alternators and PowerCommand digital paralleling controls and switchgear, all manufactured by Cummins. The equipment was provided and is serviced by Cummins DCCO, the local Cummins distributor.

The PowerCommand controls, mounted on the generator sets, provide all paralleling functions. The generator sets were installed with exhaust and noise reduction systems, allowing the work environment to remain quiet and safe.The Cummins Power Generation peak power system helps SuperFrango meet its electricity needs by monitoring utility power, starting and paralleling the generators if power fails, and transferring power from the utility to the generators as needed. When time of day electric costs require it, the system will automatically start the generators, parallel them to the utility, and control their power output so that load on the utility (and costs) are minimized. The generators provided are sufficient to operate the entire facility. When it’s time to shut them down, the system synchronizes and parallels the generators to the utility, transfers the load back to the utility, disconnects and cools down the generators, and leaves them ready to start again when they are needed.
By operating the standby power system in prime power mode at peak hours, SuperFrango achieves savings of up to 30% during the three hours a day when the cost of utility power is highest. By economizing in this way on energy, SuperFrango can invest in other areas and continue growing, contributing to the economic development of the region.

Click here to access the SuperFrango Interactive Case History.

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