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Prime Power
Case History
Aitutaki, Cook Islands
Where:
Aitutaki, Cook Islands.
What:
Three C900 D5 generator sets, each
with a 820 kVA prime power rating,
a DMC200 digital master control system,
a low voltage paralleling switchboard,
a medium voltage 11 kV/3.3 kV
distribution switchboard, and associated
bulk fuel, exhaust and external radiator
systems.
Purpose:
To provide a reliable power supply to
the growing resort and hotel, and
business and community landscape.
Primary choice factors:
Cummins Power Generation’s ability to
provide a fully integrated and automatic
prime power system and deliver a
cutting-edge diesel power station.
Cummins Power Generation
powers a growing paradise in
the South Pacific.
Aitutaki is one of the 15 islands of the Cook Islands
archipelago in the South Pacific, and with its swaying
palm trees and white coral sands surrounded by
indigo waters, is a postcard of tranquility.
As the island expands due to rising commercialism
and disappearing geographical boundaries,
Aitutaki is experiencing a growth in the tourism and
business markets, both of which demand highly
reliable electricity.
The island’s original power station, whose
architecture dates back to the 1960s, using two
veteran Blackstone generators, gave out in 2006.
A Cummins QST30 generator set was hired
from New Zealand and provided electricity until
the commissioning of the new power station in
September of 2009.
Establishing First-Rate Design Practice
Cummins Power Generation’s ability to provide
a fully integrated and automatic prime power
system was a key factor in its selection by the
Cook Island Investment Corporation to design,
build and commission the new cutting-edge diesel
power station.
Cummins Power Generation technician Craig Jenkinson headed up the
testing in Brisbane which was carried out over four days.
The island’s peak load requires two operating gensets, the third unit being
redundant, enabling servicing of the other two without power interruption.
Scott Lomate and the Cummins South Pacific’s prime and
remote power group established the best practice design
and over a number of meetings underpinned customer
confidence in Cummins’ expertise in prime power generation.
The power station was then dismantled and shipped to the
Cook Islands where installation became a simple matter
of bolting together components that had been assembled
previously, thus reducing on-site construction time.
“The old generators were fairly labour intensive to start and
operate compared with the new Cummins system that is fully
automatic and requires relatively little operator involvement,”
says Jeff Evans, Cummins South Pacific Power Generation
project manager.
Digital Master Control Model DMC200
The power station comprises of three Cummins C900 D5
generator sets, each with a 820 kVA prime power rating,
a Cummins DMC200 Digital Master Control system,
a low voltage paralleling switchboard, a medium voltage
11 kV/3.3 kV distribution switchboard, and associated bulk
fuel, exhaust and external radiator systems. These generator
sets are powered by 23-litre Cummins QSK23 engines.
The island’s peak load requires two operating generator sets,
enabling the third unit to provide a backup in the unlikely
event of a generator fault.
“We replicated the complete power station in
Brisbane so the customer could be completely
comfortable that we were delivering the system
we had promised…”
Reducing On-site Construction Time
The power station was fully assembled and tested at the
Cummins Brisbane branch prior to being shipped to the
Cook Islands – an exercise that gave the customer total
confidence in what they were getting.
Jeff Evans elaborates, “In view of the limited engineering
resources on Aitutaki, we decided to carry out full assembly,
performance testing and training for the customer at our
Brisbane facility.”
“We replicated the complete power station in Brisbane so
the customer could be completely comfortable that we were
delivering the system we had promised, and that all their
performance criteria had been met.”
“The testing and training was carried out over four days.
Testing included fully functional operation of the master control
system, including load demand call up/shut down, and load
shed capability, along with load testing of each generator unit.”
The model DMC200 Digital Master Control is fully designed
and built by Cummins and will synchronise the operation of
the diesel generator sets. The DMC200 is a microprocessor
based paralleling system designed to interface directly with
the generator set mounted PowerCommand controllers.
This control system provides enhanced reliability through a
distributed logic approach thereby enhancing uptime and
minimizing downtime or failure to start risks. Power for the
generator controls and master control unit is derived from
the generator starting batteries, and is backed up by an
independent battery system. The PowerCommand control
automatically tests starting battery power on every startup
thereby reducing the risk of failed batteries ... one of the
most common causes of generators failing to start.
The master control provides superior functionality around
load demand, load management and load prioritizing and
also includes a colour touchscreen HMI for easy operator
interface. The PowerCommand system automatically shares
loads amongst the gensets and also adds or sheds loads as
required by the available system capacity.
The Digital Master Control unit can be supplied fully
integrated into the generator paralleling switchgear package,
thereby reducing installation cost and risk or supplied loose
as a free standing unit.
For more information about integrated prime power systems,
contact our local Cummins Power Generation distributor or
visit www.cumminspower.com.
www.cumminspower.com
©2010 Cummins Power Generation Inc.
All right reserved. Cummins Power Generation
and Cummins are registered trademarks of
Cummins Inc. PowerCommand is a registered
trademark of Cummins Power Generation Inc.
“Our energy working for you.” is a trademark of
Cummins Power Generation. APCH-1004-10