Deep Sea Electronics - making groundbreaking technology which is ...

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PROMOTING ON-SITE POWER AND COGENERATION
AMERICAN INDEPENDENT POWER
AUTUMN 2010
Deep Sea Electronics -
making groundbreaking
technology which is
simple to operate and
extremely reliable

PROMOTING ON-SITE POWER AND COGENERATION
Editor:
Aidan Turnbull
powereditorial@gmp.uk.com
Sales Director:
Neb Saric
nsaric@gmp.uk.com
Publisher:
Richard Teasdale
rteasdale@gmp.uk.com
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GMP
Global Media Publishing Ltd
Autumn 2010
C O N T E N T S
News 6
What’s new with the US power industry.
CHP 8
AIP looks at one of FVB Energy’s most prestigious projects - the
South East False Creek Energy Centre (FCEC) - which features
the installation of some sewage heat pumps unique to North
America.
www.gmp.uk.com/power
AMERICAN INDEPENDENT POWER
AUTUMN 2010
Deep Sea Electronics -
making groundbreaking
technology which is
simple to operate and
extremely reliable
Deep Sea
Electronics -
making
groundbreaking
technology
which is
simple to
operate and
extremely
reliable
Established in 1975, Deep Sea
Electronics is the world's largest
designer and manufacturer of
engine and generator control
modules. It has a reputation for
its groundbreaking technology.
The FCEC has unique sewage
heat pumps.See page 8.
Russian Sales:
Sergey Stanovkin
stanovkin@dars.ru
US Sales & Subscriptions:
Alex Carter
acarter@gmp.uk.com
Asia-Pacific Correspondent:
John Goss
john.goss@ceejay.com.hk
Contributors
FVB Energy, Amot, Deep Sea
Electronics, Baldor, ComRent,
The Shaw Group, Ge Energy,
FuelCell Energy, Horizon Wind
Energy, TransAlta Corporation,
The Canadian Wind Energy
Association, International Power
Inc.
Published by:
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Diesel Engines 10
Amot's Model XTS-W+ bearing condition units have been
designed to monitor the wear condition of crank train bearings
in large diesel engines. Amot's designs are said to offer the
ultimate protection for engines from catastrophic damage.
Testing 12
New products fromDeep Sea Electronics (DSE) have been at the
forefront of the generator control industry for over 35 years.
These are subjected to vigorous EMC tests which need to be
met before any product is launched, reports Technical
Director, Dave Hartley.
Gen-sets 14
Based in Oshkosh, Wisconsin, Baldor Generators is a singlesource
ISO 9001-registered power equipment manufacturer. AIP
takes a look at some of Baldor's larger products.
Loadbanks 16
ComRent has developed protocols which set the standard for
loadbanking primary and backup power sources and systems. It
boasts it has supplied equipment for more testing contracts
than any other loadbank rental company in North America:
30,000+ projects.
Software/Simulation 18
AIP looks at Cleco Power's new US$1bn 660-MW Madison 3
power plant built by the Shaw Group in the US.
Next Issue
* Diesel & Gas Engines, Gas Turbines, Emissions,
CHP Systems, Microgeneration, Plant Training,
Boilers, Silencers, Alternators, Gen-Sets,
Loadbanks, Controls & Monitoring, UPS
Systems/Batteries, Valves & Pumps, Loadbanks &
Test Equipment, Hire & Rental Equipment, Blading,
Boilers, Fuel Cells, Filtration, Switchgear, Steam
Turbines & North America Power Review.
ComRent is loadbanking backup
& primary power. Page 16.
The Shaw Group has built the
660MW Madison 3 plant. P.18.
Our power portfolio
includes
W O R L D W I D E I N D E P E N D E N T P O W E R
M I D D L E E A S T P O W E R
2011

EDITOR’S LETTER
WELCOME
A warm welcome to this month’s
issue of Worldwide Independent
Power - as always bringing you
closer to the stories and issues
affecting on-site power and
cogeneration around the world.
For editorial comments, please do
not hesitate to contact the editor.
BIENVENUE
Soyez le bienvenu à cette issue de
Worldwide Independent Power.
Comme d'habitude, nous vous
apportons toujours plus près des
sujets qui affectent l'énergie et la
co-generation sur place autour du
monde.
N'hésitez pas contacter le
rédacteur pour des commentaires
éditoriaux.
WILLKOMMEN
Herzlich Willkommen zur Ausgabe
dieses Monates von Worldwide
Independent Power. Wie immer
bringen wir Sie näher heran an die
Ereignisse und Geschichten der
Stromerzeugungsindustrie rund um
die Welt.
Für redaktionelle Kommentare und
Anregungen wenden Sie sich bitte
an den Autor.
BIENVENIDO
Bienvenido a esta edición de
Worldwide Independent Power.
Como siempre, acercándolo a los
temas que afectan a la energía y a
la cogeneración in-situ. No dude
en contactar con nuestro editor
para cualquier cuestión editorial.
BENVENUTI
Benvenuti a questa nuova edizione
di Worldwide Independent Power.
Come sempre cercheremo di
offrirvi storie e questioni
riguardanti on-site power e
cogeneration a livello globale. Per
commenti editoriali, si prega di
contattare l'editore.
Aidan Turnbull
Editor
Is North America meeting the
demand challenge for energy
The government of Ontario has just revealed a plan aimed at increasing the amount of
renewable energy projects over the next 20 years while decreasing coal-fired generation in
the province. As part of the Long-Term Energy Plan, the government intends to refurbish
10,000 MW of existing nuclear capacity and build another 2,000 MW at the Darlington nuclear power
plant. The government also plans to shut down the Nanticoke coal-fired power plant in 2011 and
all remaining coal plants by 2014. The Atikokan coal-fired power plant will be converted to biomass
in 2013 and the Thunder Bay plant will be converted to natural gas and possibly biomass by either
2013 or 2014.
The Canadian Wind Energy Association and International Power Canada Inc, a renewable energy
company, both praised the plan, which called for 10,700 MW of renewable energy in the province by
2018. "The wind energy industry looks forward to working cooperatively with government and the
Ontario Power Authority to achieve this target and to move beyond it after 2018," comments
CanWEA president Robert Hornung.
Canada currently has 3,549 MW of installed wind energy capacity and Ontario is the provincial
leader in installed wind energy capacity with 1,298 MW. The province has also identified five
priority transmission projects and new tougher targets for conservation, including new and
upgraded lines west of London and upgraded lines and a new line to Pickle Lake.
Analysts say that a similar approach is unlikely to be followed in the US. Each state - frankly -
needs all the energy it can get, despite a reluctance to use fossil fuels. American electricity
demand is at an already high level, and it is widely predicted that demand overall will continue to
increase in the next five years and beyond. Around 350,000MW of new electricity must be
generated to satisfy extra energy requirements demand in the US by 2030. Along the way, a
‘substantial’ increase will be necessary before 2015.
US industry is generally in agreement that new power stations are required nationally. America
must increase investment in transmission systems while securing new baseload electricity capacity
to meet demand. However, there is apparently an insufficient
development of new transmission systems, and the American
power supply reserve is falling in those areas of the country
where electricity regulation is relaxed.
Several factors, including the high capital cost of constructing
a new baseload power station, the cost of complying with CO2
regulations, and deep uncertainities about fuel prices, have
become disincentives for building new capacity.
But can anyone really afford to be too picky about where the
energy comes from in the future
EUROPE ASIA-PACIFIC MIDDLE EAST
AFRICA
AMERICAS
A MERICAN I NDEPENDENT P OWER • AUTUMN 2010
5

NEWS
In brief...
Third FuelCell
Energy plant is
certified
FuelCell Energy has
announced that its 2.8
MW DFC3000 power plant
operating on natural gas
has been certified under
the California Air
Resources Board's (CARB)
distributed generation
emission standards that
were established in 2007
(CARB 2007). The DFC3000
is the largest distributed
generation power plant to
receive certification, says
FuelCell Energy.
The CARB 2007
certification confirms the
ultra-clean emission
profile of the DFC3000 to
the various California Air
Quality Management
Districts which oversee
the clean air permitting
process.
Challenges for CA
solar power
The California Energy
Commission has
temporarily withdrawn
approval for the 663.5 MW
Calico solar power plant
by Tessera Solar after
opponents said the plant
had been improperly
licensed. A 709 MW
project, also by Tessera,
faced a separate legal
challenge. The commission
approved Calico only
after Tessera agreed to
reduce its footprint in
California's Mojave Desert
to 4,613 acres.
Ohio Wind Energy
The Ohio Power Siting
Board has granted
permission for Horizon
Wind Energy to build the
150.4 MW second phase of
its Timber Road wind
farm. The wind farm plans
to use 98 wind turbines
and is choosing between
Acciona's 1.5 MW turbines
and GE's 1.6 MW units.
GE sells US gas turbines to Nigeria
US-based energy giant GE has sold four GE gas
turbines for the Omotosho Phase 2 Power Plant,
located in Ondo State, southwestern Nigeria.
By increasing the country’s supply of efficient,
reliable energy, the project will assist Nigeria in
delivering on the country’s quest for reliable
electric power, alleviating power shortages and
reducing the number of blackouts.
GE will provide four Frame 9E gas turbines,
generators, accessories, technical assistance and
training to the EPC contractor for the project, China
Machinery & Equipment Company (CMEC). GE has a
long-standing relationship with CMEC, mainly in the
power generation sector.
Owned and operated by the Power Holding Company
of Nigeria (PHCN), the new plant should add more
than 500MW of power to Nigeria’s grid when it
enters commercial service in 2013. The government
of Nigeria has set a target to add 35,000MW of new
electricity generation over the next 10 years, to
support the country’s rapid development.
“As Omotosho Phase 2 illustrates, Nigeria continues
to invest in its infrastructure to drive economic
growth,” Jay Wileman, region executive - Africa for
GE Energy, tells AIP.
“An increased supply of reliable energy also is
critical to support the country’s efforts to enhance
the standard of living for all of its citizens.”
The robustness, availability and easy maintenance
features of the Frame 9E gas turbine were key to GE
receiving the Omotosho Phase 2 contract.
“The proven success of GE’s installed fleet of gas
turbines in the country, our local service capabilities
and the ability to meet an aggressive delivery
timetable were important factors in winning the
customer’s confidence,” reports Wileman.
Planned shipment for the four 9E gas turbines for
Omotosho Phase 2 is mid-2011. Primary fuel for the
plant will be natural gas.
GE has supplied more than 100 gas turbines for
projects across Africa. More than 450 Frame 9E gas
turbines have already been installed worldwide.
Geothermal plant for Missouri University
A planned geothermal energy
project to replace a 65-year-old
power plant at Missouri University
of Science and Technology is
expected to cut carbon-dioxide
emissions while reducing annual
energy and operational costs by
up to $2.8 million.
In 2010, the USA led the world in
geothermal electricity production
with 3,086 MW of installed
capacity from 77 power plants.
The largest group of such power
plants in the world is located at
The Geysers, in California.
The Missouri S&T geothermal
In 2010 the US had an installed capacity of 3,086MW from 77
geothermal power plants.
project was among several
projects on the four University of
Missouri campuses approved for
debt financing by the UM Board of
Curators on Nov. 22nd. The
current power plant, constructed
in 1945, relies on coal and wood
chips to provide steam-generated
heat to most buildings on campus.
Other buildings on campus are
served by Rolla Municipal
Utilities.
Construction of the geothermal
system will take approximately
five years to complete. Initially,
the system is expected to save
US$1.4 million in energy and
operational costs annually - a
saving that is expected to grow to
$2.8 million in future years.
The project also is expected to
reduce Missouri S&T's carbondioxide
emissions by 25,000 tons
per year.
6
A UTUMN 2010 • AMERICAN I NDEPENDENT P OWER

NEWS
USA’s largest fuel cell project will use biogas
produced from San Diego’s sewage system
The New Energy Capital Cleantech
Infrastructure Fund (NECCIF) has announced
a US$23.5 million investment in the USA’s
biggest ever integrated fuel cell project. The
project, which includes three fuel cells
with a combined capacity of 4.5MW, will be
located on sites owned by the University of
California San Diego (UCSD) and the City of
San Diego. The fuel cells will run on
renewable biogas supplied by the San Diego
Wastewater Treatment Facility.
The facility will employ molten carbonate
fuel cells produced by Fuel Cell Energy, Inc.
of Danbury, Connecticut, and will run on
renewable biogas produced by an affiliate of
BioFuels Energy, LLC from waste methane gas
from the City of San Diego sewers.
Electricity from the fuel cells will be sold to
UCSD and the City of San Diego, offsetting
their power requirements with clean,
renewable energy. The three fuel cells will
produce approximately 35 million kilowatt
hours of electricity per year, reduce annual
CO2 emissions by more than 25 million
pounds, and save the City of San Diego and
UCSD more than US$2 million in electricity
costs over ten years.
BFE develops renewable energy projects
using various biogas sources and is located in
Encinitas, California. BFE will be employing
the Otto H. Rosentreter Company of Santa Fe
Springs, California, a leader in the design and
installation of fuel cell systems. The project
will create approximately 15 full-time jobs
during the construction period at the City's
South Bay Wastewater Treatment Plant and
the UCSD campus, as well as 50 direct jobs
at Fuel Cell Energy.
"We are grateful to the California Public
Utility Commission and the California Center
for Sustainable Energy (San Diego) for
providing grant benefits through the
California Self Generation Incentive Program
which have enabled this project to come to
fruition," Ken Frisbie, Managing Director of
BFE, tells AIP. For this venture New Energy
Capital has partnered with the CleanTech
Alliance Fund, managed by North Sky Capital,
to finance the project through a complex
combination of equity and California Self
Generation Incentive Program Grants.
San Diego’s waste water is the key to a new methane fuel
cell project.
In brief...
New TransAlta plant
The TransAlta Corp. said it
is planning to build an 800
MW natural gas-fired power
plant at its Sundance coalfired
power complex near
Edmonton, Alberta. The
new plant will be one of the
largest gas-fired facilities
owned by TransAlta. The
company filed an interconnection
application with the
Alberta Electric System
Operator. The new plant
will replace coal-fired
facilities that the Canadian
government has ordered
phased out.
San Diego - soon to be flush with money
A MERICAN I NDEPENDENT P OWER • AUTUMN 2010
7

CHP & COGENERATION
The False Creek Energy Centre
& FVB Energy
FVB Energy has successfully served the energy system needs of industrial facilities in North
America and Europe. AIP looks at one of its prestigious projects - the South East False Creek
Energy Centre (FCEC) - which features the installation of some unique sewage heat pumps.
There’s a movement in North
America towards maintaining a
combination of district energy
systems, combined heat and power (CHP)
or other on-site power generation, and
thermal energy storage. It has been
realised that these can significantly boost
energy supply reliability.
FVB Energy is one company which has
successfully served the energy system
needs of industrial facilities in North
America and Europe. A good example of
the company’s work is the South East
False Creek Energy Centre (FCEC) in
Vancouver, British Columbia, which first
opened in January 2010.
The FCEC uses mechanical vapour
heat pumps for heat recovery from
sewage that serves the base heat load for
the South East False Creek development.
The heat output of the energy centre is
26MW.
The first sewage heat pump was
installed in Phase One, with room for
expansion for a second heat pump that
The FCEC features stylish designs -
outside and inside.
The False Creek Energy Centre [FCEC] is an innovative heating plant which
produces domestic hot water and space heating for the Neighbourhood Energy
Utility [NEU] that serves some of Vancouver's communities.
will contribute approximately 70% of the
base load energy requirements for the
District Energy System.
The sewage heat pumps are installed in
a series counter-flow arrangement with
dual helical rotary compressors.
These provide the advantages of
improved full load efficiency, improved
part load efficiency, increased turndown,
improved reliability and extended
operating range, reports FVB Energy. The
units used are unique, and are the first of
their kind in North America, reports FVB
Energy.
The sewage pumped through the heat
pump is raw sewage, meaning that it is
untreated and is filtered to allow only
small particles to pass through. The heat
pumps work by pumping warm sewage
waste through the evaporator side of the
heat pump.
This heat, coupled with the mechanical
compression of the refrigerant, produces
hot water which is pumped through the
condenser of the heat pump. The heat
pump produces 80°C water on the
condenser side.
At New York’s University of Rochester
FVB Energy has completed the schematic
design and is now preparing the detailed
plan for a major new district hot water
network and related building connections.
A new district heating system will replace
an older steam system, and is being
undertaken in conjunction with the
implementation of combined heat and
power (CHP) with an ultimate capacity of
18 - 20 MegaWatts (MW) electric.
A 7 MWe low pressure steam turbine will
be installed in 2005, and a 18 MWe high
pressure turbine is planned for later
implementation.
It’s felt that both projects these reflect
national commitments - in both Canada
and the USA - towards green energy and
in the reduction of greenhouse gases.
emissions.
AIP
Internet link
www.fvbenergy.com
8
A UTUMN 2010 • AMERICAN I NDEPENDENT P OWER

Efficient and reliable solutions
for your power requirements.
essential.
www.marellimotori.com. Innovation and technology since 1891.

DIESEL ENGINES
Monitoring for diesel engines -
improved sensors from Amot
In 2009, Amot and Enertech entered into an exclusive partnership to provide ASME Code
Section III components to both existing and newly constructed U.S. and Canadian power plants.
AIP looks at some of the design solutions for the control and monitoring of engines & pumps.
Amot’s Model XTS-W+ bearing
condition units have been designed
to monitor the wear condition of
crank train bearings in large diesel
engines as well monitoring the Water in
Oil (WIO) content. As you’d expect, the
water in oil sensor monitors moisture
content in the engine’s lubricating oil.
Amot’s designs are said to offer the
ultimate protection for engines from
catastrophic damage. The sensors are also
said to be effective at reporting storage
long term trends and can be used as a
tool for class surveying.
The units feature simple low cost
installation - there is no drilling of highly
stressed engine components, says Amot,
and provides signals for engine slow down
in case of extreme bearing wear.
The proximity sensors are robust, proven
electronic sensors, which use a low
intensity electromagnetic field to detect
the position of the guide shoes at bottom
dead centre (BDC). The sensors are fixed
to custom designed brackets for different
engine types.
Engine junction boxes fit to the outside
of the engine. These allow cables passing
through the wall of the engine to be
removed for servicing if required. The
Signal Processing Unit is capable of
simultaneously processing signals from up
to 14 proximity sensors, four temperature
sensors and one water in oil sensor.
The Interface Unit houses an
Uninterruptible Power Supply (UPS) and
an 18V DC power supply. In addition, it
provides a means of connecting the alarm
signals to the control and alarm system.
The new generation XTS-W has fully
integrated water-in-oil (WIO) monitoring.
The Display and Monitor
Unit comprises full
application-specific
software, running on a
marine approved PC.
Separate screens [left]
show trends, real-time
measurement of Water
Activity (aw) and Parts
Per Million (ppm).
Alarm levels are
defined by engine
manufacturers. In
How the engine controls work.
addition, full
trend data is
available as
standard
allowing
interrogation of
the system to
determine the
rate of water
contamination.
The use of
proximity
sensing and the availability of signal
post-processing enables real-time wear
trend analysis.
Through analysis of the rate of change of
the bearing condition can provide a much
earlier indication of potential bearing
problems and save you downtime and
money, reports Amot.
AIP
Internet link
www.bearingwear.com
10
A UTUMN 2010 • AMERICAN I NDEPENDENT P OWER

WORLDWIDE LOADBANK SPECIALISTS
Crestchic loadbanks maximum power
when you really need it
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they’re up to the job - you need a stable,
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test to imitate real loads, in real time. You
need a load test solution you can rely on.
No other company specialises in worldwide
load test solutions like Crestchic.
Manufacturing loadbanks for sale and rental
for over 20 years, we have delivered reliable
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Crestchic Tailor-made load test
solutions from 30kW to 100MVA
Why look anywhere else
For more information, contact us on
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Or find us on the Internet at www.crestchic.co.uk
You can also email us: sales@crestchic.co.uk
or hires@crestchic.co.uk

TESTING
The importance of vigorous EMC
testing on products
Quality is extremely important to Deep Sea Electronics (DSE) at the forefront of the generator
control industry for over 35 years. Its new products are subjected to vigorous EMC tests which
need to be met before any product is launched, reports Technical Director, Dave Hartley.
Electro-Magnetic Compatibility (EMC)
testing is essential to ensure
electrical interference or 'noise'
levels are addressed and kept in check.
EMC can be simply defined as a product
not providing sources of electromagnetic
interference to other equipment, whilst
at the same time not being the subject of
interference from other equipment, such
that normal operation is compromised.
Generally, EMC 'noise' can be generated
by equipment, or natural sources, and be
transmitted through the air or be
conducted via cables as a potential
disturbance to a piece of equipment.
A piece of equipment can also be a
possible generator of EMC as well as also
susceptible to EMC from other equipment.
Therefore, EMC protection has to be
designed to cover both. The aim of
building in EMC protection circuitry is for
the equipment to be able to control all
reasonable levels of EMC and continue in
normal operation.
Years of testing and experience have
gone into developing Industry Standards
for a wide variety of applications, with
the BS-EN 61000 series being generally
accepted. The Standards subscribe to
acceptable test limits for Industry
Radiated Emission testing
applications, and are
widely accepted. Several
years ago, Deep Sea
Electronics (DSE) took a
decision to design and test
to EMC levels which
exceeded recognised
Standards.
Despite putting an extra
load on the design
elements of a Control
Module, the aim was to
provide additional EMC
protection as a more robust benefit in the
field. To achieve these aims, it was
necessary to provide an on-site
development and test facility, which is
now part of the fabric in DSE.
Initially, the investment level in
Industry-accepted test equipment, such as
Schaffner, was very high but this has
subsequently proved to be a wise
investment.
A screened room was built to
accommodate testing and now gives DSE
the ability to test to pre-Compliance
levels in the full confidence that results
will ultimately be confirmed at a
recognised laboratory for Certification
purposes.
There are currently seven Test and
Development Engineers trained in EMC
testing at DSE. Each engineer carries out
testing to a pre-defined set of test
procedures and standard reports.
Such is the quality of the testing and
equipment available that customers have
been known to ask if the facility could be
made available to them, for their own
equipment testing.
When all is said and done, the approach
taken by DSE can only be justified by
positive results in the field. This,
ultimately, is down to feedback from
Conducted Emissions testing
Readout from Conducted Emissions
testing.
Customers who are now increasingly
aware of EMC effects on their business.
One such major customer, in Brazil, who
carries out his own independent EMC
checks, has declared that DSE products
are the "most resilient products they have
tested", amongst all they have covered.
Based in the UK, Deep Sea Electronics is
the world's largest designer and
manufacturer of engine and generator
control modules.
Established in 1975 the company has
established a strong reputation for its
groundbreaking technology which is
simple to operate and extremely
reliable.
AIP
Internet link
www.deepseaplc.com
12
A UTUMN 2010 • AMERICAN I NDEPENDENT P OWER

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GEN-SETS
Larger power ratings require
larger enclosures
Based in Oshkosh, Wisconsin, Baldor Generators is a single-source ISO 9001-registered power
equipment manufacturer involved with providing megawatt-class generator sets in containerised
enclosures for over two decades. AIP takes a look at some of Baldor’s larger products.
At the heart of the latest Baldor
containerised IDLC generator set
[right] is a fuel efficient, emissions
compliant diesel engine and a brushless
alternator with permanent magnet
generator excitation system.
The base generator set is fitted with
primary fuel filter, electrical gear along
with other features that can include
battery charger, engine coolant heater, oil
level monitoring, and other options before
being fitted into the sound-attenuated
enclosure.
A large integral fuel tank is added along
with internal mount exhaust silencer and
heavy duty air cleaners.
Industrial Diesel Liquid Cooled generator
sets are available in standard ISO
container sizes of 40, and 45 foot overall
length. These IDLC Containerised Gen-sets
can be supplied and transported using a
standard ISO container chassis.
For locations requiring long term
operation, the generator set can be easily
removed from the chassis and placed at
ground level for easy access, says the
company.
At the heart of the containerised IDLC
generator set is a fuel-efficient,
emissions- compliant diesel engine and a
brushless alternator with permanent
magnet generator excitation system. The
base generator set is then fitted with
Inside the IDLC enclosure.
primary fuel filter, electrical gear along
with other features that can include
battery charger, engine coolant heater, oil
level monitoring, and other options before
being fitted into the sound attenuated
enclosure.
A large integral fuel tank is added along
with internal mount exhaust silencer and
heavy duty air cleaners.
The digital gen-set controller and power
connections are mounted at eye level and
are accessed though large operator
interface doors located on the exterior of
the enclosure. Bus bars and shore power
connections are included for easy power
connections for the gen-set output power
and to supply AC power for lighting and
convenience features.
Input and output power connections can
be routed through the bottom or the side
of the enclosure. DC lighting with timer
switches can be supplied in the enclosure
Baldor’s Towable Mod-Express.
[Above & below]
Baldor 2 megawatt generators
provide prime power for peak
demands. A Northwestern USA
peaking plant.
and operator compartments for use when
AC power is not available, says Baldor.
The Industrial Diesel Liquid Cooled Genset
features EPA emissions-compliant
engine for clean and trouble-free
commissioning. The containerised mobile
enclosure houses a turbocharged and
intercooled engine which has a unit
mounted radiator.
AIP
Internet link
www.baldor.com
14
A UTUMN 2010 • AMERICAN I NDEPENDENT P OWER

Green Power
makes sense and pays off
Turn Key Power Management Green Power Cogen Waste Heat Recovery Bio Fuels Diesel Gas
MAN Diesel & Turbo is your one-stop business partner for modularised power plants.
Turnkey solutions may span from planning and financing to power management and
operation. Flexible and efficient fuel applications are available from traditional liquid
fossil fuels and gasses – to renewable biofuels and waste products. Go ahead!
Find out more at www.mandieselturbo.com

LOADBANKS
Loadbanking primary and backup
power sources & systems
For more than a decade, ComRent has developed protocols which set the standard for loadbanking
primary and backup power sources and systems. It has supplied equipment for more testing
contracts than any other loadbank rental company in North America: 30,000+ projects.
Unlike other service companies with
many business interests, ComRent
asserts that it is dedicated to the
single mission of providing excellence in
load bank testing.
A spolesman told AIP: “Our unrivaled
customer service and 99% trouble-free
performance record are testaments to our
commitment.
“ComRent’s continuing success is also
attributable to our customers. The insight
we’ve gained through working with
systems development and management
customers has directly influenced our
internal operations.
“We understand the business objectives
of all who are involved in the systems
testing process, which is why we offer
such a wide range of equipment and
services, including National Accounts.”
“With ComRent’s help we
achieved something the
engineer said couldn’t be
done. This level of service
is what keeps us coming
back time and time again.”
Arthur Kuhn, Rental Manager
for Cummins Atlantic
ComRent’s National Accounts service is a
turnkey rental service for multi-state
customers
across the
USA. A
National
Account
simplifies the
procurement
of equipment
and offers
ComRent® team members perform a Roll-up at a 15MW, 11 kV 1.0 power
factor test on the diesel engine of a cruise liner in Miami, Florida.
significant savings across the entire load
bank rental process, the company
explains.
ComRent operates 15 full service offices
and inventory centres across North
America, making rentals more convenient
no matter the location of the job site. All
international rentals are managed through
its headquarters in Washington, DC.
The loadbanks ComRent can offer
include: AC, DC, resistive and reactive
loadbanks, including medium voltage
loadbanks. ComRent engineered - and is
the exclusive provider of - ‘direct
connect’ medium load banks, with no
transformers required.
Equipment avilable includes 2,000+
loadbanks (up to 50+ MW), power cables,
I-Line panels, Voltoc® Medium Voltage
power cables, power quality monitors,
switchgear TrakMats and transformers. A
DayCor® corona camera provides electric
utilities with
the ability to
monitor the
health of
critical systems
components.
The technology
means that
“The team was extremely
efficient, very
knowledgeable and very
thorough in the execution
of the testing.
Thanks to them, we are
now firing on all 16
cylinders.”
Simon Zielonka, Systems
Engineer for Royal Caribbean
visualisation of corona, corrosion and
electrical leakage is easily achieved,
providing the time to develop an effective
maintenance strategy, says ComRent.
Users report that the Cx Monitor has
‘raised the bar for the monitoring of
power quality,emperature and humidity’.
ComRent also offers advanced data
collection, storage and reporting
capabilities. System assessments and
reporting have never been faster or
easier, says the company.
AIP
Internet link
www.ComRent.com
16
A UTUMN 2010 • AMERICAN I NDEPENDENT P OWER

GAS ENGINES
Shaw Group & the new 660MW
Madison 3 power plant
AIP looks at how the Shaw Group's design work has realised the Cleco Power's new US$1bn
660-MW Madison 3 power plant in the USA. As the EPC contractor Shaw has helped to
bring one of the cleanest, greenest solid-fuel electric generating plants to the USA mainland.
Founded in 1987, Shaw Group has
grown to become a leading global
provider of full-service, value-added
engineering, design, procurement,
construction, and maintenance services.
2010 has seen Shaw's design work come
to fruition with the opening of the Cleco
Power 660-MW Madison 3 power plant in
the USA.
As the contractor in charge of engineering,
procurement and construction (EPC),
Shaw has helped to construct one of the
cleanest solid-fuel electric generating
plants to the USA . Today it is one of the
largest petroleum coke (petcoke)-fired
facilities in the world to commercial
operation in 2010.
The new electric generation unit
incorporates two 330-MW state-of-the-art
circulating fluidised bed (CFB) boilers supplying
steam, including reheat, to a single
turbine generator. Madison 3's air quality
control systems include a selective noncatalytic
reduction system, scrubber and
baghouse, reducing plant emissions to
very low levels.
Although the unit has the ability to burn
100% petcoke, it also can burn a variety
of inexpensive solid fuels, avoiding the
need to consume higher-cost natural gas
and/or oil and resulting in savings for our
client. A byproduct of oil refineries,
petcoke is typically low cost and
Cutaway of
the plant’s
boiler.
CFB layout.
conveniently located at source refineries
in Louisiana.
A closed-design pipe conveyor belt,
which carries fuels from a nearby river
oxbow to the site's crusher house, snakes
over and around railroad crossings and
highways, enabling materials to be
transported safely while avoiding
obstacles. Madison Unit 3 began
commercial operation on February 12th,
2010 and stands as the company’s largest
generating unit. Using a technology which
can use multiple solid fuels to generate
power, the 600MW unit will initially use
petroleum coke or pet coke, a byproduct
of the oil refining industry, in its boilers.
However, this unique technology,
circulating fluidised-bed technology, also
can use biomass as fuel. Research is
ongoing into the use of woody biomass as
a potential fuel since the new facility is
located in a timber-rich area.
Biomass is a carbon-neutral fuel which
will help lower the carbon footprint and
serve as a renewable fuel source.
In addition to the potential of lowering
carbon emissions, the technology also
addresses regulated emissions. Because
the boiler firing temperature is about
1,600°F (871°C), nitrogen oxides (NOx) do
not form. In addition, Madison 3 has
installed emission control systems to the
boiler that further reduce NOx. Sulphurdioxide
emissions are now almost nonexistent
thanks to the use of adding limestone
with the fuel in the boiler and
scrubbers as a post-combustion control.
The new unit is estimated to use about
1.5 million tons of pet coke and 500,000
tons of limestone each year. Both the pet
coke and limestone are barged to an
off-loading facility located on the Red
River.
Built at the Brame Energy Center, the
unit is 100% owned by Cleco Power LLC.
The unit is the utility’s first regulated
generation project in more than 20 years
and employs nearly 80 new workers.
AIP
Internet link
www.shawgrp.com
18
A UTUMN 2010 • AMERICAN I NDEPENDENT P OWER

THE WORLD’S NUMBER 1
CHOICE FOR GEN-SET CONTROL
#
THE FUTURE
OF GEN-SET
SYNCHRONISING
HAS ARRIVED!
DSE is pleased to announce the release of two new gen-set synchronising control
solutions. The DSE86xx and DSE87xx deliver single part and two-part control options
for up to 32 generators. The high levels of functionality within the products and the
versatility of the two-part solution combine to deliver a collection of products that
will shape the future of multiple gen-set control for many years to come!
DSE87xx
DSE86xx
Initial demand for these control modules is already extremely high.
To see the extensive range of features and benefits these control
modules will give your applications visit: www.deepseaplc.com
DEEP SEA ELECTRONICS PLC
Highfield House, Hunmanby Industrial Estate, Hunmanby, North Yorkshire YO14 0PH England
TELEPHONE +44 (0)1723 890099 FACSIMILE +44 (0)1723 893303 EMAIL sales@deepseaplc.com
WEBSITE www.deepseaplc.com
1975 – 2010