Integrated generator set manu- facturer Cummins believes that its Power of One initiative provides sustainstable and consistent power supply for the mining industry.

Cummins South Africa (SA) power generation GM Cletus Makombe says the initiative is an integrated approach where major components, such as the engine, alternator, transfer switches and control systems, work in har- mony from the start and are all manufactured to Cummins’ highest standards of quality.

The company notes that reliable power supply is an important factor in mining operations’ productivity and, with a range of power generation equipment and services available to local mining operations, an increase in productivity is guaranteed.

“The initiative ensures that a mine’s power system works efficiently, as it involves a pre-inte- grated design, rather than the combination of an engine, an alternator, controls and transfer switches from a variety of manufacturers. “This has resulted in smaller equipment footprints, reduced installation time and higher system reliability in a region that is regularly affected by constant and prolonged power short- ages,” he explains.

The company has several offices across South Africa that are situated close to the plants they supply to provide speedy technical assistance and maintenance services, should the need arise.

Proven Project Capabilities
Cummins is currently powering a large-scale Bacyrus 495 electric rope shovel at Debswana’s Jwaneng openpit diamond mine in Botswana, with a 2 MVA Cummins motivator – a containerised diesel generator that is genset-mounted onto a custom-built Martin trailer, which is pulled by a Western Star 6900XD truck –powered by a Cummins ISX engine.

The Cummins C2250-D5 generator is powered by a Cummins QSK 60 G4 engine, which is coupled to a Stamford alternator that produces 2 000 kVA at 6 600 volts prime power. The Cummins PCC 3201 generator controller provides control and protection to the Cummins engine and the generator.

Owing to the sheer size of the motivator, a three-man team is required to operate the machine. Cummins SA is committed to providing the most effective solution with regard to safety and reliability by ensuring that the company has a regular on-site presence, while providing instant access to technical support.

Cummins has also ensured the stable supply of prime power to the Ambatovy nickel/cobalt mine, in Madagascar, through its range of generator sets. Ambatovy is the largest capital project in the history of Madagascar, with yearly production capacity estimated at 60 000 t of nickel, 5 600 t of cobalt and 190 000 t of ammonium sulphate.

The project has an estimated project life span of 27 years, and is positioned to be the world’s largest lateritic nickel mine by end-2013. Cummins SA commercial power systems GM Nicola Morgan-Evens notes that after facing critical power shortages in November 2011 as a result of Madagascar’s poor energy supply network, the Ambatovy project bought 30 Cummins generator sets, valued at US$15-million, to help meet its requirement for prime power.

“In total, 30 Cummins C1250 D2R generator sets using KTA50-G3 engines and Stamford P7 alternators were installed at the site, which has since ensured the uninterrupted supply of power that is vitally important to this project, which has the potential to substantially boost the economy of Madagascar and the standard of living for its people,” she explains.

Morgan-Evens points out that the 1 000 kW C1250 D2R generator sets provide 30 MW of power and can run 24/7, while synchronising with the local grid, existing Cummins generators and turbines for load management. “They operate from two plants, each supplying 15 MW of power. “This comprises 15 C1250 D2R units for prime power, and an additional fifteen 0.4 kV/11 kV step-up transformers and two 20 ft containerised MV cells, with two 68 000 ℓ self bunded bulk fuel tanks.”

Morgan-Evans notes that current product development at Cummins power generation focuses on reducing the carbon emissions of engine and generator sets, which reduce pollution and global warming.

“Cummins power generation can meet any demands for standby power, whether it is a simple diesel generator set or a com- plete preintegrated power generation set ranging from 8 kVA to 3 300 kVA in size,” she adds.

With rising challenges in environmental regulations, cost constraints and ever increasing power demands, Cummins’ research and development department continues to develop power generation technology that will provide solutions for these challenges.

Cummins trains personnel through its three-year apprenticeship programme, where apprentices learn the mechanical and theoretical processes of power generation technology and the other service offerings of the company.

“Cummins apprentices gain knowledge and insight from industry experts and work alongside some of the foremost industry personnel. “Apprentices will work in the mechanical and electrical engineering fields or in the craft and technician fields. “The successful completion of a Cummins apprenticeship may lead to many opportunities to develop a career with Cummins,” highlights Makombe.