Power Generation

The HSK78G from Cummins ... works in a blistering 55 deg C and extreme altitudes.

The HSK78G from Cummins ... works in a blistering 55 deg C and extreme altitudes.

Cummins gears for next generation of power

Cummins’ latest models aim to offer a total package of gas generator capabilities and innovative gas technology for prime and peaking power applications.

September 2019

Cummins says its new HSK78G natural gas generator series represents a bold step into the gas arena for the company that pushes new levels of efficiency, transient performance and gas variation well beyond former natural gas generators.

The new series, which made its debut in the region at the Middle East Electricity (MME) show held in Dubai last March, will fuel the next generation of power, offers a total package of gas generator capabilities and innovative gas technology for prime and peaking power applications.

With a power density of up to 2.0 MW from a 78-litre engine, the HSK78G generator series is designed to provide reliable power, regardless of the natural gas source or the climate, including extreme heat up to a blistering 55 deg C and extreme altitudes, says a company official.

“The HSK78G models are suitable for a diverse set of industries from mining and manufacturing to shopping malls and hospitals,” says Craig Wilkins, director of Cummins Prime Power Segment and Global Sales Support.

“The new generator series have been designed to push the boundaries of performance to extremes while achieving a low total cost of ownership. A high electrical efficiency of up to 44.2 per cent (50 Hz) and 43.5 per cent (60 Hz) is achieved on a wide range of pipeline natural gas down to 70 methane number (MN) without impacting power output and efficiency.

“The barrier-breaking fuel flexibility of the HSK78G enables the utilisation of low-cost, low-BTU and free fuel sources, that would otherwise be considered waste products, delivering robust power even with very aggressive fuels with minimal derating. By eliminating the need and the space required for gas-cleaning systems, customers can optimise their capital (Capex) and operational (Opex) expenditures,” he adds.

The efficiency of the HSK78G is maintained by automatic engine adjustments, which account for fuel quality changes and quick load-step performance, without the need to calibrate or switch off the engine. As a result, customers can expect more stability, greater uptime and lower fuel costs leading to lower total cost of ownership. In the case of a grid failure, the HSK78G can also switch to island mode offering more reliability.

“It’s possible to burn pipeline natural gas, flare gas and biogas with high efficiency and low emissions without compromising on power output. New technology and electronic engine management systems allow the generator to automatically manage gas fuel quality fluctuations to ensure zero loss in performance via advanced on-board diagnostic control systems,” says Wilkins.

In addition to greater efficiency and lower cost of ownership, the HSK78G provides thermal efficiency at 47.1 per cent, generating 2,110 kW of thermal output for heating, cooling and steam generation. As a result, the HSK78G offers significant environmental benefits by recovering carbon dioxide (CO2), and its superior heat exchange takes up less space, offering greater design flexibility.

The models are capable of lowering nitrogen oxide (NOx) emissions down to 250 mg/N cu m (0.5 g/hp-hr), offering compliance with global regulations without the need of selective catalytic reduction (SCR).

They are designed to achieve a 30 per cent first load step at G1 with four steps to full load providing superior load pick-up and load rejection transient capabilities, resulting in fewer voltage and frequency disturbances and faster recovery times. As a result, customers can expect a more stable power supply, critical for island mode and emergency operations and a lower total cost of ownership, Wilkins adds.

The new gas generator models have the industry’s longest major overhaul service cycle of 80,000 hours and the most sophisticated predictive diagnostics in the industry, he claims.

The technology is driven by innovative tools like onboard spark plug sensors, NOx sensors, and real-time trend data collection. “The full package of onboard HSK78G diagnostics minimises unscheduled downtime while enabling customers to accurately predict maintenance needs and optimise maintenance costs,” he says.

Coupled with the product capabilities, Cummins offers customers peace of mind when it comes to servicing and maintaining the HSK78G. Best-in-class aftermarket capabilities are provided through dedicated local contacts, who are supported by a global system of service technicians, engineers and part distributions centres, experienced in offering and servicing natural gas solutions to fit any power need. 

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