Cummins celebrate dual triumphs in innovation and sustainability
The company showcases its commitment to pioneering cutting-edge solutions and environmental responsibility with two groundbreaking projects.
Cummins in the Middle East, one of the global leaders in engineering and oil & gas solutions, has achieved two significant milestones that exemplify innovation and sustainability. The company's groundbreaking projects demonstrate its commitment to pioneering cutting-edge solutions and driving environmental responsibility.
Cummins Middle East and Cummins Canada have jointly accomplished the creation of one of the Middle East's largest single-piece generator enclosures, weighing over 500 tons. Designed, engineered and fabricated in UAE, this colossal structure houses five QSK95 generators, a DMC 8000 unit, and a large pressurised electrical room.
This immense powerhouse plays a pivotal role in supplying emergency power to an LNG site located on the Pacific West coast of British Columbia which stands as one of the largest construction projects in Canada. The project, spanning from 2019 to 2023, required seamless collaboration between Middle East and Canada teams through various phases, including engineering, project management, quality testing, commissioning and logistics.
The emergency powerhouse project presented unique challenges, primarily due to its sheer size and complexity. The building, measuring 33m x 21.5m x 8.5m, required construction which was compliant with a 2-hour fire rating standard and incorporation of intricate electrical, mechanical, HVAC, fire & gas and instrumentation systems.
Apart from the main generator area, the building has a segregated electrical system comprised of an Arc Flash low voltage MCC panel, Digital Master Control panel (DMC8000), distribution boards, distribution transformer, telecom panel, electrical and instrumentation JB, Wi-Fi device, CCTV, electrical hoist (for generator maintenance), NGR etc. This room has its redundant air conditioning unit to maintain the temperature requirement of -5 to 36 degrees.
The stringent Canadian regulations and codes further added complexity to the project. The team had to conduct several design reviews and various engineering solutions to achieve the DNV requirement and also overcome the supply chain issues by using substitute material available. They also had to go through several technical material approvals from BCOGC (British Columbia Oil & Gas Commission) to overcome the supply chain issues.
After rigorous testing and quality assurance, the massive structure was prepared and transported to Canada. The transportation itself was a remarkable feat, involving careful planning and coordination, as the cargo was moved to Hamriyah Port in the UAE before being shipped to Canada. The journey involved overcoming multiple challenges, including route clearance, police escorts and meticulous execution.
In another pioneering endeavour, Cummins in the Middle East manufactured the first-ever fully modularised and containerised methanol-reformer and hydrogen fuel cell package. These innovative systems produce 200 kW of green electricity and are housed in 20-foot containers for convenient deployment. They cater to the increasing demand for green power generation, contributing to the journey towards net-zero emissions.
The methanol-reformer package comprises of two hydrogen generators producing high-purity hydrogen from a methanol and deinoised water mixture. The generated hydrogen is then compressed and stored for use in hydrogen fuel cell generators, which produce clean electricity. These packages represent a cutting-edge technology that facilitates spot generation of green power, aligning with the global transition towards sustainable energy sources.
The methanol-reformer and hydrogen fuel cell package systems project involved teams located across different regions globally. The teams were not just cross-functional but spread across Asia, Europe and North America. The diversity of the team helped Cummins navigate the challenges of handling dangerous chemicals of methanol and highly inflammable hydrogen gas. The collective knowledge enabled optimum designs and appropriate risk mitigation. Geographical spread helped the local team reach the best OEM across the globe in the quest for finding the best solution for the customer.
The uniqueness of this package is its size. They are modular 20-foot containerised units. It enables spot generation of green electricity at remote locations. Unlike big grid projects, these are fast to produce and deploy. They will help the H2 economy by enabling penetration in areas where the grid won’t reach soon. Additionally, they have much less CAPEX requirement than grid power plants putting them in reach of more customers.
These remarkable achievements by Cummins reflect the company's commitment to innovation, sustainability and delivering solutions that make a positive impact on industries and the environment. These projects demonstrate the company's ability to handle complex engineering challenges by utilising its global talent and supply chains contributing to a greener and more sustainable future whilst bringing peace of mind for the client.
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