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Rolls-Royce continues its expansion into the Latin America market through the supply of MTU Onsite Energy generator sets for the power plant of a new pork processing facility in Mexico. It is operated by one of the country’s largest and most technically advanced producers. The power plant is supported by four MTU Onsite Energy Series 4000 gas generators and one MTU Onsite Energy diesel generator under one overall control system. The site is not connected to the grid; therefore, the power solution is completely independent. This is the first off-grid solution of its kind in the Americas for MTU.

Local distributed energy systems expert, Electriz, S.A. de C.V., was awarded the business, leading engineering, procurement and construction for the project, as well as operation and ongoing maintenance of the power plant. Electriz’s ability to customize and deliver highly-efficient systems was a success factor to win the project.

The four gas units are 20-cylinder Series 4000 natural gas systems delivering all together 7.7 MW electrical power, capable of handling the pork processing facility’s altitude of 8,000 feet above sea level with the lowest derating, ensuring maximum power availability at the site. In a second phase, it is planned to use the heat out of the exhaust gas, the oil cooler and the mixture cooler to produce steam and hot water which can be used in the production processes.

A single 16-cylinder Series 4000 diesel generator system with an electrical output of 2 MW is tasked with absorbing greater load blocks than the natural gas units, offering long-term stability to the power plant. The diesel unit will run continuously with loads as low as 10 percent to minimize fuel consumption, allowing the natural gas units to produce more energy. MTU Onsite Energy’s MCS master control panel integrates plant control and remote operation, and all systems run in isolation from the power grid, providing reliable, stable and efficient electrical power to the entire facility.

The pork processing facility, located in Puebla, Mexico, features a power plant that will operate using three different fuel sources, including biogas from livestock waste in a later stage. With the help of the flexible MTU Onsite Energy systems, the plant will have the ability to double its power capacity in the future. The customer already owns and operates a combined heat and power (CHP) plant at a nearby facility using a medium-speed gas generator unit from Rolls-Royce.

Source: Rolls-Royce

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Rolls-Royce and ABB have announced a global partnership on microgrid technology and advanced automation. Together the two companies will offer an innovative, energy-efficient microgrid solution for utilities, commercial and industrial entities. A microgrid is a small scale electric grid that combines power from distributed energy generation sources such as combined heat and power plants, diesel- and gas-powered gensets and renewable sources with batteries. The microgrid provides the overall control to coordinate these resources to meet the requirements of industrial, residential or consumer loads. Microgrids can either function off-grid, or connected to the main power grid. The ability of microgrids to seamlessly separate themselves from the main grid, in the event of a potential grid fault or emergency, is an in-creasingly important feature.

Reliable power supply – even during harsh weather conditions and times of peak consumption – is critical for economic growth. Integrating renewable energy is a sustainable solution to support uninterrupted power as well as encourage clean energy use. Microgrid solutions benefit utilities, industries and commercial sites that are looking for reliable power supply as well as cost and carbon emission reduction.

Microgrids enable resilient power supply even with high penetration of intermittent renewable energy sources like wind and solar. Digital automation and control systems intelligently coordinate distributed energy resources and loads for the microgrid to function efficiently.

Rolls-Royce offers the MTU Onsite Energy brand power system solutions: from mission critical, standby and continuous power to combined generation of heat and power, and microgrids. “Due to the transformation towards decarbonization, customers need to pursue sustainable power options that also deliver utmost profitability. For this, we rely primarily on microgrids, which are autonomous energy supply systems that are efficient, reliable, and environmentally friendly,” said Andreas Schell, CEO, Rolls-Royce Power Systems.“Combining our integrated MTU diesel and gas genset system technology and our control solutions, with ABB’s modular microgrid solution, control capability and remote service, will offer customers the combined strengths of the two world leaders in technology.”

“ABB Ability™ e-mesh™ can ensure a stable power grid, even with a high share of renewable energy from various sources, working smoothly together with already installed gas or diesel engines,” said Massimo Danieli, head of ABB’s grid automation business line within the company’s Power Grids business. “ABB has a vast number of microgrid installations globally and through our partnership with Rolls-Royce Power Systems, we will further support the growing interest for microgrid solutions globally.”

The ABB Ability™ e-mesh™ solution will provide power generation asset owners a vertically integrated, unified view of their distributed energy resources and renewable power generation that is quick to deploy and that reduce operational costs. Cloud operations, site and fleet optimization, weather and load forecast and machine learning algorithms offer infinite insights for decision-making, such as knowing where to increase investments on maintenance or how to increase revenue streams to operate assets more profitable.

Source: ABB y Rolls-Royce

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Rolls-Royce is partnering with Northwestel, a Northern Canadian telecommunications company, to help provide reliable high-speed internet access to Nunavut, one of the most remote northern territories of the Canadian Arctic. 23 MTU Onsite Energy diesel generator sets are to supply emergency power. They will be delivered as part of a network infrastructure improvement plan designed to increase connectivity, including internet speeds and broadband capacity, in the territory’s communities.

As part of the Canadian government’s “Connect to Innovate” program, Northwestel developed a comprehensive plan to upgrade the region’s telecommunications infrastructure that includes the use of satellite technology with associated receiver dishes in each of the 25 Nunavut communities to increase bandwidth capacity. Each satellite-receiver pair will require backup power to ensure maximum uptime and guarantee service in the event of a power outage.

Nunavut currently has download speeds of 1-3 megabits per second. The goal, by 2019, is to increase those spends three-fold. Longer term, the Canadian Radio-television and Telecommunications Commission (CRTC), the governing body responsible for regulating the broadcasting and telecommunications industries, will require all households in Canada to have download speeds of 50 megabits per second within the next 15 years.

Northwestel partnered with Wajax, Canada’s leading provider of industrial products and services, to design two versions of MTU Onsite Energy’s backup power systems. The 19 “short” version units will include only a generator set and the four “long” units will include a generator set with room for additional radio equipment to accommodate site conditions for each location. Additionally, Wajax’s ERS (Engineered Repair Service) experts ensured each system is equipped with automatic load banks for easy engine maintenance and high-level controls for remote monitoring of the units. The units also include custom Arctic-grade enclosures to protect against the extreme temperatures – up to -22 degrees Celsius in Northern Nunavut – and meet local sound requirements.

Source: Rolls-Royce

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Rolls-Royce has signed a contract with C-Energy to extend their power plant installed capacity with further 23 MWe. The delivery includes two gas-fired gensets based on the new 20 cylinder Rolls-Royce medium speed V-engine, B36:45, that was launched at the Power Gen Asia in September this year. Rolls-Royce will also be supplying long term services for the new engines.

The new B36:45 engine series set a new standard in power and efficiency with exceptionally low fuel consumption and emissions of NOx, CO2, SOx and particulates. At 600 kW per cylinder it offers a 20 per cent increase in power per cylinder compared to its predecessor, the B35:40. The V20 is the largest variant available with an electrical output of 11,8 MWe.

The existing 60 MWe power plant of C-Energy was reconstructed in the beginning of 2015 with four B35:40V20 gas engines. At this time, this was the first natural gas power plant based on medium-speed gas engines in the South Bohemian Region prepared to supply heat and power to the local grid. Due to low coal prices however, electricity and heat in the region is still predominantly generated by coal-fired plants. Hence, the extension of the gas fired plant is considered as an additional step forward towards a green future for the region and country.

With the extension, the power plant will, from the end of 2019, deliver a total of 83 MWe electricity and heat for companies and homes in the nearby town of Tabor/Sezimovo Ústí roughly 100 kilometers southeast of the capital Prague.

Delivery of four Rolls-Royce engines among other investments helped to transform the old coal fired central heating plant into a modern power plant in 2015. Nowadays the plant not only supply power to the grid and heat to industrial customers and municipalities but also provide auxiliary services to the high voltage grid. The supply of brand new Rolls-Royce engines will enable the plant to increase its flexibility, to provide wider range of services and hence remain competitive on the pan European energy market.

The Rolls-Royce medium-speed engines will enable C-Energy to operate the plant efficiently, both in terms of cost and time. Both the B35:40 and the new B36:45 medium speed gas engines are flexibly designed for different operating modes. They can be used to generate base-load or peak power or can operate in combined cycle. The heat from the engines can be used to generate steam in the heat recovery steam generators, and the steam is supplied to industrial customers for their technological needs. The power plant can also be used for district heating by utilizing hot water from the engines.

The engines quick-start capability means the engines can ramp up to their rated load within five minutes, giving the plant access to the amount of power and heat needed within just a short space of time. In addition the new engines will be certified to provide primary and secondary grid regulation.

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At the end of October 2018, Rolls-Royce Power Systems opened a new Customer Care Center in Augsburg, Germany, focusing exclusively on customers of natural-gas-powered generator sets. This makes it one of the company’s five new customer service centers that have been in operation since the beginning of 2018. Experts from MTU work together at different locations, and across several time zones, to support customers around the world when it comes to keeping their MTU Onsite Energy systems on the go.

Rolls-Royce Power Systems is also pressing ahead with the expansion of digital services for its customers. The Digital Solutions team is set to double to 80 employees by the end of 2018.

MTU Go! products helping improve the digital monitoring of generator sets

The digital tools MTU Go! Act and MTU Go! Manage will soon be tested in the first power plants. They are replacing the data loggers previously used, and enable MTU experts and the customer to monitor the units remotely, plan maintenance and spare parts availability, analyze operator data and derive recommendations for improving product operation.

Prime Energia puts its trust in MTU’s digitally-assisted service capability

In Chile, five Prime Energia power plants featuring more than 200 MTU Onsite Energy gensets are to be connected to the public grid, providing a total output of 475 MW of reserve capacity to stabilize Chile’s power supplies. The gensets are digitally connected via data loggers to the MTU Go! Manage platform for monitoring and analyzing current system data. Prime Energia monitors the power plants in real time and controls them via the Network Operations Center in Santiago.

MTU Value Care Agreements safeguard system uptime

When the new service agreements are teamed with these new digital tools and the company’s Customer Care Center capability, the customer benefits in terms of reliability, efficiency and longevity of powergen systems are immense. Preventive maintenance work is planned efficiently, maintenance intervals are adjusted, an optimum, transparent cost structure is implemented, and system uptime is guaranteed.

Source: MTU Onsite Energy

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The new MTU Onsite Energy 20V 4000 DS3600 genset was recently launched on the market. Based on enhanced MTU Series 4000 engines, the 20V 4000 DS3600 diesel genset significantly outperforms previous offerings with a 10% uplift to around 3,000 kW of electrical output (3,730 kVA) in standby operation, and some 2,700 kW of electrical output (3,390 kVA) when generating prime power. Earlier models of this Series 4000 engine have a proven track record with over 23,000 units sold for power generation applications.

More than 30 of these new units are already set for delivery in 2018. Most of the initial consignment, supplying 75 MW overall, is destined for a global internet group to generate standby power for its European data centre. MTU Onsite Energy has already announced further advancement to an even higher level in the form of the 20V 4000 DS4000 diesel genset delivering roughly 16% more output, amounting to as much as 3,200 kW of electrical output (4,000 kVA of standby power), compared with previous offerings. At around 20 m2 both units take up strikingly little space.

Optimized engine design boosts performance

Steadily increasing power demands in mission-critical applications, like those encountered in data centres, airports or hospitals, necessitate the use of ever more powerful engines – such as the enhanced Series 4000 from MTU – to allow the gensets to step in smoothly and cover demand should a contingency arise.

Performance has been boosted by optimizing engine design to allow for a higher BMEP (brake mean effective pressure ) in the cylinders, and fitting a redesigned turbocharger and modified peripheral equipment with some astutely matched components.

Genset beats the standard

In-house expertise in all the key technologies involved here, coupled with state-of-the-art simulation and analysis tools, have allowed to develop a generation of engines with which the new diesel genset can even beat the standard. One reason is the high engine load factor which allows the standby genset to be operated at 85% of its maximum power on average – a value which surpasses the requirements set out in ISO-8528-1 by 15%. What’s more, the generator can run for up to 500 hours a year in its vital standby power role. This value goes way beyond the 200 hours specified in the standard.

In case of a power outage, delivering a dependable power supply in a matter of seconds is key. Data centres with their sensitive IT facilities present the additional challenge of mitigating fluctuations in voltage and frequency. These gensets have therefore been developed to curb these variations by design. Receiving the first order for the new genset from a global player in the Silicon Valley is a great honour.

Certified to feed the public grid

Series 4000 gensets comply with VDE guidelines (the German Association for Electrical, Electronic & Information Technologies) and are certified for mains parallel operation. This allows users to feed power into the public grid at a profit as well as safeguarding supply in case of an emergency. In terms of energy efficiency, this is also a sensible approach to dealing with the increasingly common grid instabilities resulting from the use of renewables. Certified diesel gensets from MTU Onsite Energy tick all the boxes in meeting the technical criteria for doing just this.

Source: Rolls Royce

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A consortium comprising EPC contractor TSK and Rolls-Royce has signed an engineering, procurement and construction (“EPC”) contract with Prime Energía Quickstart Spa, a subsidiary of Prime Energia SpA (“Prime Energía”), for the construction of five power plants across Chile consisting of 265 MTU Onsite Energy 16V 4000 gensets. Prime Energía is a subsidiary of the New York-based Glenfarne Group, LLC (“Glenfarne”), a developer, owner-operator and industrial manager of energy and infrastructure assets. Prime Energía’s five power plants will offer a total combined capacity of 475 MW, which will be connected to Chile’s electricity grid to provide backup capacity to the country’s power supply system.

These power plants are an integral part of Glenfarne’s strategy to develop power infrastructure that supports the proliferation of renewables and the stability of the grid in regions across the Americas with great potential for growth.

The order to deliver the power plants to the first three locations has been officially placed with the consortium, with the order for the two additional plants scheduled to follow shortly thereafter. The gensets will be digitally connected via gateways sending data to the MTU GoManage platform to monitor and analyse system data. The power plants will be remotely monitored and controlled in real time by Prime Energía’s state of the art Network Operations Center in Santiago.

Chile is one of the fastest growing economic powers in Latin America. Demand for energy is expected to grow at an annual rate of 4 per cent over the next 5 years, and the country expects to benefit from the vast availability of renewable power sources. The percentage of renewable energy in the Chilean power mix is growing at a constant rate: its share, in terms of installed generation capacity, has more than tripled since 2012, and in 2017, with a total plant capacity of around 4,300 MW, was approximately 18 per cent. By 2035, no less than 60 per cent of the country’s electricity is expected to be produced from renewable energy, increasing to 70 per cent by 2050. As Chile increases its reliance on weather variable renewable energy sources, there will be an increased requirement for fast-response, cost-competitive backup power sources such as the power plants in Prime Energía’s portfolio to stabilise the electricity grid.

Source: Rolls Royce

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Rolls-Royce has signed a contract with EPC contractor Energyco for the supply of four gensets to a cogeneration plant in Kosice, Slovakia. Based on the medium speed gas engine B35:40V20AG2, the plant will generate a total of 37 MWe heat and power for the district heating company Teplaren Kosice a.s. The contract will also include a service agreement for 5 years. The engines are produced at Bergen Engines AS, which is part of Rolls-Royce Power Systems.

One of the critical parameters required by TEKO was 3 minutes start to full load to comply with Slovakian grid support service.

The medium speed engines from Rolls-Royce are flexibly designed for different operating modes, and can be used to generate base-load, peak power or operate in combined cycle. Already three minutes from start, the engines can operate with 100 per cent load to the rated speed of 750 rpm, and are in this aspect well suited to balance changes in the grid parameters. Furthermore, by utilizing hot water from the engines, the plant will be used for district heating for the region. Heat from the engines can also be used to generate steam in the heat recovery steam generators, to supply industrial customers.

“Cogeneration plants based on our medium speed gas engines are a reliable alternative to coal-based plants and significantly more environmentally friendly. In addition, the engines’ flexibility will enable Teplaren Kosice to operate efficiently, both in terms of cost and time”, said Jeff Elliott, Managing Director of Bergen Engines.

This will be Rolls-Royces first delivery of medium speed reciprocating engines to Slovakia, complimenting the installed base of 96 MWe in central Europe. The plant is scheduled to be commissioned early 2019.

Source: Rolls Royce

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The Everywh2ere Project—part of the EU’s Horizon 2020 research and innovation programme to ensure the sustainable development and competitiveness of the European economy—will develop gensets using hydrogen fuel cells instead of the traditional fuel-based solutions. This will eliminate the CO2 emissions, noise and fumes produced by existing generator types, leading to hardware that is more environmentally sustainable and can be used in applications where conventional generators are not suitable.

The twelve partners* forming the consortium come from different areas of specialisation (hydrogen supply, engine manufacture, environmental consultancy, and construction), which will generate synergies for the adaptation of the hydrogen engine technology currently used in ships and trucks to applications in construction sites, music festivals, public events in cities, emergency situations, natural disasters and critical buildings (such as hospitals, data centres, etc.).

The five-year project, with a budget of approximately 7 million euros, is aimed at realising 8 plug and play fuel-cell gensets, with different outputs (25 kW and 100 kW), for testing from 2020 onwards at, among others, a number of music festivals, and at construction sites managed by Acciona, such as roads and tunnels, with a view to extrapolating the experience for commercial marketability from 2023.

*The organisations participating in EVERYWH2ERE along with Acciona are: PowerCell d’Appolonia; VTT; Genport SRL; Swiss Hydrogen SA; Mahytec SARL; Fundación para el Desarrollo de las Nuevas Tecnologías del Hidrógeno en Aragón; Delta1; Parco scientifico e tecnologico per l’ambiente SpA; ICLEI European Secretariat GMBH and Linde Gas. The project received funding from the Horizon 2020 Programme (grant reference 779606).

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Rolls-Royce has signed a contract with Tuinbouwbedrijf Marc Pittoors (T.B.M.P) BVBA, for the supply of a 7 MWe combined heat and power plant (CHP). The plant will be powered by two gas-fired gensets based on the new medium-speed Bergen B36:45L6 engine and will provide heat and power to a new tomato greenhouse in Belgium. The contract also includes a service agreement for 10 years. The gensets are scheduled to go into operation early November 2018.

Marc Pittoors will use the generated electricity to power the greenhouse artificial lighting and the heat extracted from exhaust gases and engine cooling systems to heat up the facility. In addition, cleaned engine exhaust gases will be injected into the greenhouse to increase the level of CO2 and boost plant growth.

For the tomato producing company, three factors were crucial in taking this decision: electrical efficiency (best in the current market), expertise (Rolls-Royce developed a gas engine in the early 90s and was the pioneer in lean-burn technology) and optimum heat balance (5 hectares of greenhouse space are illuminated and 3.5 hectares are not).

Rolls-Royce will be supplying the complete CHP plant for this greenhouse, consisting of the power generator sets, the exhaust gas systems including a selective catalytic reduction (SCR) system and heat exchangers, and the electronic control system. In total, the technology achieves efficiency rates of more than 96%. Rolls-Royce has many years of experience with CHP plants and has since 2005 delivered 52 CHP plants with a total installed capacity of 270 MWe for greenhouses in Holland, Belgium, Russia and the UK.

Source: Rolls-Royce

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