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Cogeneration
Is it Right for Your Facility?
Load
Coren Scholarships
2009-2010 Academic Year Banking
Winners Announced Best Practices
T H E E N E R C O N C A P A B I L I T Y
POWER
1.800.218.8831 WWW.ENERCON-ENG.COM
2 www.EGSA.org Powerline July/August 2009
CONTENTS
Columns
From the Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Membership Has Its Privileges.
Education . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Coren Scholarship Winners Announced
Codes & Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
EPA Regulations Tighten Controls.
Features
Clean Diesel Funding Helps Industry and Environment . . . . 16
Under the Diesel Emissions Reduction Act
Load Banking Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . 20 (DERA), diesel is getting cleaner and more
Evaluating Cogeneration for Your Facility . . . . . . . . . . . . . . . 24 efcient every day. Page 16.
Departments
Opportunities Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Association and industry events.
Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Whos who in this issue of Powerline.
EGSA Membership Application . . . . . . . . . . . . . . . . . . . . . . . 29
It pays to be a member of EGSA! Use load banking to verify system opera-
tion, commissioning, maintenance and to
Industry News. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 certify system capacity. Page 20.
The latest reports.
Correction
New EGSA Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
On page 22 of the July/
See whos just joined EGSA. August 2009 issue of Pow-
Job Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 erline, the feature story
Looking for a new job? IBC Seismic and Wind
Requirements for Power Aniruddha Natekar
Generation Equipment
contained a misspelling in the authors
name. The author was Aniruddha Natekar,
Sales Application Engineer, Cummins Pow-
er Generation Inc.
We apologize for the error.
Remember Chillicothe Metal when seeking superior design and resources, innovation, and willingness to design around your specific
fabrication services. Chillicothe Metal, a name worth remembering. needs-even on the most challenging specifications-are why we are tops
Take a load off your mind with Chillicothe Metal's total service approach in the generator packaging industry. From start to finish, it's Chillicothe
to power systems integration and equipment protection. Our experience, Metal Co., Inc. Call 309.274.5421 or visit us at cmcousa.com.
1-800-225-5250
www.russelectric.com
President
Anna, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Greg Linton, JRS Custom Fabrications, Inc.
President Elect
ASCO Power Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Ron Hartzel, Eaton Corporation
Avtron Mfg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Vice President
John Kelly, Jr., Kelly Generator & Equipment, Inc.
Baldor Electric Company. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Secretary-Treasurer
Chillicothe Metal Co., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Michael Pope, Sd-Chemie, Inc.
DEIF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2009 EGSA DIRECTORS
Diesel Gas & Turbine Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Vaughn Beasley, Ring Power Corporation
Miratech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
EGSA STAFF
MTS Power Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Jalane Kellough, Executive Director
Power Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Donald Ferreira, Dir. Communications & Publications
Cara Collins, Manager, Conventions & Meetings
Pritchard Brown, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 George W. Rowley, Director of Education
Ring Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Liz Bustamante, Membership Manager
Herbert V. Whittall, Technical Advisor
Robinson Custom Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Russelectric, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 SERVICE INFORMATION
Taylor Power Systems, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 FOR SUBSCRIBER ORDERS, CHANGE OF ADDRESS, REPRINTS,
AND BACK ISSUES (WHEN AVAILABLE), CONTACT:
members receive EGSA products and to keep the pulse of the industry and so Its a self-funding model. You join and par-
services at a reduced rate and notice much more. ticipate; money is collected; at the direction
of their availability in a more timely I started this column by discussing the of the membership, that money is rein-
fashion through email blasts, committee Membership Committee, which is present- vested in products, services and programs
communications, during conferences, etc. ly led by Bob Hach. Ten years ago when that benet you. Neat concept!
Some of the educational tools create privi- I joined EGSA during my rst conference, If youre not a member of EGSA, why
lege simply by association. Over the past I attended the Membership Committee; wait? There is an application on page 29
several years, EGSA has awarded 10 to 12 at the time, it was led by Steve Stoyanac. towards the back of this magazine designed
scholarships per year to qualied students There were 447 members. Steve Stoyanac with you in mind. Today would be a great
under the auspices of the David I. Coren begat Randall Nunmaker who begat Charlie day to begin realizing the value of member-
Memorial Scholarship Program. Indeed, it Habic who begat Bob Hach and ten years ship personally.
is a privilege to be a member of an associa- later we have just eclipsed 700 members. If you are currently a member of EGSA,
tion that is giving back and investing in the Congratulations to the present membership plan on making the most of your member-
future leaders of our association and our team and to those who led and served be- ship by joining us in Colorado Springs,
industry. fore. Your efforts have yielded great results. September 13-15. This years Fall Techni-
Consider these additional privileges Whats more, those results were achieved cal & Marketing Conference is designed
of membership: marketing data; confer- during nancial downturns in 2000, 2008 with you in mind; it reaches its maximum
ence educational programs; the oppor- and now in 2009. Great work!! value when you come and participate. Ill
tunity to inuence the industry through So, EGSA membership does indeed have see you then.
your involvement; the opportunity to be privileges. Amazingly enough, it is through
recognized for your contributions to the and because of those members that we are
industry and our association; a mechanism able to provide the privileges we all enjoy.
888-881-7118 www.comrent.com
Minuteman
load bank
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(216) 573-7600 Fax: (216)-573-5953
The DEIF Group Head ofce in Denmark with subsidiaries in Norway, Germany, UK, France, China, Brazil, USA and India
DEIF, Inc. 2057 Vermont Drive Fort Collins, CO 80525 Tel.: (970) 530-2261 Fax: (970) 530-2557 us@deif.com www.deif.com
Powerline July/August 2009 www.EGSA.org 13
EGSA offers you a big advantage: For the sharpen your competitive edge. Employing
rst time in our industry, we have an certied technicians will promote customer
objective and accurate way to determine satisfaction and you wont have to be shy
generator technician prociency. That about offering assurance that your techni-
means that the same standards will be cians are qualied. Certication can also
used to measure the skills and knowledge help you select potential new hires, analyze
of technicians from Maine to Manitoba job performance, evaluate employees and
and Mexico. Yes, Manitoba and Mexico! motivate technicians to enhance their skills
EGSA has determined that there is no and knowledge.
reason why the test could not be fairly
Think about the message that certica-
applied to any NAFTA technician.
tion sends to those with whom you do
business. Why would anyone want a
technician who isnt certied performing
Think things move pretty fast in todays
For the Employer, certication helps ensure critical maintenance or repair tasks?
business world? Think how fast theyll be
that your technicians have the critical Employing certied technicians gives you
moving one, ve or even 10 years down
knowledge and skills to succeed in their an added tool with which to market your
the road. Thats why you need every
jobs. And everyone will be comfortable business.
advantage to stay on top.
knowing that your certied technicians
As our members have said, Weve seen
Its no secret that technology is becoming expertise has been conrmed by the
too many backyard mechanics damage
more complexnot lessand that makes industry organization through a program
expensive equipment. This program will
todays On-Site Power Generation System that was developed by a university. Encour-
provide credibility for my company and
a lot more expensive. End-usersyour aging and helping your technicians become
will help build pride and a commitment
customersdont want just anybody certied signies your commitment to the
from technicians to be the best.
with a basic knowledge of mechanics to highest of standards. Plus, it lends an added
install and maintain their equipment. They level of credibility to your rm and can
want to be condent that all work has
been performed by qualied personnel. Certicate holders benet too. Certi-
Suppliers want assurance that skilled cation shows employers, clients, and
technicians are performing maintenance associates that you are committed as a
and repairs to guard against unnecessary professional. It provides recognition of
returns or warranty repairs. your knowledge and skill, shows your
commitment to your profession and can
help with job advancement. Certication
is a mark of excellence that you carry
In the past, your word was the only assur-
with you everywhere you go.
ance that your technicians are skilled and
knowledgeable. But now, through EGSAs Acquiring certication indicates that
Electrical Generator Systems Technician you have the knowledge and prociency
Certication Program, there is a way required to perform as an Electrical
that you can back up those words with Generating Systems Technician profes-
objective evidence of your technicians sional. Becoming certied can increase
prociency. your salary, enhance your skills, and make
your job more satisfying.
Certied status is an indication that an individual The Electrical Generating Systems Association Systems Association is not undertaking to render
has completed a combination of dened education, disclaims liability for any personal injury, property professional or other services for or on behalf of
experience or examination requirements. However, or other damages of any nature whatsoever, any person or entity, nor is the Electrical Generating
Certication is not a guarantee or assurance whether special, indirect, consequential or Systems Association undertaking to perform any
of the competence or ability of any particular compensatory, directly or indirectly resulting duty owed by any person or entity to someone else.
individual. Further, given the rapid changes from the Certication Program or the acts or Anyone using the services of a person who has been
in the eld, the Electrical Generating Systems omissions of any person who has been Certied Certied should rely on his or her own independent
Association cannot warrant that the Examination by the Electrical Generating Systems Association. judgment or, as appropriate, seek the advice of a
and other Certication materials will at all times In conducting the Certication Program, including competent professional in determining the exercise
reect the most current state of the art. issuing Certications, the Electrical Generating of reasonable care in any given circumstances.
1650 S. Dixie Hwy, Suite 400 Boca Raton FL 33432
561-750-5575 Fax: 561-395-8557 www.EGSA.org
Looking Ahead
Now that awareness about the DERA program has grown, the
challenge will be to keep the programs funding consistent with
the level of interest. Earlier this year more than 360 industry, non-
prot and governmental organizations signed a letter to the House
and Senate Appropriations Committees asking that the full $200
million in authorized funding be provided. Representatives Mat-
sui (D-CA) and Shimkus (R-IL) authored a similar letter cosigned
by 41 Colleagues encouraging full funding to the Appropriations
committee chairmen. A similar effort is expected in the Senate,
although todays economic climate and growing budget decit
will make it difcult to reach this level. Whatever funding level is
nally approved will likely be combined with the FY09 levels to
allow for a more sizable allocation of funds to EPA regional ofces
and states, masking the actual lower annual appropriations levels.
While interested parties should continue to communicate
their interest in higher DERA funding levels to their Members of Regional Diesel Collaboratives are public-private voluntary organi-
Congress, the bigger imperative will be to get the DERA program zations which correspond to EPA regional ofces providing education
extended beyond 2011 when the original program authorization and networking for governmental, private and non-prot stakehold-
expires. Interested parties must begin advocating with Members of ers who are interested in reducing diesel emissions.
Congress for an extension of the program, with the most effective
messengers being grant winners who can document the economic provide power for on and off-road vehicles and equipment that
and environmental benets of the funding they received and the touch virtually every industry. Our nation faces economic and
constituents who were uninformed about or unsuccessful in the environmental challenges and an upgrading of our diesel power
previous competitions and can argue that these benets can be infrastructure could go a long way in simultaneously providing
multiplied and provide local benets through the programs con- jobs and security, conserving energy and improving our environ-
tinuation. ment, providing a win-win-win solution. Wouldnt it be nice if we
Diesel engines are the workhorse of our economy. They could get always bet on those odds?
Photo 1: Load banking can verify system operation, commissioning and maintenance as well as certify system capacity. Here a load testing
mobile unit is used to test a portable generator.
3. If the oil pressure drops below the your annual maintenance plan. There is no
manufacturers recommended range, better way to have the peace of mind that
the oil pump may need to be rebuilt you are prepared when the lights go out!
or low pressure may be an indication
of excessive engine wear that could References
signal the need for an engine overhaul. 1
The American Society of Heating, Re-
frigerating and Air-Conditioning Engineers
Documentation (ASHRAE) www.ashrae.org
Ideally a digital recorder should be 2
The National Fire Protection Associa-
connected to chart frequency, voltage and tion (NFPA 110) Standard for emergency
amperage, and document in one-second and standby power systems. www.nfpa.org
sampling. This information should be
downloaded to graph a detailed perfor- About the author
mance report. Engine oil pressure and Lyndon Risser is the CEO of DynaTech
temperature should be documented at 25, Power located in Lebanon, PA. Their pri-
50, 75 and 100 percent of the nameplate mary focus is Delivering Power and Con-
rating of the generator (see Photo 4). dence through the sale, service and rental
of emergency power equipment. For in-
Conclusion formation, visit www.dynagen.com. Contact
Load bank testing should not be consid- Lyndon at lyndon.risser@dynagen.com
ered an option, but rather a critical element
of your emergency preparedness plan. If
you are the maintenance provider, con-
sider it your responsibility to recommend
load banking to your client. As a generator
owner, make sure this is included as part of
CASE STUDY
You can see from the gures above can cut total energy expenditures and tion system will pay for itself in less than
that an on-site generator that produc- greenhouse gas emissions by a signicant four years, and thereafter provide annual
es both electricity and thermal energy amount. In this example, the cogenera- positive cash ow for the facility.
For Shipping within the Continental U.S. (not including Alaska, Hawaii, or Puerto Rico): add $5 per book for shipping costs.
For shipping outside the Continental U.S.: call (561) 750-5575 or fax (561) 395-8557 for a shipping cost quote.
IMPORTANT! FULL PAYMENT MUST ACCOMPANY THIS FORM. Please Note: We do NOT ship to P.O. Boxes.
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many more types of facilities large and The prime mover can be a lean-burn natu- Is Your Facility a
small to take a fresh look at cogenera- ral gas reciprocating engine, diesel recipro- Candidate for Cogeneration?
tion as a way to improve energy efciency, cating engine, gas turbine, microturbine or The rst step in deciding whether a co-
cut greenhouse gas emissions and reduce fuel cell. (See the sidebar below for more generation system is right for your facility is
costs. information on the prime mover options to perform a quick analysis of your energy
A cogeneration system normally con- for cogeneration systems.) While the ratio use. This analysis can be reduced to a few
sists of a prime mover turning an alternator of heat to electricity production differs simple questions. If you answer yes to all
to produce electricity, and a waste heat between reciprocating engine systems and the questions, then you may be a good can-
recovery system to capture heat from the gas turbine systems, as much as 90 percent didate for a more comprehensive analysis.
exhaust and engine cooling water jacket. of the energy in the original fuel is put to 1 Have you taken all reasonable steps to
productive use in a cogeneration system. reduce both electric and heat energy
Cogeneration systems Less than 10 percent of the electricity consumption at your facility? Obvi-
used in the United States today is produced ously, if you can make improvements
can offer energy savings by cogeneration systems, but the Depart- in the way you use energy in your
of up to 35 percent ment of Energy (DOE) has established a facility, these changes will translate
goal of doubling installed cogeneration into lower operating costs and perhaps
while contributing to capacity by 2010. The European Union reduce the size of the cogeneration
building sustainability has established a similar target. Switzer- system needed as well as your invest-
land, where cogeneration accounts for 77 ment.
and protecting the percent of the countrys electricity, and 2 Is the base electrical load at your fa-
environment. Denmark (40 percent), are already well cility greater than 1000 kW? While
ahead of the curve. cogeneration systems incorporating
nicantly reduce the amount of carbon and evaluate the environmental and energy-sav- Conclusion
other pollutants that are released into the ing benets of cogeneration. This calculator Cogeneration systems that produce
atmosphere. can be found at http://www.epa.gov/chp/doc- both electricity and heat/cooling from the
To help facility managers calculate the uments/chp_emissions_calc_103006.xls same fuel can offer energy savings of up
amount of reduction in greenhouse gases to 35 percent for a wide range of facilities,
and fuel that can be achieved with a co- CHP Candidate Applications while at the same time contributing to
generation system, the U.S. Environmental Advancing technology has made cogen- building sustainability and protecting the
Protection Agency (EPA) has created an eration systems suitable for a much wider environment. The potential for cost sav-
online tool. This interactive tool can help range of applications than in the past, al- ings in energy expenditures is usually the
facility managers or consulting engineers though the simultaneous need for electric motivating reason to consider cogenera-
power and heat or cooling is common to tion, but building sustainability and LEED
all cogeneration applications. Facility types certication are becoming reasons on their
Less than 10 percent that are good candidates for cogeneration own to investigate the potential benets of
of the electricity used today include: cogeneration for your facility.
Hospitals For more information, contact your
in the U.S. today is Greenhouses consulting engineering rm or power sys-
produced by cogeneration, Hotels tem manufacturer.
Industrial/chemical plants
but the Department of Manufacturing
Energy has set a goal Commercial facilities
Government facilities
of doubling installed Colleges and universities
cogeneration capacity Food processing plants
Health clubs/swimming pools
by 2010. Nursing homes
4Low cost
4Easy to install
4No programming required
4Universal for all generator brands and sizes
4Notications by e-mail and cellular text messaging
43 ways to communicate (cellular, phone, ethernet)
4Automatic monthly e-mail to customer
(generator activity documentation) Sold by GENTRACKER
4Remote starts authorized
dealers
4Internet-based only
Generator Solutions, Inc.
533 Hayward Ave. N.
Oakdale, MN 55128
651-770-9405
Taking Generator Service to the Next Level www.dealers.gentracker.com
T. Boone Pickens Shelves Pampa plant. Construction of the oating power- variety of industries through the develop-
Wind Project in Texas Panhandle generating unit has already begun and is ment of highly efcient, environmentally
CNN reports that billionaire oil man T. due to be complete by the second quarter friendly industrial engines which convert
Boone Pickens is shelving plans to build of 2012. Following testing, it is expected both natural gas and bio-gas into electric-
the worlds largest wind farm. to begin operations in Kamchatkas port of ity. MWM opened its service facility in
Set in the Texas Panhandle, the Pampa Viluchinsk by the end of 2012. Salem, OH last year.
Wind Project was the centerpiece of The The 21,500-ton FNPP is 472 feet long MWM creates eco-friendly solutions for
Pickens Plan, Pickens campaign to wean and 98 feet wide and houses two KLT40-S producing clean, renewable energy across
the United States off foreign oil and switch marine reactors with an aggregate power industries and around the globe using a va-
to wind and natural gas. The $12 billion of 70 megawatts. Construction cost has riety of customized solutions ranging from
plan was to be complete in 2014 and been estimated at $274 million. The FNPP the use of methane gas emitted by a landll
provide enough electricity to power 1.3 is designed to be based in coastal areas in Illinois, to natural gas in California, or
million homes. Pickens said he will honor and used to generate electricity and heat; bio-gas in Schleswig-Holstein.
commitments for 667 wind turbines he has waste heat from the reactors will be able to MWM traces its roots to 1871 when it
already ordered. desalinate up to 220 tons of seawater daily. was founded by the famous auto inven-
Design specications project a reactor ser- tor Carl Benz. The name originally stood
Russia Building Worlds First vice life of 38 years, and the plant can be for the former Motoren-Werke Mannheim
Floating Nuclear Power Plant operated for 10-12 years without replacing of Mannheim, Germany. Reclaiming the
Concern Energoatom PLC and Baltiysky its nuclear fuel. MWM name allows the European-based
Zavod PLC, a part of United Industrial company to draw upon its heritage of
Corporation (OPK) have signed an agree- MWM Reclaims Name, Moves over 138 years of experience in preci-
ment to construct and supply the head Into North American Market sion engineering. Today, the company has
oating power-generating unit for the rst MWM, formerly known as Deutz Power more than 1,150 employees with world-
oating nuclear power plant (FNPP). The Systems, has opened new U.S. headquar- wide sales and service subsidiaries in 10
contract covers the construction, launch- ters in Atlanta, Georgia. The company countries. For more information, visit www.
ing, rebuilding and testing of the power provides renewable energy solutions for a MWM.net.
Air Systems, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (DD) Electric Controls & Components, Inc.. . . . . . . . . . . . . . . . . . . . . . . (MR)
Louisville, KY Coral Springs, FL
(502) 452-6312 Fax: (502) 458-0791 (954) 344-8884 Fax: (954) 827-0588
Contact: Ryan Moorman, General Manager Contact: Mario E. Jones, President
Business: Air Systems is in the air compressor business and the Business: An export management company with over 25 years of
generator business. We have a sales, service and parts department. experience in Latin America. Currently represent Marathon Electric
We rent Doosan equipment. and Thomson Technology.
baldor.com
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