Mission accomplished: Cummins gensets critical to frontline reliability

Cummins gensets

Preventive maintenance ensures that standby generators are ready for action when called upon in mission critical applications.

Generators failing to start are not an option for mission critical facilities.

Whether for public health, national security or business continuity reasons, the reliability of the generators and standby power systems is crucial to the continued operation of these facilities.

More than 3,500 Cummins Inc. generator sets are installed in mission critical applications across the South Pacific, South East Asia and North East Asia regions – testimony to the reliability of the standby power systems and aftersales support provided by Cummins.

Cummins’ routine servicing and preventive maintenance guidelines underline the fact that generators are among the most important pieces of equipment at a mission critical facility, whether it be a hospital, data centre, airport or telecommunications centre.

That importance is highlighted when the lights go out and the seconds are counted anxiously until they come back on again.

Maintenance neglect is the single most common reason for genset and power system failures, says Stuart Quinn, aftermarket business development manager for Cummins Asia Pacific’s power generation business.

Cummins genset
Thousands of mission critical applications in the Asia Pacific region rely on the reliability of Cummins gensets.

Peace of mind

“Cummins’ aim is to provide peace of mind with tailored service solutions that underpin power system reliability and ensure that any minor issues are identified prior to becoming major problems,” he says.

“Diesel and gas generator sets and their control systems are complex pieces of equipment so routine servicing and preventive maintenance are critical to overall system reliability.

“In Australia, we’re coming into the storm season which makes preventive maintenance even more critical if the generators need to come on line in the event of grid outages.

“It’s the simple maintenance items that are often missed, such as a coolant or fuel hose leaks, that can let you down. The aim with our service plans is to ensure that minor issues are identified before they become major problems.”

Cummins offers facility managers a range of capped price service solutions, from routine servicing on a quarterly, six-monthly or annual basis to mains failure testing – the ultimate test to know for certain that the generator will start in an emergency.

“We fully simulate a mains power failure and ‘black start’ the generators to ensure they are 100 percent operational. This can be carried out whenever the customer requires,” says Stuart Quinn.

24/7 support

All Cummins service solutions include 24/7 support with fast response and diagnosis, a 90-day workmanship guarantee and 12-month parts warranty, and a detailed service report.

Capped pricing can be locked in for up to five years.

Importantly, all major components of a Cummins genset are designed and manufactured by Cummins. The Cummins brand also covers digital controls, transfer switches, paralleling systems and remote monitoring.

The support capabilities Cummins has built in the Asia Pacific region are unmatched. In the South Pacific region, for example, 38 company-owned branches are dedicated to customer support in strategic locations around Australia, New Zealand and Papua New Guinea.

Factory-trained Cummins technicians carry out all generator system servicing and maintenance while Cummins’ extensive service network is equipped with comprehensive power generation knowledge to enable all makes and models of generators to be serviced.

Cummins also operates a Customer Support Centre, based in Melbourne, which is staffed 24/7 by qualified technicians and parts interpreters. The centre is available to customers in Australian and New Zealand and provides one-on-one diagnostic and technical support as a well as handling parts orders.

Cummins Office Building

Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

Cummins Custompaks are being used for water management as Thailand struggles with its water crisis

CustomPak on site

Water crisis

Sixty Cummins Inc. CustomPaks are in service in Thailand as part of a critical water management plan aimed at easing the country’s water crisis – a crisis that has caused enormous economic and social damage and stirred conflict among communities.

Over the past several decades, Thailand has continually faced water problems caused by severe drought. Water reserves in dams and reservoirs are insufficient while water resources are often contaminated with toxins caused by urban communities and the industrial and agricultural sectors.

Severe flooding is a threat, too, at a time when the realities of climate change are hanging over the country.

As a result, the allocation of precious water resources, which must be shared among various stakeholders including new and existing industry, large and small agriculture, and cities and villages has become a flashpoint.

Kittithanapat Engineering Co. (KTP), has been involved in the water management system since 1996, working closely with authorities such as the Royal Irrigation Department, Department of Water Resources, Bangkok Metropolitan Authority and others.

CustomPaks on site

600 hp CustomPaks

To help KTP meet its often urgent requirements, Cummins DKSH (Thailand) has recently supplied 60 Australian-built CustomPaks – 45 powered by Cummins’ X15 engine rated at 600 hp, and 15 powered by the QSL9 rated at 325 hp. These fully self-contained powerpacks are emissions certified to Tier 3.

The CustomPaks are coupled to hydraulically-driven, large-volume submersible water pumps sourced by KTP from US company Moving Water Industries (MWI); KTP is the exclusive distributor in Thailand for these MWI Hydroflo pumps.

Prior to Cummins’ involvement, KTP was using another diesel engine brand but service support wasn’t up to the standard required.

Long-serving KTP engineer Kittisak Thanasoot says Cummins DKSH’s reputation for technical and aftersales support along with the reliability of the Cummins product were a key reason behind KTP’s decision to specify the CustomPaks for the Royal Irrigation Department.

The ability of Cummins DKSH to respond to short delivery times was also important.

“Supplying large quantities of high horsepower diesel engines for emergency situations such as flash flooding can be a challenge for KTP,” says Kittisak Thanasoot.

“Responding to the needs of the government agencies to manage such problems in a timely manner and with least impact on communities, KTP has found the answer in our partnership with Cummins DKSH.”

Power, pride and passion

Parked semi truck

The switch back to Cummins power has been beneficial for iconic New Zealand company Uhlenberg Haulage. It's all about whole-of-life costs.

Uhlenberg Haulage is closing in on 60 years in business, having been founded in 1966 by Mike and Carol Uhlenberg.

Based in Eltham, Taranaki, in New Zealand’s North Island, the operation is today owned and operated by their sons Chris, Daryl and Tony Uhlenberg.

Describing the Uhlenbergs as “old school family truckies”, Daryl talks about the company’s time-honored journey with a definite tone of pride, especially the work of his parents in laying the foundations for what is today an iconic fleet in its own right.

Cummins Inc. made its debut in the Uhlenberg fleet in 1971 with an NH250 powering a second-hand Kenworth K923 used in logging. A second Kenworth, a new W924 with a Cummins NTC335, followed soon after hauling an LPG tanker.

The Uhlenberg operation today comprises 40 prime movers and a variety of trailing gear to cater for the myriad of a jobs the fleet is involved in.

A number of Peterbilts feature in the fleet although Kenworth is now the brand of choice with six new units to be delivered over the next 12 months to cater for business growth.

Cummins’ X15 Euro 5 engine rated at 550 or 600 hp is the preferred power specification, with 18 red engines currently in the fleet.

Uhlenberg family in front of truck

Whole-of-life support

“The switch to Cummins has been a very good experience for us. We have nothing but praise for the Cummins organization,” says Daryl.

“The whole-of-life picture is the key thing for us and we’ve got that nailed with the support we get from Cummins – parts availability, scheduled maintenance, life expectancy and in-frame rebuilds.

“So the red engines turn up, we run them to life, which is 900,000 to 1.2 million kilometers, and then Cummins does an in-frame overhaul in a timely manner. If there’s an issue, parts and support are close by.

“The support we get from Cummins Palmerston North is fantastic, second to none.”

Daryl recently looked under a Kenworth that was in the workshop for a service and was surprised to see no oil leaking from the one-million-kilometer X15. “I remember when I was a fitter we had to wear a raincoat when working under a truck,” he jokes.

Fuel agnostic

Acknowledging that the push to decarbonize is now “very real”, Daryl likes the idea of Cummins’ fuel agnostic concept where one base internal combustion engine, optimized to run on diesel, can also be customized to run on ultra-low and zero-carbon fuels like renewable natural gas and hydrogen.

“My father was a pioneer of linehaul trucking in New Zealand and he always embraced new technology. He was never scared of it,” he says.

“I tend to be a little more cautious but I can see where a 500 hp natural gas or hydrogen engine would work for us in short haul applications,” he admits. “We’re certainly willing to look closely at these alternative fuel technologies when suitable infrastructure is in place.”

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