4000 kW Caterpillar Generator Ships to Steel Mill
Steel Mill Selects 4000 kW Caterpillar Generator For Backup Power, See The Details Here!
A Canadian steel mill recently experienced a power outage that lasted for two days and caused the mill to shut down.
The downtime occurred when their installed backup generators did not successfully start. The downtime cost the mill money and production time.
The mill's engineers realized the urgent need for a medium voltage backup diesel generator. They needed an updated genset to keep the mill running during future power outages.
The mill found Generator Source online. In a matter of a few weeks, we had one of the world's largest high-speed generators in route. Read more about how we helped fulfill the requirements in the details below:
Steel Mill Experiences Power Outage Lasting for Days
Loss of utility power at a Canadian steel mill caused the following chain of events:
- Installed emergency generators did not fire or startup and could not be used during the outage.
- Power outage lasted for two days, and the mill had to shut down.
- Downtime was costly, and their staff calculated the size of the generator needed.
- Mill operates at 2400 Delta Voltage @ 1200 amps.
The engineering team determined a 4000 kW generator, with a 4160 VAC output wired in a Delta configuration would do the job.
The client found us through an online search and spoke with our representative about their generator requirements. In addition, we helped them confirm their engineering calculations were correct. The day the purchase was complete, our team shipped the generator from our facility in Brighton. The entire process took about three weeks to complete.
A Caterpillar C175-20 diesel engine is the prime mover for the Caterpillar SR5 generator. The engine is controlled by the ADEM A4 Engine Control Module (ECM) supported by a common rail fuel system design.
The generator controller is an EMCP 4 controller. Loading-4-megawatt-caterpillar. The EMCP 4 controller is an advanced generator Human Machine Interface (HMI) panel that controls the overall generator functions.
It communicates with the ECM to maintain engine speed through varying electrical grid load demands. The operator can perform multiple tasks from the panel. The installation of this generator will save the client lost dollars when the utility power fails.
Loading, LIfting & Delivering: Generator Headed North
The generator weighs 51,588 pounds with a length of almost 22 ft and a width of over 7-1/2 feet. Our pre-approved shipper arrived with two tractor-trailers capable of carrying over-sized loads. The generator was then lifted onto a flatbed. The shipping company then secured the load for transport.
This load would cross multiple state lines. Each state has an individual Department of Transportation (DOT). Permits were purchased for each state the load passes through.
Once the trucks arrive at the border, they must have a Canadian Carrier Code, Cargo Control Document, Commercial Invoice, and a Pre-Arrival Review System.
After crossing the border, a permit for each provenience entered or crossed must be obtained. Crane service was arranged for the arrival of the generator. It is important the crane is ready to complete the unloading process when the trucks arrive. Open lines of communication between the customer, trucker, crane supplier, and seller ensured a smooth operation.
We have been in the generator business for over 40+ years. We can provide generators and can arrange for shipping to a worldwide audience.
Our inventory of new and pre-owned generators can usually ship within 24 hours of purchase. Often, we arrange crane services at the customer's destination. Aiding in permits acquisition and border requirements are part of our customer service package.
Contact Us for more information or with any critical generator questions.
- Medium Voltage Use in Steel Mills
- Steel mills can use the medium voltages to power:
- Smelting Furnaces - Electric arc and induction
- Rolling Machine - Large motors work more efficiently with voltages such as 4160 VAC
- Transformers - Step-Up transformers to power higher voltage. Step-down for low voltage equipment
- Smelting Furnaces
In the early days of steel production, fossil fuel powered blast furnaces were used to bring the metal or ore to the molten state. Advancements in technology now allow steel mills to use an electric arc or induction furnace.
Electric arc furnaces can range from 1-ton units for cast iron products to the 400-ton units used in large steel mills. When electrodes are lowered to ore or recycled steel, a high-voltage arc is produced. This arc melts the material.
Arc furnaces have a higher operating temperature, less dissolved gases, quick startup, longer life refractory lining, and can produce a variety of steel.
Electric induction furnace uses electric currents to produce molten metal. The furnace works on two principles:
Electromagnetic Induction - Furnace contains a coil wrapped around pot. When current flows through coil an electromagnetic Steel Mill Electric Arc Furnace is formed (sometimes called eddy currents). The current flow leads to joule heating
Joule Heating - Often referred to as ohmic or resistive heating. As the current flows through the coil heat develops to make metal molten.
Understanding Rolling Mills
A rolling mill is a piece of equipment that reduces the thickness of a metal ingot in various steps of compression. The machine applies large amounts of pressure to the ingot while passing through the roller system. As the ingot is moved through the machine it's lengthened and widened.
This is considered a cold process because the metal is not in molten form. However, heat is produced and often engineers test the temperature of the ingot to ensure it does not rise above specified temperature during rolling.
Multiple roller machines take the reduced ingot and process it to desired thickness and wind it into a coil. We often see semi-trucks with one or two coils transiting to the next destination. Without backup power machines, controllers and controlling software can suffer issues during startup because of an improper shutdown. Product damage can occur depending on its stage in the rolling phase.
The induction furnace is a rapid, clean non-polluting method of heating. But it cannot process steel and refining is not as extensive as electric arc furnaces.
Both arc flash and induction furnaces require a medium voltage input and can use step-up transformers to satisfy power requirements. Other equipment such as lighting, overhead cranes and low-voltage electric motors receive voltage from step-down transformers. Power loss during the smelting process can cause extensive damage to equipment, resulting in expensive repairs. An emergency generator and associated systems can provide the needed power when utility power fails.
Generator Source has a long history of helping companies worldwide buy, sell, rent and service 60 Hz industrial generators.
To see our current inventory of generators click here. If you have a question about your next power generation project, give us a call at (877) 866-6895 or contact us online today!
Story Summary
Why did the steel mill need such a large generator?
The mill requires medium voltage (4160V) power to run large equipment like electric furnaces and rolling mills. The 4000 kW capacity allows the mill to continue full operations during a power outage.
What are the key components of this generator system?
The genset features a Caterpillar C175-20 diesel engine, ADEM A4 Engine Control Module, and EMCP 4 controller.
How was such a massive generator transported to Canada?
It required specialized oversized load trucks, permits for each state/province, and extensive documentation to cross the border. Generator Source arranged all logistics.
What types of equipment will this generator power at the steel mill?
It can power electric arc furnaces, induction furnaces, rolling mills, and other equipment that uses medium voltage power.
Why is backup power so critical for a steel mill?
Power loss during steel production can cause extensive equipment damage and very costly shutdowns. The backup generator prevents these issues during utility outages
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