Prime PowerCase HistoryDENSO HARYANA PVT. LTD

Where: Manesar, State of Haryana, India

Supply:3 x 1,160 kWe QSK 60 gas generator sets and 3 x 1,500 kVA diesel generator sets, plus associated equipment and control systems

Application:Power generation from natural gas in conjunction with diesel generation, plus heat recovery

Natural gas reduces costs for major Indian automotive component manufacturer

DENSO is one of the world’s leading suppliers of advanced automotive technology, employing more than 120,000 people in more than 30 countries. All the world’s major automotive manufacturers are customers for DENSO’s systems and components. DENSO HARYANA PVT. LTD. started operation in 1999 and became the first company in India to manufacture gasoline engine management systems. DENSO Haryana customers include the largest passenger car manufacturer in India.

Engine management systems are manufactured at DENSO Haryana’s state of art plant at Manesar, an industrial area on National Highway number 8 in the State of Haryana. Situated just 40 miles from the centre of the national capital New Delhi, Manesar has grown rapidly from a single village into a large and busy area. Proximity to the capital has led to the government choosing the Manesar industrial area for several of its national institutes. One difficulty with the area, however, is the quality and availability of power. Companies have to look to their own solutions.

DENSO Haryana decided to use a 1,875 kVA uninterruptible power supply to ensure its critical plant load and keep production lines running.

DENSO Haryana became a Cummins customer in 1999 with the installation of five 1,500 kVA 11 kV diesel generating sets to handle the balance of the plant load. The exhaust from the generator sets was used for steam generation through a waste heat recovery boiler. But operating on diesel power 24x7 was proving to be expensive. The alternative of using natural gas had obvious economic attractions, and Cummins came top of the list for supplying a solution. DENSO Haryana had been impressed by Cummins superior response to transient loads on island mode, along with Cummins dependability, product reliability and support.

The first steps into using natural gas came in 2010 and 2011 with the replacement of two of the 1,500 kVA diesel generator sets with 1,160 kWe QSK 60 gas generator sets. Cummins ESB was able to provide the solution using the infrastructure that was already in place. The gas generator sets were installed on the original foundation and the existing electrical and mechanical auxiliaries were retained, with minor modifications.

After the success of the installation of the first two gas generator sets, in 2012 a third was installed, this time as a green field project, with Cummins ESB playing a role in the layout design. The Cummins ESB team was able to provide a complete turnkey solution, from alternator modification to the provision of a control system. The result is that all the diesel and gas generator sets operate in a synchronised way.

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The Cummins ESB team was able to provide a complete turnkey solution, from alternator modification to the provision of a control system

Both gas and diesel generator sets are managed remotely Natural gas fuels Cummins 1,160 kWe QSK 60 generator sets

Throughout the work, Cummins ESB faced a number of obstacles. The common cooling water header for diesel generators was modified, to meet required flow rates for gas generator sets. The exhaust lines from the diesel generator sets shared a common header leading into a waste heat recovery boiler for steam generation. For the gas generator sets, Cummins ESB designed the integration between the exhaust and diverter dampers to match the flow rates required for the existing waste heat recovery boiler. And all the gas generator sets had to be synchronised with the diesel sets.

The whole system runs 24x7, 365 days a year with stops only for scheduled maintenance. The site’s control room monitors the gas and diesel generator sets remotely, and the generator sets are operating close to 90% of rated capacity on island mode. All in all, the move to natural gas has been an effective step for DENSO Haryana – thanks to the hard work, knowledge and experience of Cummins ESB.

For more information about Prime Power or other energy solutions, contact your local Cummins Power Generation distributor or visit www.cumminspower.com/energysolutions.