Successfully Overcoming Project Disaster

The Challenge

In 2019, Collicutt was approached by one of our clients who had just won the electrical design and build contract for a new residential high rise to be built in downtown Los Angeles. Part of that contract included the supply of an emergency backup generator that would provide power for the building during a power grid outage that is so common in California.

Besides the usual backup power requirements for a building of this type, there were a few challenges that made this project unique:

  • This unit was going to be placed on the ninth floor of the building.
  • Once the unit was in place on the ninth floor, the building would be completed around and above it.
  • The crane doing the lifting was being removed immediately following the generator installation to make way for the remaining building construction. This meant that the generator was on the construction schedule’s critical path.
  • Because this building is downtown LA, the logistics surrounding the lift of the generator were very complicated. Traffic restrictions had to be minimized and the lift radius of the crane was restricted due to the surrounding buildings and infrastructure.

The Solution

When the contractor started their design process, they reached out to our team at Collicutt. We worked with them and their engineering teams to understand the building electrical loads, design constraints, construction schedule, and the lifting constraints.

We proposed a customized MTU 12V4000 DS1500 solution complete with:

  • IBC rating (earthquake rated)
  • Rypos DPF and custom mounting rack
  • Custom sound attenuating enclosure
  • Custom tank to meet fire code for a rooftop design in downtown LA

Disaster Strikes!

The project kicked off and proceeded smoothly until the completed unit left our fabrication facility. But then disaster struck!

Shortly after the truck carrying the generator left the fabrication facility, we received news that they drove under an overpass without checking height restrictions and our custom built generator struck that overpass and was totaled in an instant! The only good news was that no one was injured in the accident.

However, we now had a huge problem! We needed to get a new generator built in record time in the middle of one of the worst global supply chain challenges we have seen in recent times. If we failed to get the generator to site before the building crane was dismantled, we would be on the hook for obtaining permits to close roads in downtown LA and assembling a crane capable of lifting a 1500kW generator to the ninth floor of a building that was already constructed!

We immediately placed the order for the new generator and worked with MTU to expedite the build of the generator in any way they could. We also worked with our fabricator and had them build the enclosure and other custom components ahead of time so that they would just have to set the components in place and bolt them down once the generator was ready. To maintain schedule our fabricator’s staff agreed to work around the clock to complete their work once the generator was delivered to them!

Talk about team work!

The Outcome

Although there were many tense moments throughout this build process, we were able to pull our team together and work through supply chain issues and other manufacturing logistics to get the generator produced as quickly as possible.

In addition to this, thankfully, the building construction had been delayed due to unrelated issues so the building crane was still in place to lift our generator!

This left one final challenge that we had to overcome. Much of the building had now been constructed so the options for lifting the generator to the ninth floor were limited. The building crane had limited lifting capacity and it had limited lifting radius due to the proximity of the surrounding buildings and roadways.

To overcome this challenge, we had the generator transported to a riggers yard where we drained the fluids (oil and coolant) and removed the enclosure. We then dismantled the generator package down to it’s frame. This would allow us to lift the frame, engine, alternator, and radiator in individual lifts.

See the photos below for some of the teardown progress:

  1. Completed unit arrived at riggers

2. The enclosure was removed

3. Removal of components began

We transported the components from the riggers yard to the construction site over a two day period and lifted each component starting with the frame. The video below illustrates the tight lifting window that was being navigated:

As each component was lifted, we secured it into place and “rebuilt” the generator package on the ninth floor of the building! After two days of crane picks and placements, we had the generator back together in its final location ready for commissioning and startup! This allowed our client to complete construction of their building and remove the building crane without the generator scope causing any further project delays!

This project is a great example of; applied expertise, project management, technician talent, and overall teamwork being used to overcome huge challenges!

 

For more information on our power generation services or solutions, contact us via email or at the number below:

888.682.6888 or info@collicutt.com

 

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Collicutt Becomes Alberta’s Distributor for MTU/Rolls-Royce Onsite Energy for Diesel Generators

Collicutt Energy Services Becomes Alberta’s Distributor of MTU/Rolls-Royce Onsite Energy for Diesel Generators

Collicutt Energy Services is proud to announce that as of January 1, 2022, we are Alberta’s distributor for MTU/Rolls-Royce Onsite Energy for diesel power generation.

This partnership now allows Collicutt to offer our clients both diesel and natural gas power generation options, meeting more client needs by providing them with more variety, reliability and customer assistance.

MTU has over 60 years of power generation expertise along with over 100 years of experience in diesel engine engineering worldwide. That knowledge along with Collicutt’s power generation experience makes this a very strategic partnership.

MTU’s diesel gensets are designed for maximum reliability, featuring low fuel consumption, long service intervals and low emissions to reduce costly downtime. The MTU product portfolio for diesel power generation includes the MTU Series 4000, 2000, 1600, 0080 and 0225 and covers a power range of 27-3,250kW (60 Hz). With mature and reliable design, they are designed to operate in any situation— even in extreme conditions.

The combination of MTU’s product offering with Collicutt’s in-house expertise in power system design, build, and project management, allows Collicutt to deliver a higher standard of power generation service and products throughout Alberta.

In addition to our current solutions, Collicutt is now able to offer more mission-critical solutions along with other applications that include:

  • Data Centers
  • Healthcare and hospitals
  • Sewage and water treatment
  • Hotels
  • Airports
  • Commercial and public buildings
  • Agriculture
  • Aquatic Centers
  • Government buildings
  • Greenhouses
  • Landfills
  • Industrial manufacturing
  • Nuclear power plants
  • Rentals
  • CHP
  • Residential and utilities
  • Power stations

Collicutt continues to lead the power generation industry throughout North America and beyond. Our relationship with MTU/Rolls-Royce Power Systems started in California in 2015 and has continued to grow since. In June of 2021 we also announced the new agreement regarding the distributorship of natural gas power generation and oil & gas engines in Alberta.  This 2022 announcement is quite the milestone as it gives Collicutt the advantage of offering our clients more comprehensive power generation solutions since both natural gas and diesel options can be utilized.

 

Call us for more information at 888.682.6888.

See our News &  Careers page for more announcements and blog posts.

Check out our Equipment site here!

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Collicutt’s Focus Is Problem Solving

Collicutt was recently featured in the November issue of Resource in Focus Magazine!

“As a leading manufacturer of custom power generation equipment, Collicutt Energy’s highly trained and experienced team designs, engineers, and manufactures power solutions, while also working to continually raise the standards for customers, whether repairing, overhauling, servicing or performing preventative maintenance on all brands of engine. Collicutt’s mandate includes offering a wide variety of services while keeping customer downtime to a minimum.

This family-run business has recently experienced exciting growth, including the company’s role as a distributor for products including MTU, Waukesha, Motortech, and Scania – in particular, expanding territory in Alberta as a distributor for MTU/Rolls Royce Power Systems for oil & gas systems and natural gas power generation.”

Learn more about what Collicutt does and how we provide unique solutions to our clients by downloading the full article with the case study link below!

For more solution options see our Services and Solutions pages.

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Customized Rental Solution!

One of our customers in Beverly Hills was doing a major office renovation and they required temporary electric power for the duration of the work. This seemed like a simple enough request for our rental group to handle but there were some challenges that had to be addressed!

The Challenge

The challenges were generally centered around the constraints of the job site and included:

  1. The temporary generator could not be parked on the street due to city bylaws
  2. The only other available locations for a temporary generator came with their own challenges:
    • A very small underground parking stall with extremely tight access and inadequate ventilation to allow an engine to run for an extended period of time
    • The top of a parking structure which would require a crane to lift it into place
  3. Noise restrictions were in place due to the proximity to other businesses
  4. California  has some of the strictest emissions requirements and building code requirements in North America. This means that power generation equipment must be able to meet the strictest emission standards and must be designed to handle earthquakes which are also common to California

 

The Solution

Our rental team worked with the customer to determine the potential power demand that they would experience during their office renovation. Once our team understood this requirement, we began to look at our rental fleet and selected a few potential options. From these options we narrowed down the selection to a rental unit that was the correct size, met the noise restrictions, and met the emissions requirements.

We then worked with our customer to provide a temporary venting solution for the generator exhaust. This had to meet the local building code requirements as well as the exhaust venting specifications for the generator. Once this was done, our rental team coordinated the generator drop off and set-up (props to our delivery team for backing this unit into place!) ensuring that our customer had the electric power they needed for the duration of their office building renovation project!

 

For more information on a rental solution or any other power generation solution, contact us via email or at the number below:

1-888-682-6888 or info@collicutt.com

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Data Center Expansion

One of our data center customers in southern California had recently been experiencing an increase in demand so they began expanding their center’s capacity. As the number of data servers increased, their requirement for emergency back up power was also increasing. Unreliable power is the biggest threat a data center can face! Power quality issues can cause equipment failure, downtime, data corruption or data loss, none of which are acceptable outcomes. So, this requirement to upgrade their emergency generators was critical!

Because Collicutt has been providing service work for them and their existing 2250kW generators for a number of years, we sat down with them to understand the challenge that they were facing.

The Design Challenge

Our customer had a few design constraints that needed to be solved. They obviously had a emergency power shortage but they also had the following issues that had to be addressed:

  • Size restrictions with their facility limited the footprint of the generators that they could use
  • California  has some of the strictest emissions requirements and building code requirements in North America. This means that power generation equipment must be able to meet the strictest emission standards and must be designed to handle earthquakes which are also common to California
  • Noise restrictions due to the proximity to other businesses
  • An existing generator that was no longer up to code and could not be made compliant
  • Switchgear upgrade project running concurrently with the generator upgrades
  • Programming to ensure paralleling of the units worked seamlessly with all the upgrades underway

The Solution

For the first unit they required, we designed and provided a custom 2250kw standby generator with a level 2 sound attenuated enclosure and a 3540 gallon subbase fuel tank. The fuel tank is UL142 double walled with secondary containment and rested just beneath the generator base. The enclosure had fixed intake louvers and a vertical discharge plenum to help hamper excessive noise to protect surrounding businesses. The enclosure was custom made with aluminum side and roof panels to ensure a non-corrosive housing designed for prolonged life. We also provided a critical grade silencer to quiet the large generators exhaust to meet city noise restrictions.

When the trucks showed up on site with the first generator and all its components, the customer’s crane company was a “no-show” due to equipment failure. As the old saying goes, “time is money” and a data center construction site is no exception. Collicutt was able to call on one of our crane contractors and get them out to site on short notice. They were able to successfully offload all of the equipment and maintain the schedule!

Our customer has now placed an order for a second 2250kW with the same basic specifications. Collicutt will be removing their non-compliant generator to make room for this second 2250kW. We will also assist them in selling the non-compliant unit using our  surplus equipment website and sales team.

In addition to this, we we able to provide paralleling programming and implementation so that when the new generators are installed and the switchgear upgrades are completed, they will be able to parallel these two new units with their existing generators.

This solution will provide them with high quality emergency power for years to come helping to guarantee their customers have secure data and data processing regardless of inevitable utility power outages.

 

 

 

For more information on this or any other power generation solution, contact us via email or at the number below:

1-888-682-6888 or info@collicutt.com

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Collicutt Energy Services Expands its Territory as Alberta’s Distributor for MTU/Rolls Royce Power Systems

Collicutt Energy Services Expands its Territory as Alberta’s Distributor for MTU/Rolls Royce Power Systems

Collicutt Energy Services has signed an agreement with MTU/Rolls Royce Power Systems to expand its territory to distribute MTU systems and product lines in Alberta starting June 1, 2021.  This includes natural gas power generation and oil & gas engines.

A subsidiary of Rolls-Royce, MTU Onsite Energy Corp. is one of the top power system manufacturers globally and has been serving the oil and gas industry for over 70 years with the highest standards in durability, reliability and technological expertise. MTU series of diesel engines offer exceptional efficiency and durability to meet the rigorous demands of industry operations. In addition, MTU engines meet and exceed worldwide emission standards with optimum fuel economy, designed by leading-edge engineers pioneering emissions policies.

Along with the entire line of MTU Series of engines, Collicutt Energy Services adds the Detroit Diesel Series 60 engine line to its robust solution-based products and services. The MTU 1000, 1100, 1300, 1500, 1600, 2000 and 4000 engine series cover a power range of 75-3010 kW and 101-4036 bhp.

MTU’s complete range of products includes diesel engines and systems for:

  • Power units for mechanical and hydraulic drives for rotary tables, draw works, mud pumps and other well services
  • Generator sets for electric drilling rigs for rotary tables, draw works and mud pumps
  • Generator sets for continuous duty and prime power
  • Fracturing units
  • Nitrogen vaporizing/generating units
  • Cement pumps
  • Blenders
  • Coil tubing

The partnership with MTU allows Collicutt Energy Services to broaden services to a larger geographical area while aligning its sales and service team with the forefront of industry innovation and advancement.

As an MTU parts and service provider, Collicutt Energy Services’ trained technicians uphold exacting maintenance and warranty requirements to ensure productivity, safety and efficiency in the harshest of conditions. As a result, the company’s customer base will benefit from streamlined sales, service and warranty work on new and existing oil and gas equipment, reducing costly downtime and safety risk.

This cooperative distributorship with MTU/Rolls Royce Power Systems first began in California in 2015 and now allows the company to maintain elevated supply and serviceability in Alberta’s abundant oil and gas industry.

Collicutt MTU Announcement – June 2021

Check out our announcement on EnergyNow and the BOE Report. 

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Emergency Power for a High Rise

A few years ago a customer approached us with a project that they were about to take on in Southern California. They were looking at building a 600 unit, residential high rise apartment complex complete with some major retail stores in the ground floor. They were required to provide an emergency power generation system for this building and this is where Collicutt got involved.

The Design Challenge

There are always challenges to sort through with any project and this one was no exception. Besides the usual design constraints associated with projects in California like strict emissions compliance and seismic ratings, this project had some unique aspects that had to be addressed.

  • First, the generator would have to be installed in the parking garage of the building prior to the construction of the upper floors of the building. This put us on the critical path for project construction. We had to deliver on time!
  • Second, because the overall building design was still in process, we needed to allow for late changes prior to placing the generator into production in the event that we would need to upsize or downsize the generator and its components
  • Third, because of the seismic requirements and the fact that the generator was to be installed inside the building, the fuel tank had to be equipped with ballistic rated retainer walls. Basically, this is a double walled fuel tank that is filled with cement between the inner and outer wall to provide a puncture proof solution for fire rated indoor applications
  • Fourth, because the unit was located indoors, it needed to be equipped with a special exhaust silencer to meet the city sound requirements for indoor applications.
  • Finally, the installation of the generator would need detailed planning, coordination, and safety oversight. Due to the construction site location, offloading and placing the generator would require local road closures with the added challenge of dealing with overhead power lines. This meant that we would have to coordinate a crane and the trucking company within a very tight timeline while ensuring we had the time for a safe lift!

The Solution

Our Collicutt team worked closely with our customer throughout the design phase of this project. As the design progressed the customer realized that their electrical load had increased. Because of this, we upsized the original 1000kW generator to a 1250kW unit designed to provide enough critical power to meet full load requirements with a reserve factor of 10%. The model we selected was a 16V2000 DS1250 with IBC rating, complete with a roof mounted DPF and a UL2085 rated fuel tank.

In addition to this, there were various automatic transfer switch changes and breaker adjustments that the customer requested and we were able to accommodate within the time constraints. We were also able to coordinate the appropriate air quality permit for the customer so that their generator has all the permits required for operation.

The end result was that our customer received the generator at site on schedule. Our trucking and crane contractors were able to safely unload the generator, lower it two stories into the parking garage, and remove their equipment within the allotted road closure permit constraints.

It was a great team effort and now the building program can go on!

 

For more information on this or any other power generation solution, contact us via email or at the number below:

1-888-682-6888 or info@collicutt.com

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What is a D-UPS and Why Should You Care?

D-UPS stands for Dynamic Uninterruptible Power Supply. It can also be referred to as a dynamic rotary uninterruptible power supply (DRUPS) or as a flywheel energy storage power system.

So what is it and what does it do?

Many data centers, hospitals, and other industries that depend on stable electric power have back up emergency generators for when the power grid fails as they simply cannot tolerate a power failure. To complicate things further, many of these industries cannot tolerate a power source that falls outside a narrow performance tolerance.

The default solution to this situation has been to power these critical applications through an Uninterruptible Power System or UPS that is battery based. Basically, utility power runs a battery charging system which charges a large battery bank. The battery bank then powers the critical loads by converting its DC power to highly stable AC power using a DC to AC inverter.

Although these systems have many advantages and have a proven track record in some industries, they do have many shortcomings, including the need for massive battery banks capable of storing enough power to last during an extended power grid failure.

The Solution

The D-UPS eliminates the need for costly and finicky battery banks while still providing a highly dependable and stable power supply for critical loads. Basically, a D-UPS is a combination of an electric motor (which also doubles as a generator), a flywheel, a diesel engine, and a reactor (or choke coil).

A D-UPS system depicted in the diagram below.

Essentially, utility power is fed into the D-UPS system. It powers an electric motor which spins a large electro-mechanical flywheel. This flywheel stores  kinetic energy. The electric motor, in conjunction with a choke coil, works as an active filter and removes power quality problems from the utility power (e.g., harmonics, RFI, frequency variations, etc.).

When the utility power fails, the stored kinetic energy in the flywheel is released and powers the electric motor which now becomes a generator. This generator now provides uninterrupted power to the critical load. At the same time, the diesel engine fires up and, within 2 to 10 seconds, takes over from the flywheel to drive the generator providing sustained, uninterrupted, stable power for the critical systems downstream.

Take Action!

If you are involved in the construction of a new facility that requires high quality, uninterruptible power or if you looking at upgrading your existing back up power systems it is worth considering a D-UPS system.

Collicutt is able to work with you in doing the evaluation and we are able to provide the Kinolt D-UPS system through our association with MTU. If the evaluation determines that a static UPS is required, we can work with you to provide the backup generators for this system.

We currently maintain over 360MW of power generation equipment for data centers in California and many of these are D-UPS systems from various manufacturers.

If you have questions about your existing power generation system or would like to inquire about a new system, give us a call. We are always glad to help!

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