MC (Ghaddar Machinery Co) has supplied a 1,000 kVA diesel generator with Cummins engine and Nidec alternator to a bitumen factory based in Karbala, Iraq. This new deal has meant that Ghaddar Machinery’s Iraq Branch was effectively expanded the power station of the Bitumen factory in Karbala province.
Based on the excellent performance over the past two years of the two Ghaddar Generators 1000 KVA each powered by Cummins Engine KTA38-G5 and Leroy Somer Alternator TAL049E, an expansion of the power station was requested, and an additional unit was added to bring the total capacity of the station to 3000 KVA. The 3 Generators are operating in synchronization to power the factory.
Maintaining their outstanding reputation for high performance power even in the harshest conditions, the latest KTA range is jacket water aftercooled design. Its inbuilt step timing control system ensures optimum engine timing at all combinations of load and ambient temperature, improving cold starting and reducing light load fuel consumption to greatly enhance engine efficiency.
Features and benefits of the KTA38-G5 include:
*Aftercooler: Large capacity integral aftercoolers are supplied with cooling water separate from the engine jacket. This provides cooler, denser intake air for more complete combustion and reduced engine stresses for longer life and low exhaust emissions.
*Cooling System: A two-pump, two loop system must be employed; i.e. the engine jacket is cooled by one radiator or heat exchanger and the aftercoolers are cooled by a separate radiator or heat exchanger. Both cooling systems are independent of each other. The jacket water pump is supplied engine mounted from the rear of the gear cover. The aftercooler water pump is customer selectable and can be provided mounted on the front of the gear cover. Cummins provides conventional water inlet and outlet connections for the jacket system. Aftercooler water pump inlet and aftercooler core outlet connections are provided for customer use and ease of plumbing on the aftercooler system.
*Lubrication: A large capacity integral gear driven pump provides pressure lubrication to all bearings and provides supply for piston cooling. Cummins supplied large capacity oil pans are recommended for Prime and Continuous Power applications.
*Pistons: Pistons are dual Ni-resist, aluminum alloy, ground and shaped to compensate for thermal expansion which assures a precise fit at all normal operating temperatures. Oil cooled for rapid heat dissipation. Two compression rings and one oil ring. Utilizes offset piston pin for reduced susceptibility to liner cavitation.
The Leroy-Somer TAL 049 industrial alternator used in the generator is an all-purpose industrial alternator suitable for all standard generators sets applications. The TAL alternator range is designed to meet the general needs of stand-by and prime power applications in telecom, commercial and industrial markets. All products in the TAL series are manufactured to Leroy-Somer high quality standards and are built with class H insulation materials. The new TAL low voltage alternators, with optimal performance for commercial and industrial applications, offer a simple and efficient solution for all onsite power requirements.
The bitumen produced at Karbala site is a byproduct of the Karbala oil refinery in South Karbala province, around 100km away from Iraq’s capital Baghdad. The refinery is built on a 6km² plot of land and produces liquefied gas, gasoline, gas oil, fuel oil, jet fuel and asphalt/bitumen. The oil produced at the refinery meets international standards, equivalent to European production, and serve the growing domestic demand for oil in Iraq.
The oil refinery is part of a joint collaboration between ATCONZ and Invest International, as well as the joint development agreements signed by the Italian and Iraqi governments. The facility has a refining capacity of 140,000 barrels of crude oil per day (bpd). Bitumen naturally occurs as a solid or highly viscous liquid during the refining process. It is refined into petrols such as gasoline or simply distilled into tar. Bitumen tar is used for various useful purposes, including binding aggregates to create driveways, roadways/highways, and parking lots (asphalt concrete). It is also used for producing roofing felt, sealing flat roofs, waterproofing materials for buildings, as a binding agent in road asphalt, for coatings, floor tilings, soundproofing, and other construction elements. It is also used in some industrial products such as batteries.