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Aussie innovation saves livesThe 1,000th Bushmaster Protected Mobility Vehicle produced by Thales Australia at its Bendigo facility was delivered to the Australian Defence Force at a ceremony in June.

The Bushmaster is a light armour vehicle designed and built in Australia, and fi tted with a Cat® 3126E diesel engine rated at 300 bhp. Currently in service with the Australian Defence Force, Royal Netherlands Army and British Army, the Bushmaster provides armoured transport for infantry who dismount from the vehicle before going into action and is a great success story.

Capable of carrying up to nine soldiers and their equipment, fuel and supplies for three days; transportable by air and mine-protected, the Bushmaster is built to save lives in combat and has been used in confl icts in Timor-Leste, Iraq and Afghanistan.

At the ceremony, Thales Australia CEO Chris Jenkins said the Bushmaster is such a recognised life-saving vehicle thanks to its

performance on overseas operations with the Australian Defence Force and other customers. “To have produced 1,000 vehicles is a testament not only to the Bushmaster’s innovative design and technology, but also to the high quality of its manufacturing.”

He added that Australian industry has played a vital role in this achievement.

“There are around 120 companies in the Bushmaster supply chain, whose hard work, innovation and commitment to delivery have helped make the Bushmaster what it is today."

Peter Wootton from Energy Power Systems Australia (EPSA) has worked with Thales since the early development of the Bushmaster and says it was a pleasure to mark such a milestone.

“The Bushmaster has proven to be highly successful and it was great to hear its praises from the Australian Defence Force. It was produced, designed and built in Bendigo and has employed many people in the area.”

“The fi rst Cat engine was delivered in 2004 but we started working with Thales a few years earlier in the development phase, so we have a strong collaborative history.”

Peter adds that as an armoured personnel carrier, the Bushmaster has “saved a lot of lives” with its unique design able to defl ect blasts in combat.

“The design is so successful that several countries have developed similar vehicles. There are also 15 Fireking vehicles built by Thales in operation in South Australia that are a variant on the versatile design.”

< Stephen Lupi, EPSA GM Engines, presents a commemorative trophy to Chris Jenkins, Thales Australia CEO, fl anked by Peter Wootton, EPSA, and Frank Cinanni, Thales Australia.

< Stephen Lupi, EPSA GM Engines, presents a commemorative trophy to Chris Jenkins, Thales Australia CEO, fl anked by Peter Wootton, EPSA, and Frank Cinanni, Thales Australia.

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Welcome to the spring edition of Engine Room, sharing stories of the great work that our staff, dealer partners and customers are doing across Australia, PNG and the Solomon Islands.

You'll notice Engine Room's new look and we hope that you fi nd it more enjoyable and easier to read. Thank you to all of those who have contributed.

This column is an opportunity for me to talk directly on developments affecting EPSA, including the Caterpillar announcement appointing EPSA as the exclusive distributor of Mannheim gas-fuelled generators. This means that customers can expect full support for their existing MWM engines and broadened support for Cat® CG Advanced Gas Power Engines from EPSA.

We’ve hired all of MWM Energy Australia’s personnel and we welcome them to EPSA. They will be providing great service to customers with existing MWM-brand power generation equipment and to future Cat CG customers. Thanks to the EPSA team for making the transition so smooth and for making our new staff feel so welcome.

The full story about MWM is on the following page and more information can be found at www.energypower.com.au/resources/latest-news.aspx.

EPSA goes mobileEPSA has recently launched a mobile version of its website, www.energypower.com.au, to meet the unstoppable rise of smartphones and tablets as a way to communicate and do business.

Message from the CEO

Compatible with all handheld devices on both Apple and Android operating systems, the mobile site delivers quick access to EPSA's email and phone contacts across all business segments, as well as to branch details via the user's state or postcode.

EPSA has 19 branches across Australia, says EPSA Information Systems Analyst Luke Theobald, "and with our relationships with Caterpillar and our dealer partners, we are represented in over 90 locations throughout Australia, Papua New Guinea and the Solomon Islands.

Our customers are in a diverse range of markets and the new mobile site is specifi cally targeting staff and customers

on mobile devices, with catered content and structure to better service these users. They are often remote and offsite, so with the advance of our mobile website, we are accessible to help our customers 24/7.

It is important that we're responsive to customers, especially for our Cat Rental Power clients. A high proportion of our clients access us through a mobile device, so the EPSA mobile site makes it even easier to get hold of us. CatRental Power is a 24/7 business so the development of the site, which also promotes our 1800 number, is essential for round-the-clock customer service."

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With a renewed focus on gas around the world and a commitment to the gas power generation business in Australia, Caterpillar Inc. has appointed EPSA as the exclusive distribution channel in Australia, PNG and the Solomon Islands for Mannheim-sourced gas generator sets.

Following Caterpillar’s acquisition of MWM in November 2011, EPSA took on the distribution and support role for existing MWM products and Cat® CG products in territory, effective 1 September 2013.

EPSA has proven itself to be a very capable supplier of gas generator sets in the past. With the introduction of the highly successful Cat CG132, CG170 and CG260 series gas generators into our region, EPSA is now able to offer a complete line of gas electric power products ranging from 50 to 4,300 electrical kW to meet a wide range of customer application needs.

EPSA has employed the experienced MWM Australia personnel in order to provide a seamless transition and ongoing support to customers with existing MWM-branded power generation equipment. “We are thrilled to bring the MWM Australia knowledge, capability and reputation to EPSA and to be able to offer their

solutions to our customers. I am also delighted to welcome MWM Australia staff to the EPSA team,” says EPSA’s General Manager Engines, Stephen Lupi.

MWM Energy Australia Managing Director, David Sparano, who has joined the Gas team at Caterpillar, says that MWM Australia’s customers will still receive the same Mannheim products they know but now under the Cat brand.

With over 3,000 units and 3,700 MW of installed gas-fuelled power generation capacity in the Asia–Pacifi c region, this move further strengthens Caterpillar’s position as a world-leading supplier of gas engines and generator sets.

With this change in distribution, EPSA will deliver sustainable support gas power generation.

“We will fully support existing MWM product and grow the Cat CG product sales in our region,” adds Stephen.

The transition to an exclusive EPSA distribution channel for Mannheim products, complemented by an in-house service and parts support capability, represents an excellent opportunity for EPSA in a growing market for gas power generation.

Founded by Carl Benz, MWM brings to Caterpillar more than 140 years of experience in the development and optimisation of gas engines for natural gas, special gases and diesel. MWM is one of the world's leading providers of highly effi cient, eco-friendly cogeneration plants for decentralised energy generation with combined heat and power.

Susu Mamas in Papua New Guinea is a wonderful organisation that addresses the health needs of mothers and their babies.

Also providing family and youth health services around the country, their clinics offer services for maternal and child health and also help to reduce maternal and child mortality rates in PNG.

EPSA has donated two generators to Susu Mamas clinics in Lae and Mt Hagen, in conjunction with dealer partner Hastings Deering PNG. Back-up power is essential to safely store life-saving vaccines.

organisation that addresses the health needs of mothers and their babies.

in Australia, PNG and the Solomon Islands for Mannheim-sourced gas generator sets.

NSW – L to R:

Shane Wooller and Stephen Morton WA – L to R:Colin French and Callum Gemmell NSW – Chris Hewes

EPSA welcomes MWM AustraliaMessage from the CEO

VIC – Back Row L to R: James Cork, Hans Eggers, Kathryn Archer, Brian HawksworthFront Row L to R: Glenn Butcher,Tom Lazarowicz & Mark McCracken

Big Cats power big data

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About 2.5 quintillion bytes of data are created daily, according to IBM. That fi gure may be unfathomable, but for data centre specialists like Metronode this type of big data is big business. Coupled with rapid technological advances in areas like medicine, science and meteorology, every banking transaction, Facebook 'like' or YouTube video contributes to this enormous spike in information captured globally.

With expertise in next-generation data centre design and construction, Metronode currently manages 10,000 square metres of operational data centre facilities for large corporations, fi nance institutions, government, defence, utilities, and IT and telco providers.

Data centres are fast becoming one of the largest consumers of energy, says Michael Kalny, Head of Engineering for Metronode’s parent company, Nextgen Group.

“Around two per cent of total power produced by Australian power stations goes towards supporting data centres, while approximately 50 per cent of all the energy consumed by data centres directly powers the IT equipment (storage and processing), with the remaining 50 per cent consumed to cool that equipment.

“Our data centres must always be available, effi cient, secure, reliable and resilient, and we depend on uninterruptible power supply (UPS) systems for continuity of service. We are building a new generation data centre in Perth and were looking for an effi cient and ecological solution to implement seamless, continuous power.

“Our new generation data centres are based on a modular build confi guration that reduces the build time by more than 60 per cent compared to a traditional, non-modular build. We are now complementing these with a modular supporting power plant based on Caterpillar‘s Critical Power Module (CPM), which includes a UPS, generator and switchgear within an ISO shipping container for conditioned continuous power.”

“CPMs fi t the bill because they are completely customisable,” says EPSA UPS Business Manager Greg Conrad, who assisted EPSA’s tender application by “adapting our offer to suit Metronode’s site specifi c conditions.”

“Retrofi tting can be quite expensive and can add weeks to a construction schedule, so with a customised CPM there is a reduction in travel time and installation costs, and minimal work disruption from outages. We also delivered signifi cant cost effi ciencies, with lower upfront costs, a lower cost of ownership and a high energy effi ciency rating, which was integral to the brief.

“Our CPM helps deliver a lower power utilisation effectiveness (PUE), which is the industry standard metric for measuring infrastructure losses compared to IT equipment losses, and it requires minimal power to run the site. We could also offer all the 24/7 service capabilities of WesTrac in Perth.

"The fi rst of its kind built in Australia, each of the three CPMs is a 40-foot ISO shipping container with a 12-hour base fuel system, diesel generator and integrated fl ywheel UPS technology, all meeting Metronode’s low noise requirement with a quiet 65 dB(A) at seven metres noise requirement," adds Greg.

“Due to the timeframe and specifi c customer requirements, each CPM was constructed and rigorously tested in Sydney and then shipped to Perth as a complete unit. The speed to market was just 16 weeks. This is a unique design for us and allows for further expansion. The whole principle of this bespoke design was that it could be scalable and take on more modules.”

"In collaboration with Cat®, the CPM has been designed, developed and built at EPSA’s facility in Ingleburn, NSW, to meet Metronode’s stringent technical requirements to achieve Uptime Tier III performance," says Michael.

“The commercial and technical teams at EPSA have been very supportive and accommodating to deliver a quality product both on time and within our allocated budget.”

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Last December, Engine Room reported on border protection patrol boats that were to be powered by Cat® propulsion engines and marine generators. Now, we're thrilled to announce that the fi rst of these vessels has been offi cially named Cape St George.

Through a design, construct and in-service support contract valued at approximately $330 million, Cape St George is the fi rst of eight new boats being built by Austal for the Australian Customs and Border Protection Service.

The vessel was launched at Austal’s Henderson shipyard in January 2013. It has since undergone fi nal fi t-out and sea trials, with some other testing completed prior to fi nal delivery to the customer.

“For each vessel, EPSA is supplying and commissioning two Cat 3516C HD Propulsion Engines each rated at 2525 kW, two ZF9050A Reduction Gearboxes, a DNV Class-compliant Alarm, Control and Monitoring System and one Cat C4.4 Emergency Generator rated at 65e kW,” EPSA’s Regional Sales Manager for WA, John Taylor, told Engine Room last year. The vessel-naming has been a milestone for all involved.

Among the very special guests, the ceremony was attended by the Australian Special Minister for State, the Hon. Gary Gray AO, along with former President of the Australian Senate, Margaret Reid AO, who offi cially named the vessel.

“Close to 300 staff have been involved in the construction of this fi rst vessel and the contract has underpinned work at our Henderson shipyard,” said Andrew Bellamy, Austal CEO. “I would like to thank our staff and Austal’s many suppliers for their important contribution on Cape St George as we look forward to delivering all eight patrol boats by August 2015.”

Construction of the second Cape vessel is well underway, with the keel laid in January. At Engine Room, we look forward to bringing you news of future developments as these vessels are launched and enter operations.

Protecting our borders

The ceremony was held at Henderson Shipyard in WA. Seen here on the patrol boat’s bridge are (from left to right) Graham Backhouse, General Manager and President, Austal Australian Operations; Margaret Reid AO, honourable guest; Marion Grant, Deputy CEO Border Management, Australian Customs and Border Protection Service; and Scott Pisel, Commanding Offi cer, Cape St George.(Photo courtesy of Austal.)

"The offi cial naming ceremony is an occasion that allows us to celebrate the fi rst of eight, state-of-the-art, highly sophisticated Cape Class vessels that we are designing and constructing using our hallmark aluminium design," said Austal Chief Executive Offi cer Andrew Bellamy.

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Access to reliable and secure water sources and their effective management is essential for the continued development of Australia’s lucrative coal mining industry. One effective source on a mine site is from mine dewatering.

Every mine will require dewatering at one time or another during its lifecycle, as it is a common method of coping with groundwater seepage, mine excavations, intersecting aquifers and excessive rainfall.

A dewatering pump is much more than just an effective water solution, says John Rook from Durapower Industries, who has been supplying these pumps to the mining industry for over a decade.

“It is a critical piece of infrastructure used to maintain effi ciencies and keep the industry operational at times of severe environmental challenges, such as those seen in the Bowen Basin over the last few years.”

Durapower supply many of its innovative Flowforce™ dewatering pumps to companies operating in central Queensland, which contains the largest coal reserves in Australia. Covering an area of over 60,000 square kilometres with 47 operating coalmines, the Bowen Basin is also an area of highly seasonal rainfall as well as susceptibility to drought.

“The impact of intense rains like those of the fl oods of 2008, 2011 and 2013 is costly. Three of the nation's biggest mining companies reported signifi cant lost production in the region as a result of the January 2013 fl oods alone. This is where the pumps show their worth by facilitating the rapid removal or draining of ground or surface water from mineshafts,” says John, adding that they are crucial for keeping the pits dry, because when water enters a pit it hampers operations.

“In today’s economic climate, reliability and value for investment are high on the purchasing criteria for mining companies. Flowforce™ pumps create dry pits, resulting in increased production days, and assist in protecting the environment through dust suppression and for transferring environmentally sensitive water.

“Our state-of-the-art Flowforce™ dewatering pumps are predominantly Cat®-powered and are directly coupled to the engine, providing greater reliability. They can be mounted on a trailer, skid or pontoon, and can be confi gured to start, shut down and be monitored from the safety of the offi ce.”

Designed and manufactured in Queensland, Flowforce™ pumps feature a dual skin fuel tank option for security in environmentally sensitive locations and utilise Cat engines from 31 kW to 653 kW.

They also include the Cat Product Link remote maintenance-tracking device for effi cient and effective fl eet management, says EPSA’s Phil Smith. Product Link collects and sends data such as engine run and alarm status, location and alerts when maintenance is needed.

“The ability for Durapower’s customers to work with live data to remotely monitor operations is critical in managing both cost and time effi ciencies and for being prepared to manage the environmental challenges.

“We are providing an integral component that makes Flowforce™ pumps stand out for innovation and design. And with Hastings Deering providing fi eld servicing, we have been able to deliver a complete solution for Durapower, allowing them to deliver the very best to their clients.”

John adds: “We not only supply the pumps, we work with the customer to ensure correct pump selection so that it will work fi rst time, every time. And we chose to work with EPSA and utilise Cat engines because Cat is globally recognised for reliability and offers a broad product range.

“EPSA also consistently delivers great customer service. We pride ourselves on offering that, so it is important that our suppliers do as well. Our customers can call on Cat service agents anywhere in the world, which adds to the appeal.”

Forcing the fl ow

value for investment are high on the purchasing

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EPSA has recently supplied Caterpillar’s Olympian-branded generators for an innovative project to provide coconut oil-fuelled power generation on the Pacifi c Island nations of Timor-Leste and the Solomon Islands. The used Olympian generators are part of a project to power two remote villages with no access to the utility grid.EPSA is working with Queensland-based Raw Power Systems (RPS) and Solomon Tropical Products in the Solomon Islands on the project, an initiative of the Secretariat of the Pacifi c Community (SPC) and funded by the European Union. SPC is an international NGO helping Pacifi c Island nations achieve sustainable development and agricultural enhancements.

Coconut oil is environmentally friendly and sustainable with virtually zero emissions, says RPS Director Sandy Kelly.

“We have developed an effective and compact system that enables diesel generators to operate reliably on 100 per cent coconut and other vegetable oils, and EPSA was our fi rst choice as a partner to help implement this clean energy solution. The outstanding quality of Cat®

and EPSA’s renowned customer service is crucial to the project’s viability and success.”

As emerging economies, over 70 per cent of the populations of both Timor-Leste and the Solomon Islands have no access to grid power, resulting in a high dependency on expensive

imported diesel for fuel, says EPSA Business Development Manager, Chris Sanderson.

“The capacity to use coconut oil as fuel is crucial to the economic development of both countries. In addition to supplying areas without power, the coconut by-products also give villagers other opportunities to earn revenue.”

Long referred to as the “tree of life”, the coconut is an underestimated crop with potential for the entire plant to support local economic development, adds Sandy.

Chris says that by using existing resources, real tangible benefi ts can be delivered.

“Locally produced coconut oil reduces the requirement for expensive imported fuel, thus providing lower energy costs and, unlike depleting fossil fuels, it is a renewable energy source. Coconut oil for industrial power is virtually free energy as the coconuts can be harvested and processed locally. Any village can install a small system to provide power with an average usage of only three coconuts per kilowatt hour.”

The use of vegetable oils to power diesel is not new. Inventor Rudolf Diesel ran his original engine on peanut oil, while coconut oil was used in the Philippines during WWII when diesel was in short supply. Today, coconut is the world’s most extensively grown and used nut.

The harvesting of coconuts and production of the oil and other by-products will drive rural development and employment. The beauty of this system is that it can be run on any vegetable oil, opening the doors for development in many industries in the future.

Cat and the coconut

and the Solomon Islands. The used Olympian generators are part of a project to power two

“The capacity to use coconut oil as fuel is crucial

the coconut by-products also give villagers other

potential for the entire plant to support local

A word from Fredon Air ... “We are working as contractors on a sensitive, classifi ed project where we needed to supply –10°C chilled water to a mining site along a 3.5 kilometre pipeline,“ says Des Benjamin, NSW Service Manager.

"Critical to the brief was managing low chilled water temperatures for a critical cascading production procedure.

Due to the site-specifi c challenges and operating at subzero temperatures, we needed a portable chiller and approached Cat Rental Power to assist as we already worked with them for generator requirements. The CRP team bent over backwards to help us with the unique

requirements and responded with both a highly competitive rate and proactive support in suggesting and making modifi cations that were unique to our project.

The chiller is a mission-critical part of the process in servicing our client, so to have the trusted relationship with Cat Rental Power is imperative. Their fl exibility and service is fi rst-class."

Fredon Air is one of Australia’s foremost suppliers of electrical,

data, security, air conditioning and communications technologies services

to government, large corporations and the construction sector. It is also a leading supplier of voice, data and audio-visual, working with numerous prestigious Australian corporations.

©2013 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, "Caterpillar Yellow," the "Power Edge"trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

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