THE WORLD OF AJ POWERDiEsEL gEnERATing sETs WORLDWiDE

ISSUE 9 SUmmEr 2013

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WELCOmE...

Welcome to the Summer edition of ‘InSight’, the company magazine of

AJ Power Limited.

Inside you will find it packed with dealer case-studies, new product information and other happenings in the world of AJ Power.

If you would like to feature in our magazine or have any photographs you would like to contribute, please contact me.

We are now getting closer to the 10th anniversary of AJ

Power. In the last edition we talked about the formative years which mainly consisted of design, product validation and testing. We have now moved forward to the period 2005 - 2008.

A stroke of luck? Or good business sense led to a fruitful agreement with a major British construction equipment manufacturer to design and manufacture a range of branded generating sets. During the period of this contract AJ Power grew three fold and the 7 Series range was added to the already established 3 and 5 Series. To cope with the ever increasing demand two new production tracks were added.

During February 2006 the company secured its first £1million pound contract for the supply of 3 Nos 11kV AJ2750 mTU 20 cylinder powered units to a major London Bank. Within weeks a further order for a similar unit was received and the 9 Series product range was conceived.

In 2007 AJ Power was placed an impressive 4th place in the Sunday Times fast Track 100 which is a list of the UK’s fastest growing companies and has since reappeared.

The early days proved crucial for AJ Power. The combination of product quality, attention to detail and customer focus by the ever expanding team soon established the company in both domestic and overseas markets.

Check out the next edition of InSight for another piece of AJ Power history!

Editor Christina stewart

| cstewart@ajpower.net � +44 (0) 28 3836 4031 + 1 Charlestown Drive,

Craigavon, BT63 5GA, Northern Ireland, United Kingdom

Christina

The opinions expressed in InSight are not necessarily those of the editor or AJ Power Ltd.

Photograph from 2006 of Mark McShane, Electrical engineering manager who joined AJ Power in 2004 and is still with the company. Pictured is an AJ2750 mTU, this

was one of four units ordered for a Data Centre in London in 2006.

10th Birthday for AJ Power

2 INSIGHT mAGAZINE www.ajpower.net

FOrEWOrD

LONDON SOUTHEND AIrPOrTAJ440 SCANIA POWErED GENSETPrOVIdINg BACk uP POWEr TO NEW TErMINAL

We are pleased to have recently been involved in a project for London

Southend Airport.

The airport can trace its origin back to 1914 and its first flight to 1915 when it was used as a base of the royal Flying Corp, the fore runner of the r.A.F. Its commercial operations did not start until 1935 and by the late 40’s scheduled services were operating to Continental Europe and the Channel Islands.

During the 1960’s Southend Airport was the third busiest airport in the United Kingdom. By the mid 70’s traffic at the airport was in decline and stagnated over the next 30 years under competition from London’s others larger airports.

an AJ440 Scania powered genset, complete with sound attenuated canopy, InSight3200 control panel battery charger, coolant heater, bunded base fuel tank and permanent magnet generator (PmG). The AJ440 will be used to provide back up power to the terminal, including a new watch tower.

The entire project is expected to be completed just before Christmas 2013.

Following its purchase by the Stobart Group (famous for the green liveried trucks) in 2008 there has been an on-going program of development. The airport is currently under-going a major extension to the passenger terminal. The extension will see the arrivals hall, departure lounge and passenger security areas all grow in size, with expected passenger numbers of 2 million per year by 2020.

AJ Power have supplied

INSIGHT mAGAZINE 3www.ajpower.net

→PrOJECT PrOFILE: SOUTHEND AIrPOrT

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We have recently secured and delivered 29 units of AJ66,

60kVA, gensets for an offshore wind farm, located near Cumbria, in the Irish Sea.

When discussions first began it was clear that we would need to review our standard design to meet the specification for this project. Our highly responsive mechanical and electrical design teams here

at AJ Power convened with the customer and a fast design turnaround allowed for the manufacture of the large quantity of gensets over a four week despatch period.

As the wind farm is located in the Irish sea we needed to take

account of the wet and salty environment, remote location and the need for an extended running. With this in mind our

engineer’s developed a special canopy for the 29 units. This canopy has one sided service access, through two wide side doors, and the control panel is also side mounted. The canopy inlet and outlet ducts were modified, and Total Plus insulation was applied to the meccAlte UK alternators to protect from sea

AJ POWEr HAVE rECENTLY SuPPLIEd 29 gENSETS FOr AN OFFSHOrE WINd FArm, IN THE IrISH SEA.

THErE’S POWEr IN WIND...WITH A LITTLE HELP FrOm SOmE GENErATING SETS

CASE STudY: OFF-SHOrE WINd FArM

4 INSIGHT mAGAZINE www.ajpower.net

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water damage.

These gensets were also supplied with an externally mounted 125A

socket for ease of installation, a low engine level oil shutdown for additional protection and a 1100 litre bunded fuel tank for extended operation. The

gensets were delivered to the wind terminal assembly port at Belfast Harbour, where they were then positioned onto a platform which was then lifted vertically onto the special transport vessel to be taken out to sea. The offshore wind farm is expected to provide enough

power to meet the annual electricity consumption of approximately 300,000 households in the North of England and will be one of the largest offshore wind farms in the world when construction begins in 2014.

“This is a very special project, which needed a special solution and we are glad to have been

involved.”(Joe Bradley, Director of Sales, AJ Power Ltd).

CASE STudY: OFF-SHOrE WINdFArM

INSIGHT mAGAZINE 5www.ajpower.net

→ PrODUCT NEWS - AGCO POWEr 8.4 LITrE GENSET

and moreALL YOu WOuLd ExPECT FrOmAJ POWEr...

AJ POWEr ArE PLEASED TO ANNOUNCE THE INTrODUCTION OF THE AGCO POWEr 8.4 LITrE ENGINE TO OUr rANGE OF GENErATING SETS

NEW FOr 2014 AGCO POWEr 8.4 LITrE GENSET

Validation testing is nearing completion of a range - topping 5

Series generating set.

The new AJ330 is powered by the AGCO Power 8.4 litre engine, known for its refined power and superb efficiency. The latest common rail technology combines smoothness and

economy, with excellent governor response. This engine is packed with premium features, including individually balanced connecting rods, circular pattern cylinder head bolts and wet cylinder liners.

This engine dominates the world of high horse power tractors and agricultural

Engine genset Rating (standby kVA)

320 DSrG 6649 DTG 11049 DTAG 13874 DTG 165

74 DTAG/1 17574DTAG/2 20074 DTAG/3 22074 CTAG 27584 CTAG* 330

* New model

6 INSIGHT mAGAZINE www.ajpower.net

PrODUCT NEWS - AGCO POWEr 8.4 LITrE GENSET →

NEW FOr 2014 AGCO POWEr 8.4 LITrE GENSET

equipment in the 275 - 375HP band. It is the standard fit in tractors and combine harvesters of AGCO’s leading brands. This superior performance engine will now make its debut in the world of power generation in the AJ330 model.

Looking at the design of the canopy the new stiffening chamfers

(angles corners), not only add a design differential, but they enhance the canopy rigidity and thereby

reduce the noise levels. This feature will appear across the 5 Series range over the next year.

As well as enhanced rigidity, access has been improved and air velocity has been reduced.

This new model will be available in 2014 and like all models in the 5 Series range it will come with a wealth of standard features and additional options.

The New 8.4 Litre AGCO Power Generating Set

INSIGHT mAGAZINE 7www.ajpower.net

The European tour schedule for Jerry, Nii, Victor and Emmanuel

consisted of one week at the AJ Power factory in Northern Ireland, one week with AgCO Power at their factory in Nokia, Finland, and a third week with meccAlte and Scania in England.

The week spent with the team at AJ Power was a busy week and

a chance for the G&J staff to see the production process first hand. Training was given on a variety of areas including the control systems; InSight3000, InSight3200, InSight4000 and the ATS2 Transfer switch. Part of the program included practical genset fault finding, remote communications and detailed

InSight6000 synchronising training complete with a practical demonstration. In the later part of the week training continued with genset sizing, PDI, installation, commissioning and maintenance.

With such an information packed week time was squeezed in

to allow for some time-out shopping and sight-seeing in Belfast. (Due to the compact training programme the evening sampling of the locally brewed products was kept to a minimum!)

Next it was on to Finland to visit AGCO Power. The training here involved a 3

day training course covering an overview of the different AGCO Power engines involved in

IN APrIL OF THIS YEAr A COMPrEHENSIVE TrAININg PrOgrAM WAS ArrANgEd FOr FOur VALuEd EMPLOYEES OF Our dISTrIBuTION PArTNEr IN gHANA, g&J TECHNICAL SErVICES.

Victor and Nii from g&J Technical Services pictured with Stephen

mcGrath, AJ Power Aftersales Support Technician (centre) at the AJ Power

factory.

TrAINING PrOGrAmS

TAILOrED

TrAINING NEWS

8 INSIGHT mAGAZINE www.ajpower.net

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power generation, particularly those in the AJ Power range. The highlight of the visit was a factory tour through the impressive fully automated engine plant, where the engines are completely assembled by robots. At AGCO intensive training was given on practical engine fault finding which is proving invaluable since the G&J staff have returned from the training program.

After all that hard learning, the training was finished up in a manner, which is now customary at AGCO. It is tradition to finish by taking the trainees to the AGCO Sisu owned sauna, which is in a log cabin, by a lake right beside the AGCO factory. Guest are treated to Sisu own brand refreshments and can cool down from the heat of the sauna by jumping into the lake outside.

The team then returned to the UK to visit meccAlte UK. meccAlte provided

an overview of the range of alternators, including in-depth training on meccAlte’s PmG, their mAUx winding (i.e auxiliary winding) and practical fault finding. Training was also given on dEr and dSr AVr’s as well as the software used to program.

Finally last but not least a visit to Scania GB for a two day session going through

theory of 9,12,13 and 16 litre engines. The practical training included stripping a 16 litre engine and removing a piston, removing a balance shaft from a 9 litre engine, rebuilding as well as carrying out adjustments for valve clearance and injector settings. Also covered were service requirements. • PDE injection (including

some engine pressure checks)

• Scania ECU software (SDP3) - how to use and connect

This program was a massive undertaking by G&J, not only in terms of

cost, but more importantly in committing four experienced employees out of their business for three weeks during a very busty period. This invariably put the team back in ghana under increased pressure, however the invaluable knowledge gained by the travelling team will stand them in good stead going forward. Indeed just recently they have commissioned a complex synchronising project unaided.

COngRATuLATiOns and well done to the four who successfully completed the training and also the service team back in ghana who ‘held the fort’ whilst their colleagues completed their European Tour 2013!

It seems Nii and Victor were the most photographed of the group during their European Tour. Here they are again at MeccAlte and Scania. (Nii left, Victor, right)

PrODUCT NEWS

INSIGHT mAGAZINE 9www.ajpower.net

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POWErBOAT rACING FOr JS POWEr

In Spring this year an amazing journey started for AJ Power distribution partner, JS

Power, when they became the major sponsor of “One Hull of a Boat”. “One Hull of a Boat” is an aptly named powerboat, bought by the local people of Hull, which would compete in the P1 Powerboat Championship, with the UK legs beginning in Hull.

At the steering wheel of the boat was JS Power managing

Director, Jonathan ‘Jono’ Searby. Never having driven a powerboat before, Jono travelled to Southampton with navigator, Sam Whitaker, for some intensive training and qualifications to attain. With these in the bag all eyes were set on the first race in Hull on 2/3 June. racing at Hull came to an abrupt end for the team when the boat flipped due to a “freak” wave, thankfully without

serious injury. The team reached their aim of raising the profile of the City of Hull. The race weekend saw 30,000 spectators (double that of in 2012) with over £ 3.5m spent in the City as a result of the event.

Next race was Plymouth at the end of June. The team did not disappoint,

coming 6th overall. Sky Sports have shown a program of the amazing story behind the boat, the boat has travelled to schools, talks have been given by Jono and Sam, the boat has been on display for photographs and mUCH mUCH more... All testament to the interest in the story and the love people have for this endeavour. The team have just competed at Torquay on 10/11 August and

the story still continues.

AJ Power are proud to have been involved with One Hull of a Boat and

look forward to seeing how the story continues.

read more about this incredible story at

http://onehullofaboat.wordpress.com/

Navigator Sam Whitaker (left) with JS Power Managing Director and Pilot of One Hull of a Boat, Jonathan Searby (right).

10 INSIGHT mAGAZINE www.ajpower.net

→ dEALEr STOrY: JS POWEr

FOLLOW THE AJ POWEr SPONSOrED FErrArI 458

ExHIBITION ALErT!!!MYANMAr 2013

Date Location13-14

SeptemberELmS round 4,

Hungaroring, Hungary

27-28 September

ELmS round 5, Paul ricard, France

IN CO-OPErATION WITH Our LOCAL dISTrIBuTOr IN MYANMAr WE WILL BE ExHIBITINg A rANgE OF gENSETS FrOM 20kVA TO 200kVA AT THE FOLLOWINg ExHIBITION.

INSIGHT mAGAZINE 11www.ajpower.net

→FOLLOW THE AJ POWEr FErrArI/ MYANMAr

It’s been a busy few months for the JmW motorsport team since the Spring Edition of

InSight magazine.

In June they tackled the iconic Le mans 24 hour race, coming 10th in class. The Le mans 24 Hours race saw the unveiling of the new livery following the Dunlop “Design the Driver” competition. The new livery features a picture of John Boyd Dunlop on the side of the Ferrari 458 in honour of it being 125 years since he founded Dunlop!

Next date on the diary for the team was the ELmS third round at the red Bull ring in Austria in July. At the wheel of the Ferrari were Andrea Bertolini and Joel Camathias. A fuel

pressure issue meant a plan was put in place to conserve fuel to ensure the team took the chequered flag in a strong position. JmW motorsport finished in an impressive second place.

The team now look forward to the 4th and 5th rounds of the ELmS in September.

Check out JWM Motorsports website for further details:

https://jmwmotorsport.kontribune.com/

CAUGHT ON CAmErASUmmEr 20131. AJ Power engineers on their self-built raft during a charity raft race in Portrush, NI.2. AJ Power staff Julianne and Lesley caught on camera at our annual BBQ held in July.3. AJ Power Sales manager

Andy Mackey pictured with James of G&J Technical Services, Ghana at AGCO in Finland.4. Joe Bradley, Director of Sales, during trip to Qatar.5. Senior Electrical Engineer

Eugene in myanmar (2nd from left)6. AJ Power was pleased to welcome Dr martin Weale CBE (third from right) of the Bank of England’s monetary Policy Committee on Wednesday 22nd may 2013.

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AJ Power Limited,1 Charlestown Drive, Craigavon, BT63 5GA

Northern Ireland, United Kingdom � +44 (0) 28 3836 1000

� www.ajpower.net

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