5 Ways to Protect Your Power Pack During Emergencies
COVID-19 related events are having a profound effect on local grocery store inventory. The resilience of the supply chain will have a significant impact on the health and welfare of all of us.
Even those that until now may not have fully understood the role that we in the refrigerated transportation industry play in keeping fresh produce on the shelves, they are indeed watching us now.
One key element is the Power Pack reefer generator to ensuring the successful throughput of the perishable cargo under your care.
All of us here at Power Pool Plus remain available to assist where possible. Your team, however, is the first line of defense against unexpected generator shutdowns. And the proper maintenance practices that you follow may make the difference between success and failure.
Here are some fundamental steps that everyone on your team should know in regards to Power Pack maintenance.
- Keep extra fuel filters on hand - Bad fuel is the #1 cause for generator failure. Checking for clogged fuel filters is an excellent first action to power pack shut down. Replace each as needed and be sure to correctly prime each filter before installation. If equipped with a RACOR filtration system, visually check for debris and clean as necessary.
- Avoid low reefer count per Power Pack - In other words, try to limit the times that each power pack is under-loaded, or under 50% capacity. Under-loaded Power Packs will cause a condition known as wet-stacking, indicated by thick black exhaust smoke, which may limit engine performance when you need it most.
- Check Oil Levels Daily - Daily inspection of oil levels, including reserve make-up tanks (if equipped), will prevent surprise shutdowns due to low oil pressure.
- Check Coolant Levels Daily - Change in reefer load quantities from low to high can affect engine operating temps causing some coolant to release from the system. Daily inspection can reduce shutdowns due to low coolant levels.
- Keep up with routine maintenance schedules - The best line of defense against power pack failure is to keep fresh eyes on your machines as frequently as possible. Here are our suggestions:
-
- Every 250 Hours
- Change Oil and Filters
- Change Fuel Filters
- Inspect Belts and Hoses for Wear (Replace as Needed)
- Inspect for Oil and Coolant Leaks
- Address any concerns ASAP or contact Power Pool Plus
- Every 500 Hours
- Same as above PLUS change Air Filters
- Inspect radiator for dust and debris build-up. Note: clogged radiators should only be cleaned by professionals with the right equipment and skill to prevent delicate radiator damage.
- Every 250 Hours
These steps are only a few first response actions to keep your power pack generator healthy and operational. If there are other concerns or questions related to power pack maintenance, please contact Power Pool Plus for more details.
Considering a used Power Pack? Here's how to reduce risk.
Used reefer gensets, known as power packs, can offer refrigerated container operators both large and small an inexpensive way to expand their operation and increase refrigerated container throughput. Lower initial investment costs of used power packs also reduces financial barriers, allowing start-up operations the flexibility to gain entry into the reefer market.
Yet, buying anything used is risky. Knowing what to look for is key.
Understand your needs first.
Since the supply of preowned power packs may be limited, there’s a tendency to purchase the first one that comes along, usually the one that first appears to be in good condition. But it’s very important that the power pack you choose fits your needs correctly. A generator that is too large – having a kW rating that’s higher than your expected load - can be almost as bad as having one that’s too small for your needs. Our article on wet-stacking highlights this.
If your operation will need to power 20, 30, or 40+ reefer containers, then be sure your power pack is sized to meet at least 70% of that number consistently. In this way, you will not risk unexpected generator shut-down due to overloading and your connected load will be sufficient enough to avoid problems associated with wet-stacking.
Be realistic
Good or bad, used power packs will have a history to them. It's fair to assume that before being replaced most power packs are typically used right up to the point of near failure; until the very last bit of productivity is squeezed from their essence.
What remains is a worn-out engine that’s unable to maintain horsepower, a generator with windings that are nearly torn from the stator and unable to produce electrical current safely, a rotten container that’s rusted through, broken and unusable receptacles, plus many other failings. With thousands of dollars in perishable cargo at stake, used machines are hardly something that can be purchased AS-IS and be expected to provide quality power generation. This is the risk.
Even if the used power pack that you are considering is not nearly as bad as the one pointed out in this example, it is safe to say that purchasing a used machine will offer limited life expectancy and require some sort of additional investment. Major failures can happen at any time creating huge and unexpected repair bills with potentially long power pack downtime – what’s that worth?
These costs are real and need to be figured into the overall operating expenses of purchasing and owning a used power pack with questionable history and limited records availability.
A better solution,
One that won’t leave you stranded like an old, worn-out power pack might.
Allow Power Pool Plus to provide the right used power pack for you. Our experienced team will identify the right generator package that’s properly sized to meet your requirements. Because finding one that’s sized correctly for your needs may not always be easy.
Through our comprehensive inspection process and in-depth operational evaluations, Power Pool Plus offers peace-of-mind on every used generator package purchased through us.
Here’s how we do it
Once a used generator passes our initial operational analysis, it goes through a process that we call re-qualification.
The engine and generator are the core components of any refrigerated container power pack. So our re-qualification process focuses on documented and historical failure facts based on each make and model genset. And with 30 years’ experience there is quite a bit of history to lean on.
Our intent is to extend the service life of a known low hour engine or generator set at a cost savings to our customers – often times as much as half the cost of purchasing new.
Understanding that the negative effects of fuels, oils, coolants, water, UV rays, age, and dry rot are the #1 enemies of power units, we go through an exhaustive process on any used machine that we evaluate. Key engine and generator parts are evaluated and replaced as necessary to ensure a product that is capable of handling the demands of typical power pack operations.
Other components like the shipping container enclosure, fuel tank, receptacle panels, and controls are reconditioned or replaced as needed.
The end result will allow your operation to be successful through owning a used reefer power pack with the assurances of professional inspection and re-qualification provided at a significantly reduced cost over a new machine.
While it’s difficult to eliminate all risk when purchasing used gear, our team reduces the chances of failure significantly and provides our customers with equipment that will offer productive output while maximizing your operation’s profitability for years to come. And isn’t that why you’re looking for a power pack in the first place?
Don’t take the risk on your own. Trust Power Pool Plus to deliver results and savings.
*Remember to properly maintain your equipment according to manufacturer’s recommendations to ensure long operational life with minimal downtime.
How to manage black exhaust smoke
Attention to load will improve power pack performance.
Power packs are the lifeblood of most reefer cargo operations. Keeping them in top shape through regular maintenance is a necessity.
Understanding load and how it affects power pack health is a critical part of this process.
Is your power pack underloaded?
It might seem obvious that overloading a power pack can have negative implications for a generator’s performance. Yet under-loading can be just as serious, if not more problematic to its long term health.
What does it mean to under-load a power pack?
An underloaded power pack is defined when the amount of load (Reefers) is far below the available power (Plugs) that the power pack is equipped to handle.
This situation may be unavoidable from time to time as there may only be limited numbers of refrigerated containers in your yard - as might be the case between shipments. Other times, it is a practice done intentionally under the misconception that this helps prevent the generator from having to work too hard.
The negative effects of under loading (wet-stacking).
Professionally built Power Packs are designed to precise specifications based upon the amount of load (or electricity) they are demanded to produce. Anything short of that, and the generator is not operating to its fullest potential. They will use more fuel, burn oil, and wet stack (produce black smoke) – issues that in time will lead to a shorter equipment life expectancy and sudden failure.
If you are experiencing black exhaust smoke issues, a rather common occurrence called wet-stacking is likely due to the power pack's lack of load.
Solution
To correct this situation, avoid running them on less than the optimal load for long periods of time. We understand that this may not always be practical given the number of reefers available. However, diesel-powered generators perform best when they are fully loaded up with reefer plugs. So be sure to manage them to full capacity periodically or consistently maintain them at an optimal load per generator.
What is the optimal load?
The number of actual reefers needed to obtain optimal load will vary from one size power pack to another. As a general rule of thumb, it is recommended to maintain a minimum of 70% capacity to reach the point at which the generator is working efficiently enough to burn cleanly and avoid maintenance concerns like wet-stacking (Black Exhaust Smoke).
As an example, the optimal load on a 40 plug power pack should be around 28 reefers. This is provided, of course, that the 40 plug power pack is built to proper specification.
* Care should be taken for hot boxes being brought down to temp not to overload the unit. Always follow the manufacturer's recommended operating instructions.
Conclusion
When possible, load up your Power Packs and let them run. Do this, and your black exhaust smoke issues will go away. But if problems persist, it could be signs of a bigger concern. Contact Power Pool Plus for further direction to help resolve.
Have other Power Pack performance questions? Contact us today.
Power Pool Plus welcomes LATAM sales manager
Power Pool Plus Welcomes Jose Alberto Castillo Magaña as Sales Manager of LATAM
Alberto provides his experiences in customer support to port equipment sales
(Alpha, New Jersey USA) Power Pool Plus is proud to announce the addition of Alberto Castillo as our Regional Sales Manager of Latin America. Alberto joins Power Pool Plus with past experience in addressing the heavy lifting requirements of both port and construction equipment operators. Mr. Castillo will be responsible for developing new business relationships and promoting our reefer generator products and related services throughout Mexico, Central America, and South America. Mr. Castillo is trained in mechanical engineering and is an accomplished sales professional with experience in solving unique challenges that maximize customer efficiencies.
Ports throughout Latin America are ever expanding their footprint in the perishable goods trade. This new role with Power Pool Plus will be to provide unique power generation solutions for port operators that are actively engaged in the throughput of refrigerated container cargo. Alberto is no stranger to the requirements of port operations. Based out of Mexico City, Mr. Castillo has most recently represented Taylor Machine Works International as the Regional Sales Manager of Mexico and SITSA in Mexico City as Sales Representative for Kalmar equipment and terminal tractors. Both roles addressed the capital equipment needs of port facilities.
According to Adam Hulse, VP Sales, “Having a regional representative in Latin America has been a goal for Power Pool Plus for some time. Alberto’s valued experiences and innate appreciation for meeting customer expectations is a perfect fit to the character of Power Pool Plus that we believe our customers in this region will benefit from. Everyone on our team is very excited to have him on board with us.”
“Power Pool Plus has the right products to address port operators throughout Latin America,” says Mr. Castillo. “I am excited about this opportunity to apply my knowledge and creative imagination in helping our customers with their reefer power needs.”
From spikes in seasonal cargo throughput to the efficient use of power packs to mitigate challenges in dependable ground power, Power Pool Plus is committed to helping port operators throughout Latin America to be successful in managing the ever expanding volumes of refrigerated container cargo. Mr. Castillo’s experiences and professional acumen will be an asset not only to Power Pool Plus, but to the customers that he will effectively serve.
4 Conversation Starters to Creating a Custom Power Pack
A power pack that fits exactly into your unique work environment can help maximize workflow efficiencies and help your team save both time and money.
What if you had a customized power pack that was designed around your operation and the challenges which you face daily?
Typical designs can feature 30, 40, or 50 or more receptacles all placed in one location on the power pack enclosure. Yet, unique yard layouts, stacking limitations due to container handling equipment, and other defining factors create challenges in trying to position all your reefer 
stacks around a single power source. These challenges disrupt operations creating extra labor time.
But it doesn’t have to be this way.
And it all begins with having a complete understanding of what the operator is looking to accomplish.
4 questions that help get the conversation started might be.
1) How many plugs (or reefer cord connections) will be needed?
- Power packs that operate with too many unused plugs on a regular basis operate inefficiently and can create engine problems due to wet-stacking.
- Having the right amount of receptacles that maintain a level of capacity near 75% is ideal for engine health and fuel efficiency.
2) Where will the reefer stacks be positioned in relation to the intended power pack placement?
- Too tight and critical airflow might be affected. Creative thought on power pack design can address this.
- Too far away and reaching the power pack may be challenging. Bringing the receptacles to the reefer stacks through the use of remote trees may be needed.
3) What is the expected run-time between fuel deliveries?
- Sizing the fuel tank appropriately to this key factor can be the difference that allows an operator to run non-stop between deliveries.
4) What is the operating climate?
- Certain elements of design can help mitigate the negative effects of either tropical heat and humidity or artic cold.
Allow Power Pool Plus to create a custom power pack solution for you. Contact us today.
Recent Custom Projects
Y-Splitters - Are they good or bad?
When you have more reefers in your yard than plugs available on your Power Pack, it might be tempting to use electrical Y-splitters on your reefer extension cords to increase capacity. But here’s why this practice should be avoided, if possible.
As the demand for fresh produce grows globally, shipping companies have been keeping pace by ordering new reefer containers by the thousands. These latest reefer designs are far more efficient and consume less energy than previous models. So conventional wisdom might suggest that Power Pack diesel generators can handle more reefer containers. Using Y-splitters is an easy way to do this.
What are Y-Splitters?
Designed for temporary use to meet short-term demand spikes, Y-Splitters allow multiple reefer cords to connect to a single power source receptacle.
Caution is advised
While adding more connections than a power pack is designed for may provide a temporary and safe solution when connected to newer low-current reefer boxes, caution should be exercised as it is possible to exceed the specifications of the power pack.
Many container fleets still have a big share of older reefer versions in use today. These, of course, draw a much higher current than the newer designs. When reefer yard technicians cannot control the age of the reefer containers that reach their yard, the risk of overloading power packs increases.
Hot Reefer Boxes
And what if several of the reefer boxes are hot when connected using Y-splitters? When these boxes all come online at once, it’s quite possible that the current draw will exceed the limitations of the power source. With loads of perishable cargo under your care is it really worth the risk of damaging your power pack and losing the valuable cargo entirely
Safety
Then there is the safety aspect. Y-splitters when improperly handled can bypass the integrated safety designs of the receptacle panel. The safety of personnel is paramount. ESL Power Systems, manufacturers of reefer and intermodal electrical components, recommends the following guidelines when using Y-splitters:
- Do not connect or disconnect reefer plugs to a splitter while energized
- Reefer plugs must be connected to the splitters female cord connectors before connecting the male plug to an interlocked outlet
- Use of multiple Y-splitters on the same circuit is not recommended
- Do not exceed the Y-splitter rated current
Y-splitters can be an effective tool for meeting short term, high volume throughput of reefer cargo. Use them with caution while understanding all the variables involved. And if more plugs are needed to meet short or long term refrigerated container demands, increase your capacity safely with additional power packs or portapacks from Power Pool Plus.
For questions on how to properly apply refrigerated container load to your power packs, contact Power Pool Plus.
Ted Shelson, VP Marketing
Power Pool Plus
Power Pool Plus receives Silver Sponsor Awared at 2019 PMAC Conference
Power Pool Plus was an honored recipient of the Silver Sponsor Award at this year’s 2019 Annual General Meeting of the Port Management Association of the Caribbean (PMAC), held at the Westin Resort in Fort Lauderdale, Florida from June 26th – 28th, 2019.
The mission of PMAC is "To foster operational growth and financial efficiency, and to enhance the level of service to the mutual benefit of Caribbean Ports and their stakeholders through the sharing of experience, training, information and ideas." This, their 22nd annual event, featured a number of noteable stats; first time held in the USA, highest particiapation at 17 of 18 member ports, and one of the largest attended meetings to date.
Attendees and speakers from around the Caribbean Basin and points around the globe shared insight on the digitalization of the port environment, predictive analysis of port equipment to mitigate machinery downtime, the future of port modernization, and a topic critical to the needs of Caribbean port operators, discussing current regional initiatives in disaster relief and logistics. The latter topic remained of high importance due to the nature of island relief as island ports being the only conduit to receive such aid.
Presenting to the group, Ted Shelson, Marketing Director/Power Pool Plus, provided a general overview to the delegation of our Purpose Built Power Generation Solutions and how they can be uniquely configured to meet the individual needs of every port customer whether for reefer, ground power, or a specialized combination of the two.
Power Pool Plus
Purpose Built Power Generation Solutions
Learn more at:
www.powerpoolplus.com
www.pmac-ports.com
How load affects Power Pack performance
Proper Loading of Power Pack Reefer Generators
Are your reefer loading processes harming your power packs?
In a recent survey we asked the question, ‘What is your typical practice for connecting reefer plugs to your power pack?’ Possible choices included:
- We fill the receptacle panel then start the power pack.
- We connect one at a time while the power pack is running.
- We connect them in groups of 5 or more at a time.
While the number of responses varied between the choices, a significant number selected choice #1, indicating that loading the power pack’s receptacle panel with connections prior to generator start is the preferred choice.
It’s easy to understand, perishable cargo tends to move in large quantities. And with many reefers hitting the docks at any one time, the goal, of course, is to quickly get these refrigerated containers connected to power. But take a moment to consider that this technique may have the potential to cause damage to your equipment which could potentially render your cargo without any electrical power.
Why this is bad.
Loading too many reefer boxes at one time on a power pack can cause the engine to work excessively hard to catch up to the required load. In the meantime, this may result in a drop in generator performance as the engine struggles to maintain sufficient power to meet this sudden demand. The results will be a reduction in hertz or electrical frequency causing potential damage to the generator’s voltage regulator. Loss of frequency can flow downstream to the reefer causing damage to refrigeration compressors. Additionally, there is added stress on the fuel delivery system to maintain engine power.
Either of these scenarios will leave you with a down machine, expensive repairs, and a load of perishable cargo without electrical power to maintain temperature.
How to avoid a problem
A systematic approach to loading Power Packs should be incorporated in order to avoid costly and time delaying damage.
Power Pack Loading Procedure, a Best Practice Approach
Every power pack is different and may have varying engine and generator configurations. It is strongly advised to review and understand all of the manufacturer’s operations manuals prior to beginning any power pack starting procedure.
Once started, here are some guidelines to ensure that you maintain the best performance from your power pack generator.
Applying load
Once power pack is properly started allow the engine to warm up for 5 minutes before loading reefers. Engage Main Breaker to ON Position.
For ESL Power receptacle panels:
- Insert a single reefer plug into the panel and secure locking ring by rotating clockwise
- Depress the plunger to energize receptacle.
- Repeat steps 1 and 2 above for each additional receptacle plug added to the panel.
Continue loading reefers until reaching a load of 50%. At this time, check amperage on the generator control panel. This is important to ensure that your generator is managing the load and working within optimal engine performance. Refer to the specifications of your power pack for total amperage information.
If at 50% capacity total amperage is under the specified maximum amperage of your power pack, then continue to load reefers gradually to full capacity, but continue to monitor the ammeter.
If amperage is OVER the maximum amperage STOP LOADING and wait for refrigerated container compressors to cycle before continuing to load more.
Loading too many reefers, especially hot reefers, at any one time may cause the amperage draw to exceed the limitations of your power pack.
Maximum amperages vary depending on the specifications of your power pack. If you are unclear on the maximum amps for your power pack, contact Power Pool Plus for information. Operating a power pack at near max amp rating should be monitored closely to avoid tripping main circuit breaker and losing all connected reefers.
A special note on loading: At minimum, there should always be at least a load of 25% of total panel capacity. In other words, if operating a 40 plug power pack, minimum load will be 10 reefers or 8 for a 30 plug machine. This will protect your power pack in 2 ways:
- Avoid the damaging effects of wetstacking – thick black exhaust smoke.
- Allow a more efficient use of your power pack. More reefers attached to your power pack means less fuel burn per reefer – which will save you money.
Unexpected shut down while connected to full load of reefers
Should an unexpected engine shut down occur, either through a run-fault event or manual stop, never perform a re-start while connect to a full load of refrigerated containers. Instead, load should be removed from the power pack and brought back on gradually. Best practice would be; de-energize ALL ESL receptacles, ensure that the main breaker is CLOSED, and re-start the power pack. At this time bring reefers back on line following the procedure highlighted above by energizing the ESL receptacles individually until all are successfully back online.
Manually shutting down an operating Power Pack
Often times, out of convenience, bad habits, or simply insufficient operator instruction, emergency stop (E-stop) buttons are routinely used to shut down a running power pack.
Emergency stop buttons should only be used for emergency situations, such as pending harm to personnel or equipment.
Using E-stop buttons as a regular means of power pack shut down can cause damage to the engine and generator components by not allowing a proper disconnection of electrical current to the load and necessary slow cool down of the engine.
Instead, follow this procedure,
- Open main generator circuit breaker
- Allow engine to cool down for 10 minutes
- Press the stop button located on the generator control panel. The generator will then stop. Some power packs have a built in shut down procedure that initiates upon pressing the stop button on the Control Panel. Check your Owner’s manual for specific information on your power pack design characteristics.
In short, unless it is an actual emergency, use the stop button located on the Control Panel and NOT the Emergency Stop buttons.
Wrapping it up
Each Power Pack is different with unique engine kVA and kW output. But the process for loading them to protect the Power Pack from overloading is the same. Following these quick and easy steps will ensure long lasting performance from your reefer power solution.
Power Pack maintenance doesn’t begin and end with oil changes. It starts with proper machine operation. No matter if your operation handles chilled loads, frozen loads, or pre-trips hot reefer boxes, Power Pack performance can be greatly affected by the way in which load is applied. Following these procedures to ensure that you get the most out of your reefer power system.
For more details on power pack operations read: 7 Best Practices for Every Power Pack Operator.
Have questions?
Please contact us today to learn more.
How to Avoid Port Congestion?
Photo Credits: Michael Neelon/Alamy; Columbia Group
Recent port expansion projects around the world are a sign of the competitiveness to attract some of the newest and biggest container ships. What has been slower to keep pace is the supporting infrastructure in surrounding areas. Roadways leading in and out of terminal gates are creating truck traffic gridlock at many ports. Sensitive refrigerated cargo is at risk if not moved quickly.
As more and more port operators are turning to alternative methods for moving their cargo off terminal, barge service has become much more viable. Utilizing existing waterways, barges offer the ability to bypass this congestion by moving cargo from the main port to areas more easily accessible to trucking and rail.
This is especially important for refrigerated cargo where timing is critical.
Yet moving reefer by unmanned and unpowered barge can present a host of challenges for the reefer cargo operator.
Power challenges for the barge operator
- Conformity of reefer diesel generators, or power packs, to the business of container handling. The greater its design fits into the regular operation the faster barge loading and unloading can occur.
- Long transit times without the ability to refuel can present a major barrier to the barge operator.
- Limited space; tightly packed containers on barges leave little room for diesel powered generators to breathe.
- Proximity to salt air and water environments, especially during heavy seas, can be problematic for mechanical equipment.
- Generator failure while in transit is a recognized concern to maintaining operational success for the reefer barge operator.
Power Pool Plus has been addressing these challenges for nearly 30 years by engineering and building power pack designs that are Purpose Built to deliver a reliable and continuous reefer power supply over multiple days of unmanned overseas transit.
What Does it Mean to be Purpose-Built?
If you’re in the business of handling refrigerated cargo, then you know all too well about the constant reliance on electrical power to keep your perishable cargo fresh (at least while it's under your watch). The need for generators to supply this electric power is great.
Using standby generators that are designed for emergency use may not be the best solution for managing the harsh realities of the reefer cargo industry.
What’s required is a purpose-built solution that can provide substantial electrical supply in a robust package that fits neatly into the working environment of the shipping industry.
But what does Purpose-Built mean?
To be purpose-built a product must have the ability to complete a specific task so uniquely that every aspect of its design takes the following elements into account:
- How it is going to be used? (Application)
- Where it will be used? (Environment)
- Who will be using it? (Safety)
- When it will be used? (Time Frame)
Power Packs, generators designed for powering refrigerated containers, are an example of such a product. But not all power packs are created equal. Simply being called a Power Pack does not make it purpose-built for reefer cargo application.
Power Pool Plus takes all of the above elements into consideration when designing power packs.
How it will be used (Application)
Our Power Packs are designed to be easily handled in and around a port environment including ships and barges. Outfitted with both fork pockets and corner pockets our power packs can be easily moved or positioned by any heavy lift port equipment.
For use on a barge, space is limited. Yet maintaining proper airflow is critical to power pack performance. We take that into consideration while still allowing our machines to stack neatly between containers.
Where it will be used (Environment)
Uneven ground, constant repositioning, salt air/water, extreme heat and humidity, cold arctic waters – these are just some of the harsh realities of keeping the cold chain intact. Our power packs are designed and built with these considerations.
Who will be using it (Safety)
In ports things move fast and keeping people safe is priority #1. Power Pool Plus goes to great lengths to ensure this is met.
To reduce the risk of electric shock, we use only ESL’s line of safety interlock receptacle modules. This ensures safe handling of electric plug connections made at the Power Pack panel.
When it will be used (Time Frame)
How long will your power pack need to run unattended? Fuel delivery in ports can be a big problem. And on barges, it’s impossible until next port call. Our power packs are designed with standard 1000 gallon (3785l) fuel tanks ensuring long runtimes of 36 to 48 hours depending on use and application. Additionally, our on-board engine lubricant reserve tanks with automatic refilling are essential to avoid low oil engine shutdowns during unattended operation on sea or land.
Of course, these are just some of the standard purpose-built features that set Power Pool Plus apart.
Have a very unique requirement?
Our engineering team can design a purpose-built power pack specifically for you. Just let us know the details.