posted by Wendy Stott
Published: February 21, 2011
Seattle,
Washington: Saving thousands of gallons of fuel while battling through
thunderous 50-foot waves are challenges for today’s commercial fishing
boats operating in the frigid Bearing Sea. Those challenges are met by
the Gen-Tech system, a patented workboat power generation improvement
that is a major energy and fuel saver.
The Gen-Tech system eliminates running a separate auxiliary
engine for generator operation when the main engine is in travel mode.
When equipped with the Overhung Load Adaptor (OHLA) from Zero-Max, the
two hydraulic pumps connected to the primary engine work effortlessly
providing generator power so auxiliary engine operation is unnecessary. A
fuel cost savings of $2300 or more in an 8-day fishing excursion is
typical using this system according the Gen-Tech.
“The
auxiliary engine is not fuel efficient when in the travel mode,” reports
Erling Skaar, president of Gen-Tech. “Our system maximizes the
operating efficiency of the primary engine with the help of the Overhung
Load Adaptor so running a secondary engine is unnecessary. The
additional load on the main engine from operating the Gen-Tech system is
negligible, and therefore highly efficient and fuel saving. There is no
added wear to the engine or connecting components. Thanks to the OHLA’s
rugged design, we’re assured of smooth and reliable pump and generator
operation. That’s extremely important in the adverse and hostile
environments that these fishing vessels are subjected to.”
Workboat Of The Future Has Innovative Power System Incorporating Zero-Max Technology
First application for Gen-Tech system was a
state-of-the-art workboat called the North American, a 35 year-old
110-foot house forward fishing vessel capable of carrying a full load of
King Crabs weighing 170,000 lbs. The North American is a crab boat that
ventures forth for the Alaskan King Crab fishing season. As movies and
TV shows have accurately depicted, the King Crab season is a high-risk
business where crews and boats frequently face catastrophic storms,
injury and death. The equipment needed to deal with these conditions
requires the best and most robust technology, exactly the way the North
American was designed and outfitted. What makes the North American’s
power system so unique is the Gen-Tech system aboard. According to Mr.
Skaar, that system is a product of over 9 years of innovative research,
rigorous testing, the development of new technology and a dedicated
mission statement.
“When the fishing vessel isn’t
risking it all for a quick fortune and the continuation of an epic
lineage,” according to the North American’s website, “its being put to
use as a working model for the environmentally conscious vessels of the
future.” Its fuel saving and pollutant reduction features make for a
greener fishing operation which has a positive global impact.
How The Gen-Tech System Operates
Gen-Tech’s secret is in the patented controller and
software design. The controller actually “learns” the power requirement
for the input to the hydraulic pumps from the ship’s main engine. Using
that information, the controller then adjusts the displacement of the
hydraulic pump to maintain stable frequency and voltage through the
entire RPM range of the main engine.
In the Gen-Tech
system, the Overhung Load Adaptor (OHLA) from Zero-Max provides a
rock-solid, permanent mounting surface. It transmits rotary motion from
the main engine to the hydraulic pumps. Using the OHLA in the system
eliminates the need for a secondary gearbox to operate the hydraulic
pumps that can be more costly. Also, the OHLA adds much more stability
in the drive train than a gearbox. Most important, the OHLA enhances
motor operation by eliminating premature motor or pump failure due to
overhung loads (axial or radial) on the pump and motor shaft. In high
seas, violent shifting motion multiplies power train stress so the
OHLA’s stability role is even more important than in calm operating
conditions. It allows the Gen-Tech system to operate flawlessly in
wildly fluctuating conditions.
The
OHLA (Model 1036S) is belt driven off the main engine (Caterpillar
Model 399-1125 hp) via a 2.8 to 1 speed ratio using a Gates polychain
drive. With a SAE-D face mount, the OHLA has a 13 tooth 8/16 spline
input, a 2-1/4 inch output shaft and a 7-inch pitch diameter on the
OHLA’s pulley. For added durability, spherical bearings were selected
for this application. Extra rugged to meet all operating conditions, the
OHLA housing is made of 25,000 PSI tensile cast iron with shafts of
130,000 PSI stress-proof steel. Weight is 195 lbs.
The OHLA operates at 1540 idling rpm, 2500 cruising rpm and
3360 maximum rpm. Connected to the two variable displacement hydraulic
pumps mounted “piggyback”, the pumps produce 3000 psi pressure and
deliver 120 gallons per minute.
“With Gen-Tech, the
North American cruises at 10 knots using only 21 gallons of fuel an
hour,” reports Mr. Skaar. “Without Gen-Tech, the North American cruises
at 10 knots using 25 to 26 gallons of fuel an hour. While the dollar
savings for an actual 8-day fishing excursion is huge at $2300, also
huge is the reduced carbon emissions and pollutants that help preserve
our fishing environment. We’re pleased to have discovered the Zero-Max
OHLA and having it integrate so effectively in the Gen-Tech system.”
