Five years ago, an inquiry for a 1250 kVA standby power solution initiated, transformed into one of the most prestigious and technically demanding infrastructure assignments powering the iconic Pamban Bridge. What unfolded was not just a delivery of diesel generator sets, but the successful execution of a mission that tested engineering precision, site resilience, environmental adaptation, and human spirit.
Spanning over 2 kilometers, the New Pamban Bridge connects Rameswaram Island to mainland India, replacing the historic century-old structure. Featuring 100 spans of 18.3 meters each and a 63-meter vertical navigational lift span the first of its kind in India the bridge stands as a modern marvel designed to allow unhindered passage for both rail traffic and maritime vessels. It is more than just a piece of infrastructure; it is a gateway to progress, tourism, trade, and spiritual journeys.
Understanding the strategic importance of uninterrupted power for the bridge’s advanced vertical lift system and surveillance infrastructure, Cummins delivered a tailored power solution engineered for reliability. Following an in-depth feasibility study and on-site technical assessment, we installed two high-performance CPCB II compliant gensets, powered by robust 19L Quantum Series engines ensuring seamless operation even under demanding conditions.
Considering the mission critical application of the bridge, the dual configuration allowed for assurance of enabling continuous power delivery during maintenance or in the rare event of generator downtime.
The environment posed a formidable challenge salt-laden sea air, aggressive winds, and corrosive moisture made marine adaptability a key factor. To meet these, Cummins installed gensets renowned for their durability in high-load operations, fuel efficiency, and low emissions. The engines were fitted with advanced Cummins PowerCommand® control systems enabling real-time load monitoring, diagnostics, and smooth synchronization with bridge operations.
The bridge’s lift system itself is a mechanical symphony. Two massive towers house dual motors, each equipped with separate gearboxes and wheels. These motors receive power from the gensets at an engine speed of approximately 1000–1500 RPM, then reduce it to 750 RPM before the gearbox further slows it to a precise 5 RPM at the wheel level. Only one side operates at a time, yet both towers engage simultaneously during a lift. The lift cycle has four speed stages 25%, 50%, 75%, and 100% with the full lift taking approximately 5 minutes.
Installation was meticulous. Cummins conducted 10–12 hours of rigorous factory testing, followed by site-level trials. The team pre-mapped engineering resources, handled alternator crating and acquisition, aligned vibration control systems, and customized integration for the site’s unique needs. Despite complex logistics and environmental constraints, the units were delivered and installed on time. The project was further strengthened by the excellent aftermarket support from Cummins, with a dedicated service team present on-site and a single point of contact to ensure seamless communication and escalation when needed.
The true essence of this partnership was reflected in the relationship built with the customer. In a remarkable gesture of trust, Cummins was invited to the bridge’s top tower and operations area, where the customer shared every aspect of the lift mechanism and setup.
The DGs have already clocked 200+ operational hours with no performance issues recorded to date. The customer highlighted the seamless communication, regular service updates, and gratitude expressed through emails recognizing Cummins’ consistent support.
Cummins’ presence is not just technical it’s deeply symbolic. With the bridge inaugurated by Hon’ble Prime Minister Shri Narendra Modi, the gensets stood silent but strong, enabling uninterrupted operations during this highly visible national event. The bridge, now fully operational, serves as a lifeline for Rameswaram, powering economic activities, spiritual pilgrimages, and essential transport.
From overcoming marine corrosion and structural limitations to integrating high-precision mechanical systems, Cummins’ involvement was holistic. Every bolt, every test, every step walked by the team under blazing sun and salty winds reflected a commitment that transcended machinery. The team’s resilience was evident when they tackled physical challenges on-site walking kilometers daily due to restricted vehicle access ensuring the project’s completion under the toughest conditions.
In powering the New Pamban Bridge, Cummins did more than install a generator it powered national progress, customer trust, and engineering history. With every rotation of the lift wheels, the gensets whisper a story not of horsepower alone, but of hardship endured, relationships built, and excellence delivered.
