GE Industrial Solutions ES Group / UPS Solutions. GE Flywheel UPS. Flywheel Energy. An Integrated Solution

Transcription

1 GE Industrial Solutions ES Group / UPS Solutions GE Flywheel UPS Flywheel Energy Using An Integrated Solution

2 Key Drivers that Makes GE Flywheel UPS Attractive Low Total Cost of Ownership / Flywheel 20 Year Life Fully GE Tested & Integrated w/ups Module Small Footprint / High KW per Sq Ft Green Sustainable Energy Storage Limited Ambient Cooling Needs Reduced Maintenance Costs High Efficiency Both UPS and Flywheel Simple Installation Page 2

3 Flywheel UPS - Numerous Great Fit Applications Segment Application Trends/Needs Datacenter IT Support Higher Ambient Temps, Spatial Software Redundancy, Less UPS Backup Time, Scalability, Green Initiatives, TCO Importance Industrial Critical Process Healthcare Casinos Broadcast PLC, Robotics, Control Systems Imaging Equipment Operations Support Digital Transmitters Short Term Power Quality Improvement; Prevention of Process Downtime Short Term Power Quality Improvement; Prevention of Ruined Scans Continuous Operations for Security and IT Subsystems during short term power issues Continuous Broadcast TV Operations during short term power issues Page 3

4 Flywheel UPS - Existing Customer Examples Production started in Over 1000 Flywheels Installed with over 12 Million Field Cycles of Operation Page 4

5 Applicable GE UPS Modules for Flywheels Series TLE HighPower UPS kva Modules, 480/277VAC, UL, 60Hz kva Modules, 400/230VAC, CE, 50Hz Transformerless Topology Efficiency Up To 97% ; With Ecomode Up to 99% Unity Output Power Factor 3-Level IGBT Technology Parallel Up To 6 Flywheels per UPS Module Series TLE MidPower UPS kva Modules, 480/277VAC, UL, 60Hz* kva Modules, 400/230VAC, CE, 50Hz Transformerless Topology Efficiency Up To 96% ; With Ecomode Up to 99% Unity Output Power Factor 3-Level IGBT Technology * TLE MidPower 60Hz available 2017 Series SG MidPower UPS kva Modules, 480/277VAC, UL, 60Hz kva Modules, 400/230VAC, CE, 50Hz Output Isolation Transformer Topology Efficiency Up To 94% ; Ecomode on some models Output Power Factor Level IGBT Technology Page 5

6 GE Flywheel Module Overview Max Power Rating: 300kW Max Energy Storage Rating: Standard Flywheel: 4000kW secs Enhanced Flywheel: 6000kW secs Rotational Speed: Standard Flywheel: 24,500-36,750 RPM Enhanced Flywheel: 14,000-36,750 RPM Footprint / Weight: 6.25 sq ft (0.58m²) 1783 lbs (794kg) Height to match TLE UPS >150kva Rolls on Casters Standard Features Include: DC Internal Breaker Top or Bottom Cable Entry Touch Screen GUI Options Include: MODBUS, SNMP comm Customer Interface Board 75 tall (1905mm) 30 wide (762mm) 30 deep (762mm) Flywheel Energy Page 6

7 Inside the GE Flywheel Assembly IGBT Bi-Directional Converter Redundant Fans Magnetic Levitation Control Module (MBC) Flywheel Module Redundant Power Supplies DC Breaker Flywheel Controller Module Vacuum Pump Top or Bottom Cable Entry Page 7

8 Next Generation Flywheel Module Design Rotor Permanent Magnet Housing Vacuum environment Hub 4340 Aerospace steel Magnetic Bearings Fully active 5-Axis Stator Dual Mode Motor/Generator Mechanical Battery stores energy by spinning a mass, producing high power output Dual Mode Motor Generator converts kinetic into electricity with fast recharge capability Five-Axis Active Magnetic Levitation eliminates any bearing maintenance, no friction losses. High Power Density / 300kW Scalable to 6 Units on a UPS 99.4% Efficient 36,750 RPM High Speed 20 Year Life / Low Maintenance Air Cooled

9 Sample Screens of Touch Screen Color GUI

10 Flywheel - Simplified Power/Control Diagram DC AC IGBT Power Converter To UPS Module DC Input Soft Start 3Phase AC DC Monitoring Motor Generator Controls Power Conversion Module Controller Magnetic Levitation Controller User GUI Page 10

11 Flywheel UPS for Power Anomaly Application Power Protection for short term power problems Will ride-thru short term power issues such as: Sags Surges Spikes Brownouts Switching Transients GE UPS System Utility Rectifier Inverter Critical AC AC/DC DC/AC AC Output DC AC Time Line - Utility Outage to Alternate Source Pickup Utility Outage 2 sec. 6 sec. 2 sec. 2 to 15 min. Flywheel Support Time GE Flywheel * Note: Batteries could take 100+ min to recharge, to 95% capacity RP Page 11

12 Flywheel UPS for Continuous Power Application Standby GenSet picks up load before Flywheel runtime depleted GenSet AC Automatic Transfer Switch Genset Start Signal Rectifier AC/DC GE UPS System For typical applications where Standby GenSet(s) come online in 10 seconds or less. Inverter DC/AC Critical AC Output Utility AC Time Line - Utility Outage to Alternate Source Pickup DC AC Utility Outage 20-50sec Flywheel Support Time 2 sec. 6 sec. 2 sec. 2 to 15 min. GE Flywheel * Note: Batteries could take 100+ min to recharge, to 95% capacity RP Page 12

13 Flywheel UPS for Battery Life Extension Application Flywheel extends life of UPS Batteries Genset AC GE UPS System Automatic Rectifier Inverter Critical Transfer Switch AC/DC DC/AC AC Output Utility AC DC Paralleling Cabinet Flywheel absorbs short duration disturbances, reducing battery cycles thus increasing battery life Flywheel provides voltage support eliminating whiplash and Coup de Fouet drop in UPS DC Bus voltage GE Flywheel VRLA Batteries Page 13 RP

14 Parallel Flywheel Operation Genset AC GE UPS System Automatic Rectifier Inverter Critical Transfer Switch AC/DC DC/AC AC Output Utility AC Flywheel Energy Flywheel Energy Flywheel Energy DC Paralleling Cabinet (see next slide) Parallel for either higher capacity (power), run time or redundancy No communication required for paralleling due to droop sharing methodology GE Flywheels Page 14

15 DC Paralleling Cabinet Suggested when paralleling 3 or more flywheels Offers isolation of a flywheel for maintenance Reduces number of cables onto UPS Module DC landing which may not have room for all cables All branch breakers are 250A DC Can add Main DC breaker if desired To UPS Module DC Cable Landing Area To Flywheels Page 15

16 GE Flywheel UPS Why Select GE? Vycon sells their flywheel product to Schneider, Eaton, Vertiv, Socomec, Riello, Toshiba, and Mitsubishi. So why is the GE Solution bring higher value? GE-Branded & Fully Supported One Point Responsibility. No Finger Pointing Full Testing/Validation of numerous configurations Fault & Short Circuit Testing Product & Firmware Mods to maximize operation and reliability RoHs, REACH Compliance EHS, Cyber Security Compliance Matching Cab height/color to TLE GE Labeled GUI display screens Docs & Product Revision Controls Service Team Cooperations Integrated 1 Year warranty NOTE: GE UPS Module Warranty is valid for use with Vycon Flywheels only RP Page 16

17 Flywheel vs Battery Comparisons Page 17

18 Flywheel vs VRLA Battery Comparison Maintenance HVAC Costs Availability (MTBF) Life Expectation Max Operating Temperature Installation Cost Hazardous Materials Toxic & Explosive Gas Emissions GE Flywheel Minimal / Annual None >50,000 hrs (see next slide) 20 yrs 104 degr F, 40 degr C Low None None VRLA & Lithium Ion Battery Frequent / Quarterly High >2,000-8,000 hrs 3-5 yrs (V), 6-8 yrs (L-I) 77 degr F, 25 degr C (V) Med to High Yes Yes Footprint Diagnostics / Monitoring Disposal Requirements OSHA RequirementsOS Small Accurate None None None Large (V) ; Medium (L-I) Speculative (V) ; Required (L-I) Yes Frequent Required Often / Quarterly Reports Page 18

19 Flywheels vs Batteries Size, Hazards Wet Cell Batteries Example: 1200kW VRLA Batteries Example: 300kW Wet Cell Batteries Flywheels VRLA Batteries Flywheel Page 19

20 Carbon Footprint / Sustainability Utilizing Flywheel energy storage systems reduces the carbon footprint as compared to a 5 minute Battery Plant by an astounding 95%. 1000KW UPS Comparison VRLA Battery Plant GE Flywheel Embedded Carbon Emissions (CO 2 / kg) Energy Storage for 1MW UPS 6 Cabinets/Strings 4x300kw Flywheels Total Energy Storage Weight (kg) 14,693 1,297 Total Embedded Carbon (kg CO 2 ) 16,750 4, Year Energy Storage Replacement 3 Times 0 Times Total 15 Year Lifecycle Embedded Carbon (kg CO 2 ) 67,000 4,810 10,000lbs of Lead / Acid 200lbs of Steel Which is more sustainable for our planet? Page 20

21 15 Year TCO. Flywheel vs VRLA Batteries 15Yr TOC ($K) Flywheel for 150kva UPS $95K (1 flywheel) Batteries for 150kva UPS $115K (1 string) Flywheel for 250kva UPS $95K (1 flywheel) Batteries for 250kva UPS $180K (2 strings) Flywheel for 500kva UPS $190K (2 flywheels) Batteries for 500kva UPS $380K (4 strings) $0 $50 $100 $150 $200 $250 $300 $350 $400 Capex Install Yrs 1-4 Maint Yr 5 Repl Yrs 5-9 Maint Yr 10 Repl Yrs Maint Yr 15 Repl Assumptions: 1. Annual Maintenance: 1 PM/Yr Flywheel, 2 PM/Yr Batteries 2. Runtime: Flywheel 15-30sec support, Battery System, 8-12min support 3. Battery Replacements include jars, installation, disposal costs 4. Flywheel extra energy costs offset by Battery higher cooling costs

22 15 Year TCO. Flywheel vs Lithium Ion Batteries 15Yr TOC ($K) Flywheel for 150kva UPS $95K (1 flywheel) Batteries for 150kva UPS $139K (1 string) Flywheel for 250kva UPS $95K (1 flywheel) Batteries for 250kva UPS $205K (2 strings) Flywheel for 500kva UPS $190K (2 flywheels) Batteries for 500kva UPS $440K (4 strings) $0 $50 $100 $150 $200 $250 $300 $350 $400 $450 Capex Install Yrs 1-4 Maint Yr 5 Repl Yrs 5-9 Maint Yr 10 Repl Yrs Maint Yr 15 Repl Assumptions: 1. Annual Maintenance: 1 PM/Yr Flywheel, 2 PM/Yr Batteries 2. Runtime: Flywheel 15-30sec support, Battery System, 8-12min support 3. Battery Replacements include jars, installation, disposal costs 4. Flywheel extra energy costs offset by Battery higher cooling costs 5. Lithium Ion Batteries at 2X VRLA Battery cost

23 Flywheel MTBF Page 23

24 Flywheel Runtime Charts Page 24

25 TLE Flywheel UPS 60Hz 480VAC Enhanced Flywheel Backup Time: TLE UPS, 480V 60Hz GE UPS Models 50kva* 80kva* 100kva* 120kva* 150kva* 225kva 250kva 400kva 500kva 750kva 1000kva UPS kw # of Flywheels * Denoted TLE kva module ratings available in 2017 Standard Flywheel Backup Time: TLE UPS, 480V 60Hz GE UPS Models 50kva* 80kva* 100kva* 120kva* 150kva* 225kva 250kva 400kva 500kva 750kva 1000kva kw # of Flywheels * Denoted TLE kva module ratings available in 2017 Page 25

26 TLE Flywheel UPS 50Hz 400VAC Enhanced Flywheel Backup Time: TLE UPS, 400V 50Hz GE UPS Models 60kva 80kva 100kva 120kva 160kva 200kva 320kva 400kva 600kva 800kva kw # of Flywheels Standard Flywheel Backup Time: TLE UPS, 400V 50Hz GE UPS Models 60kva 80kva 100kva 120kva 160kva 200kva 320kva 400kva 600kva 800kva kw # of Flywheels Page 26

27 SG Flywheel UPS 60Hz 480VAC Enhanced Flywheel Backup Time: SG UPS, 480V 60Hz GE UPS Models 50kva 80kva 100kva 120kva 150kva 225kva 300kva kw # of Flywheels Standard Flywheel Backup Time: SG UPS, 480V 60Hz GE UPS Models 50kva 80kva 100kva 120kva 150kva 225kva 300kva kw # of Flywheels Page 27

28 SG Flywheel UPS 50Hz 400VAC Enhanced Flywheel Backup Time: SG UPS, 400V 50Hz GE UPS Models 60kva 80kva 100kva 120kva 160kva 200kva 250kva 300kva 400kva 500kva 600kva kw # of Flywheels Standard Flywheel Backup Time: SG UPS, 400V 50Hz GE UPS Models 60kva 80kva 100kva 120kva 160kva 200kva 250kva 300kva 400kva 500kva 600kva kw # of Flywheels Page 28

29 End of Presentation Page 29

30 External GE Flywheel vs Integrated Flywheel Comparisons NOTE: This section compares GE s Flywheel UPS versus any competitor with Line Interactive UPS Power Electronics and an internal/integral flywheel. Not all competitors use this topology. Page 30

31 Flywheel UPS Design Comparison Power Protection GE Double Conversion UPS w/external Flywheel Line Interactive UPS w/integrated Flywheel Maximum Power Quality Support Minimal Power Quality Support Extra Protection Page 31

32 Flywheel UPS Design Comparison - Technology GE Double Conversion UPS w/external Flywheel Line Interactive UPS w/integrated Flywheel GE Double Conversion UPS Line Interactive UPS GE Double Conversion Benefit Dbl Conv Mode Eff up to 97% Eco Mode Eff up to 99% High Input Power Factor, Insensitive to frequency drift by the standby generator. Frequency held at 60HZ Wide Input Voltage Range before switching to DC Energy support Line Interactive Eff up to 97% Input Power Factor dependent on Input Voltage & Load Example: 400VAC/0.90pf Load = 0.99pf Input 430VAC/0.90pf Load = 0.70pf Input Issues with frequency drift of generator. Will deplete Flywheel energy if outside preset limits Narrow Input Voltage Range (+10, -15%) before switching to DC Energy support GE Flexibility in Operating Modes maximizes operating efficiency Constant High Input Power Factor to maximize sizing of Input Feeder Frequency kept at 60HZ. Does not require FW energy to operate when outside preset limits Less reliance on Flywheel /Batteries so component life is extended Page 32

33 Flywheel UPS Design Comparison Key Benefits GE Double Conversion UPS w/external Flywheel Line Interactive UPS w/integrated Flywheel GE UPS w/external Flywheel UPS w/internal-integrated Flywheel Key Benefit of GE Flywheel UPS Can take Flywheel in parallel bank off-line without affecting overall UPS operation No downtime for Flywheel Preventative Maintenance Add Flywheels for capacity or redundancy at any time Operate Flywheel in parallel with Batteries for system hardening and extended support time Must take down entire UPS System Must use Utility Bypass for Flywheel Maintenance Must add entire UPS module to get additional runtime, as Flywheels are integral Cannot add batteries More Maintenance Flexibility Zero downtime for PMs No need to go to Bypass. System Cost and Footprint savings Battery Hardening prolongs battery life; Redundant DC energy storage. Page 33

34 Flywheel UPS Design Comparison Internal Flywheel GE Double Conversion UPS w/external Flywheel Line Interactive UPS w/integrated Flywheel AC Flywheel DC Flywheel GE External Flywheel Competitor s Internal Flywheel Key Benefit of GE Flywheel High Speed. Low Mass Design Low Speed, Large Mass Design Hi Speed provides more energy/runtime Permanent Magnet Motor Homo-polar Motor Design No External Power Source to generate electrical field 5-Axis Full Magnetic Levitation Mechanical Ball Bearings/Magnetic Bearing Minimizes friction losses No Mechanical Bearings Bearing Replacements required every 3-5yrs. 8hr downtime during bearing changeout. No Maintenance Costs ; No Downtime Page 34