Flywheel Presentation

GE Industrial Solutions ES Group / UPS Solutions

GE Flywheel UPS Flywheel Energy

Using…

An Integrated Solution

CONSULTANTS - ARHCITECTS - ENGINEERS - PLANNERS

Sean J. Kozielec, P.E. Senior Engineer

Brent Spangler Senior Electrical Project Manager

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 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

PLC, Robotics, Control Systems

Short Term Power Quality Improvement; Prevention of Process Downtime

Healthcare

Imaging Equipment

Short Term Power Quality Improvement; Prevention of Ruined Scans

Casinos

Operations Support

Continuous Operations for Security and IT Subsystems during short term power issues

Broadcast

Digital Transmitters

Continuous Broadcast TV Operations during short term power issues Page 4

Flywheel UPS - Existing Customer Examples

Production started in 2003. Over 1000 Flywheels Installed with over 12 Million Field Cycles of Operation Page 5

Applicable GE UPS Modules for Flywheels Series TLE HighPower UPS      

200-1000kva Modules, 480/277VAC, UL, 60Hz 160-800kva 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      

50-150kva Modules, 480/277VAC, UL, 60Hz* 60-120kva Modules, 400/230VAC, CE, 50Hz Transformerless Topology Efficiency Up To 96% ; With Ecomode Up to 99% Unity Output Power Factor 3-Level IGBT Technology

Series SG MidPower UPS * TLE MidPower 60Hz available 2017

     

50-300kva Modules, 480/277VAC, UL, 60Hz 60-600kva Modules, 400/230VAC, CE, 50Hz Output Isolation Transformer Topology Efficiency Up To 94% ; Ecomode on some models Output Power Factor 0.80-0.90 2-Level IGBT Technology Page 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)

Flywheel Energy

30” wide (762mm) 30” deep (762mm)

Page 7

Inside the GE Flywheel Assembly Redundant Fans IGBT Bi-Directional Converter

Magnetic Levitation Control Module (MBC)

Redundant Power Supplies

Flywheel Module

DC Breaker

Flywheel Controller Module

Vacuum Pump Top or Bottom Cable Entry

Page 8

Next Generation Flywheel Module Design

Mechanical Battery – stores energy by spinning a mass, producing high power output

Rotor

Permanent Magnet

Housing

Vacuum environment

Hub

4340 Aerospace steel

Magnetic Bearings Fully active 5-Axis

Stator Dual Mode Motor/Generator

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

Sample Screens of Touch Screen Color GUI

Flywheel - Simplified Power/Control Diagram AC

DC IGBT Power Converter Soft Start

3Phase AC

To UPS Module DC Input

DC Monitoring

Motor Generator Controls

Power Conversion Module Controller

User GUI

Magnetic Levitation Controller

Page 11

Flywheel UPS – Typical System Block Diagram

GenSet AC Automatic Transfer Switch

Utility

GE UPS 480VAC Module

Rectifier

DC

AC/DC

Inverter DC/AC

Critical AC Output

Flywheel Energy

20Amp/L-L 480V CB on load side of UPS

AC Auxiliary Power for flywheel controls and vacuum pump)

GE Flywheel Page 12

Operation Sequence: Utility Normal / Feeding UPS GenSet AC Automatic Transfer Switch

Utility AC

GE UPS System

Rectifier AC/DC

Inverter DC/AC

DC

Critical AC Output

Bi-directional IGBT converter

AC

GE Flywheel Page 13

Operation Sequence: Utility Outage / Switch to Standby Generator GenSet AC

Genset Start Signal

GE UPS System

Inverter DC/AC

Rectifier AC/DC

Automatic Transfer Switch

Utility AC

DC

Critical AC Output

AC

Utility Outage

Time Line - Utility Outage to Alternate Source Pickup

2 sec.

6 sec.

Flywheel Support Time

2 sec.

2 to 15 min.

GE Flywheel Page 14

Parallel Flywheel Operation Genset AC Automatic Transfer Switch

Utility AC

GE UPS System

Rectifier

Inverter

Critical

AC/DC

DC/AC

AC Output DC Paralleling Cabinet (see next slide)

Flywheel Energy

Flywheel Energy

Flywheel Energy

 Parallel for either higher capacity (power), run time or redundancy  No communication required for paralleling due to “droop” sharing methodology GE Flywheels

Page 15

DC Paralleling Cabinet To UPS Module DC Cable Landing Area

 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 Flywheels

Page 16

Flywheel UPS – With Battery Option Genset AC Automatic Transfer Switch

GE UPS System

Rectifier

Inverter

Critical

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/Coup de Fouet drop in UPS DC Bus voltage

GE Flywheel

VRLA Batteries

Page 17

Flywheel vs Battery Comparisons

Page 18

Flywheel vs VRLA Battery Comparison GE Flywheel

VRLA & Lithium Ion Battery

Maintenance

Minimal / Annual

Frequent / Quarterly

HVAC Costs

None

High

Availability (MTBF)

>50,000 hrs (see next slide)

>2,000-8,000 hrs

Life Expectation

20 yrs

3-5 yrs (V), 6-8 yrs (L-I)

Max Operating Temperature

104 degr F, 40 degr C

77 degr F, 25 degr C (V)

Installation Cost

Low

Med to High

Hazardous Materials

None

Yes

Toxic & Explosive Gas Emissions

None

Yes

Footprint

Small

Large (V) ; Medium (L-I)

Diagnostics / Monitoring

Accurate

Speculative (V) ; Required (L-I)

Disposal Requirements

None

Yes

RequirementsOS OSHA Requirements

None None

Required Often Reports Frequent / Quarterly Page 19

Flywheels vs Batteries – Size, Hazards Wet Cell Batteries

VRLA Batteries

Example: 1200kW

Example: 300kW

Wet Cell Batteries

Flywheels

VRLA Batteries

Flywheel

Page 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%.

VRLA Battery Plant

GE Flywheel

1.14

2.70

6 Cabinets/Strings

4x300kw Flywheels

Total Energy Storage Weight (kg)

14,693

1,297

Total Embedded Carbon (kg CO 2)

16,750

4,810

3 Times

0 Times

67,000

4,810

1000KW UPS Comparison Embedded Carbon Emissions (CO

2/

kg)

Energy Storage for 1MW UPS

15 Year Energy Storage Replacement Total 15 Year Lifecycle Embedded Carbon (kg CO 2)

10,000lbs of Lead / Acid

200lbs of Steel

Which is more sustainable for our planet?

Page 21

15 Year TCO‌. Flywheel vs VRLA Batteries 15Yr TOC ($K) $95K (1 flywheel)

Flywheel for 150kva UPS

$115K (1 string)

Batteries for 150kva UPS

$95K (1 flywheel)

Flywheel for 250kva UPS

$180K (2 strings)

Batteries for 250kva UPS

$190K (2 flywheels)

Flywheel for 500kva UPS

$380K (4 strings)

Batteries for 500kva UPS $0 Capex

Install

$50 Yrs 1-4 Maint

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

$100 Yr 5 Repl

$150

$200

Yrs 5-9 Maint

$250 Yr 10 Repl

$300 Yrs 10-14 Maint

$350

$400

Yr 15 Repl

15 Year TCO‌. Flywheel vs Lithium Ion Batteries 15Yr TOC ($K) $95K (1 flywheel)

Flywheel for 150kva UPS

$139K (1 string)

Batteries for 150kva UPS

$95K (1 flywheel)

Flywheel for 250kva UPS

$205K (2 strings)

Batteries for 250kva UPS

$190K (2 flywheels)

Flywheel for 500kva UPS

$440K (4 strings)

Batteries for 500kva UPS $0 Capex

Install

$50 Yrs 1-4 Maint

$100

$150

Yr 5 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

$200 Yrs 5-9 Maint

$250 Yr 10 Repl

$300

$350

Yrs 10-14 Maint

$400

$450

Yr 15 Repl

Flywheel MTBF

Page 24

Flywheel Runtime Charts

Page 25

TLE Flywheel UPS – 60Hz 480VAC Enhanced Flywheel Backup Time: TLE UPS, 480V 60Hz GE UPS Models UPS kW # of Flywheels 1

50kva*

80kva*

100kva*

120kva*

150kva*

225kva

250kva

400kva

500kva

750kva

1000kva

50

80

100

120

150

225

250

400

500

750

1000

↓ 113

↓ 72

↓ 57

↓ 45

↓ 33

↓ 19

↓ 16

↓

↓

↓

↓

140

111

92

75

48

43

22

15

75

68

40

28

15

87

55

42

24

15

69

55

33

22

42

28

2 3 4 5 6

* Denoted TLE kva module ratings available in 2017

Standard Flywheel Backup Time: TLE UPS, 480V 60Hz GE UPS Models kW # of Flywheels 1 2

50kva*

80kva*

100kva*

120kva*

150kva*

225kva

250kva

400kva

500kva

750kva

1000kva

50

80

100

120

150

225

250

400

500

750

1000

↓ 71

↓ 44

↓ 35

↓ 29

↓ 22

↓ 15

↓ 12

↓

↓

↓

↓

87

70

58

46

32

28

16

12

48

43

26

21

12

58

35

28

18

12

45

35

23

16

28

20

3 4 5 6 * Denoted TLE kva module ratings available in 2017

Page 26

TLE Flywheel UPS – 50Hz 400VAC Enhanced Flywheel Backup Time: TLE UPS, 400V 50Hz GE UPS Models kW # of Flywheels 1

60kva

80kva

100kva

120kva

160kva

200kva

320kva

400kva

600kva

800kva

60

80

100

120

160

200

320

400

600

800

↓ 94

↓ 72

↓ 57

↓ 45

↓ 32

↓ 23

↓

↓

↓

↓

140

111

92

71

56

31

22

103

83

51

40

22

69

55

33

22

69

45

30

55

39

2 3 4 5 6

Standard Flywheel Backup Time: TLE UPS, 400V 50Hz GE UPS Models kW # of Flywheels 1 2 3 4 5 6

60kva

80kva

100kva

120kva

160kva

200kva

320kva

400kva

600kva

800kva

60

80

100

120

160

200

320

400

600

800

↓ 59

↓ 44

↓ 35

↓ 29

↓ 23

↓ 17

↓

↓

↓

↓

87

70

58

46

36

22

16

69

55

33

26

16

45

35

23

16

45

29

21

35

26

Page 27

SG Flywheel UPS – 60Hz 480VAC Enhanced Flywheel Backup Time: SG UPS, 480V 60Hz GE UPS Models kW # of Flywheels 1

50kva

80kva

100kva

120kva

150kva

225kva

300kva

40

64

80

96

120

202

270

↓ 142

↓ 88

↓ 71

↓ 59

↓ 45

↓ 22

↓

174

139

115

91

54

39

81

62

2 3 4

80

5 6

Standard Flywheel Backup Time: SG UPS, 480V 60Hz GE UPS Models kW # of Flywheels 1 2 3 4

50kva

80kva

100kva

120kva

150kva

225kva

300kva

40

64

80

96

120

202

270

↓ 94

↓ 58

↓ 46

↓ 38

↓ 30

↓ 16

↓

115

92

76

60

35

26

53

40 53

5 6

Page 28

SG Flywheel UPS – 50Hz 400VAC Enhanced Flywheel Backup Time: SG UPS, 400V 50Hz GE UPS Models kW # of Flywheels 1

60kva

80kva

100kva

120kva

160kva

200kva

250kva

300kva

400kva

500kva

600kva

54

72

90

108

128

180

225

270

360

450

540

↓ 103

↓ 79

↓ 63

↓ 51

↓ 35

↓ 25

↓ 17

↓

↓

↓

↓

155

123

101

77

62

48

38

24

17

114

91

74

62

44

32

24

96

80

61

47

37

76

61

49

2 3 4 5 6

61

Standard Flywheel Backup Time: SG UPS, 400V 50Hz GE UPS Models kW # of Flywheels 1 2 3 4 5 6

60kva

80kva

100kva

120kva

160kva

200kva

250kva

300kva

400kva

500kva

600kva

54

72

90

108

128

160

225

270

360

450

540

↓ 65

↓ 48

↓ 37

↓ 32

↓ 23

↓ 18

↓ 14

↓

↓

↓

↓

97

77

64

48

38

30

24

18

13

72

57

45

37

27

21

17

60

50

37

29

24

47

37

30 37

Page 29

End of Presentation

Page 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 31

Flywheel UPS Design Comparison – Power Protection GE Double Conversion UPS w/External Flywheel

Line Interactive UPS w/Integrated Flywheel

Minimal Power Quality Support

Maximum Power Quality Support

Extra Protection

Page 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%

Line Interactive Eff up to 97%

GE Flexibility in Operating Modes maximizes operating efficiency

High Input Power Factor, 0.98-0.99

Input Power Factor dependent on Input Voltage & Load Example: 400VAC/0.90pf Load = 0.99pf Input 430VAC/0.90pf Load = 0.70pf Input

Constant High Input Power Factor to maximize sizing of Input Feeder

Insensitive to frequency drift by the standby generator. Frequency held at 60HZ

Issues with frequency drift of generator.

Will deplete Flywheel energy if outside preset limits

Frequency kept at 60HZ. Does not require FW energy to operate when outside preset limits

Wide Input Voltage Range before switching to DC Energy support

Narrow Input Voltage Range (+10, -15%) before switching to DC Energy support

Less reliance on Flywheel /Batteries so component life is extended Page 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

Must take down entire UPS System

More Maintenance Flexibility

No downtime for Flywheel Preventative Maintenance

Must use Utility Bypass for Flywheel Maintenance

Zero downtime for PMs No need to go to Bypass.

Add Flywheels for capacity or redundancy at any time

Must add entire UPS module to get additional runtime, as Flywheels are integral

System Cost and Footprint savings

Operate Flywheel in parallel with Batteries for system hardening and extended support time

Cannot add batteries

Battery Hardening prolongs battery life; Redundant DC energy storage.

Page 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 35