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