Applying Flywheel UPS in Power System

One powerful future.
Applying Flywheel UPS to improve

Electrical Systems Power Quality
Ricky Goh
Sales Representative for
CAT Electric Power Solutions
Integrated Solutions Provider
TRANSFORMED BY 6 SIGMA Page 2 | CATERPILLAR: CONFIDENTIAL GREEN

Agenda
• Introduction to Flywheel UPS
• Power Conditioning
• Advantages of Flywheel UPS over Traditional
UPS
• Applications & Reference Sites
• Flywheel UPS Family

What is a UPS?
UPS = Uninterruptible Power Supply

A device which provides continuous
power to the load during a disruption
of the primary power source.

Why Need UPS?

With the Flywheel UPS = No Down Time
1. No more loss of production

• Productivity increased
• Profitability ensured
2. No more wastage of raw material
• Reduced wastage
• Reduced unnecessary cost
3. No more Loss of Man-hours
• No time loss on re-start of processes
4. Equipment protected from Power Issues
• Equipment preserved
• Reduced unnecessary breakdown & maintenance
Typical Systems Operations with UPS
Auto Non-Critical
Transfer Load
Utility / Switch
Mains
Cat Flywheel UPS
Start Critical
Cat Signal Load
Gen-Set

Agenda
UPS

Cat Flywheel UPS
 Flywheel UPS Industry leader
 Patented Integrated Flywheel UPS
 17+ years in the making
 5 continent sales
 40+ country implementations
 3500+ units shipped
 9001:2008 ISO certification
 90+ million hours of field runtime

Flywheel Technology
The Flywheel - Rotor
• Material: 4340 Steel • Diameter: 648 mm (25.5”)

• 600lb (270kg) • Thickness: 178 mm (7.0”)
Flywheel Technology
300kVA / 240kW Motor/Generator/Flywheel
Field-replaceable
ball-bearing cartridge
Field coil
Magnetic bearing
integrated into
Flywheel, motor-
field circuit
generator
rotor
Air-gap
No permanent magnets
armature
enables high tip-speed
and high output power
Smooth back-iron,
no slots and low loss

Flywheel Technology
• Flywheel constantly spins
(7,700 rpm) in a vacuum &
magnetically unloaded
• Top & Bottom DC Field Coil
levitate flywheel
• Stores energy as motion
(Kinetic Energy)
• When power is interrupted,
inertia keeps it spinning
• It is a generator and converts
kinetic energy to electricity
Agenda
UPS

Parallel On-line UPS System
Power Conditioning
• ~98% AC-to-AC efficiency

• Increased reliability: Fewer
components in critical power path
• Continuous power conditioning and
harmonics mitigation
• Exceptionally compact design
• Transient Voltage Window sampled Energy Storage
333 times every 50 micro-sec’s
Load Transfer during Power Failure
Discharge
Recharge
Standby
UPS synchronizes on Genset provides the power –
the Genset Flywheels are recharged
Signal to the
Genset starter
(adjustable)
UPS and Genset work in
Genset starts and parallel (adjustable)
stabilize
t0 + 2 s t0 + 7,5 s t0 + 9 s t0 + 12 s
Power continuity provided by the Flywheel

Power Conditioning
Frequency
Outage
Spikes
Brownout
Corrected
Transients
Sine wave
Surge The CAT UPS corrects
all 9 IEEE defined power problems
Sag by use of TVSS, line inductance,
active filtering, power converters and
Harmonic flywheel energy.
Distortion
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Handling Major Power Problems



Power Conditioning – Voltage Regulation
+10%
+2%
Nominal Voltage
RMS Voltage sampled

every 5 cycles
-2%
-10% (-15%)
Power Conditioning

Power Conditioning
Harmonics Cancellation
• UPS controls measure load current harmonics using

DSP technology
• Inverter is controlled to supply harmonic currents while

maintaining clean sine wave output voltage
• Load harmonics don’t appear on the input
12/09/99
Power Conditioning
Power Factor Improvement

• Utility Inverter Supplies Leading and Lagging Load Currents
(Reactive - kVAR)
• Input Supplies the Real Power (kW) for the Load

Power Conditioning
Fast Transient Protection
• Fast Transient detection –– 50 microseconds
• Compares the instantaneous voltage to a “Prevailing
Voltage” sine wave constructed from 50 microsecond
samples over a rolling 500 cycle period.
• Voltage restored to average prevailing voltage in ~ 1ms
upon disturbance.
– 100 micro seconds from detection to driving the
voltage (1PWM cycle)
– full restoration of voltage in ~1ms
– instantaneous energy available from 800VDC bus.
Power Conditioning
Fast Transient Protection: Voltage Window
Incoming Voltage Adjustable Instantaneous

Voltage Tolerance Window Voltage Reference
TRANSFORMED BY 6 SIGMA (+/- 25% Typically) Page 31 | CATERPILLAR: CONFIDENTIAL GREEN
Power Conditioning
Overload Capability
1000% for 10 msec

500% for 1 Sec
200% for 30 Sec
125% for 10 Min
105% Continuous

Power Conditioning
Gen-set Walk-in
• Eliminate Block Loading

• No Discernible Voltage Variation
• Linear Current Walk-In
• Sample time of 3 Seconds, Adjustable Parameter
Agenda
UPS

UPS – Crucial Necessary Expense
Integration Costs
•Capital expenditure
•Foot Print (m²)
•Indirect constraints
Operating Cost
•Efficiency
•Power consumption
•Maintenance
Footprint – Twice the Power in half the space
250kVA/225 kW Battery-Based UPS 250kVA/225 kW Flywheel UPS
3.7 Sq m (minimal battery) 1.3 Sq. m
7.43 Sq. m. w/ service clearance 2.69 Sq. m w/ service clearance

Front Access only
Financial Return from Flywheel UPS
Potential of lower Capex

• Less facility preparation
• Lower installation cost
• Increased Floor / Commercial space

Operating Temperature
25 Degrees C Optimal Up to 40 Degrees C

Flywheel UPS can be installed in electrical rooms and other low cost
spaces with higher ambient temperatures that are not conducive to batteries.
No heavy cooling required - lower utility bill

Maintenance
» 2 - 4 PM’s / Year » 1 PM / Year

» Hours of service » 4 yrs bearing change out
» Costly Battery replacements

Maintenance
Flywheel Section View
Field-replaceable
ball-bearing cartridge

Lower maintenance and eliminated replacement costs

without batteries
• Requires minimal maintenance
• Built for long life, +20 years

Efficiency
~90-94% Efficient 97 - 98% Efficient

Efficiency
Poorly designed systems can cause a “chain reaction” on efficiency

Efficiency Cost Savings – 960 kW @ 11Pesos per kWh
Traditional Double Conversion UPS:
960kW X 0.07
0.93 X 11 Php/kWh X 8760hrs
= Php 6,962,787
CAT Flywheel UPS:
960kW X 0.02 X 11 Php/kWh X 8760hrs

0.98
= Php 1,887,869
Utility Cost Savings PER YEAR = Php 5,074,918 !!!

Higher efficiency - lower utility bill

Green - Environmental Friendly

• Battery-free UPS technology could contribute
greatly in facilities GREENER

Total Cost of Ownership
Overall lower cost of Operation
• Small Footprint -> Increased Commercial Space
• High Temperature Tolerance -> No need for A/C and Utility

Cost
• Low Maintenance -> Reduced Maintenance Cost and

Labor
• Higher Efficiency -> Lower Utility Cost
• No Batteries -> Green and no extra handling cost

Agenda
UPS

Industrial Power Protection Applications

•Toilet ware manufacturer with heating kiln
•Ceramic ware manufacturer


• Foam Mattress Factory
• Textile Factory


• Water Pipe producing Factory for extrusion machine

Plastic Bag Plant
• 23 ea. 300kVA UPS

• 3 ea. 900kVA UPS
• Protects multiple plastic extruders
• 9.0 MW total UPS load


Food Manufacturing Plant : Protect the UV sterilization + UHT
- Milk , raw food, can food


Mills
- SAG Mills - Flour Mills
- Rice Mills
- Sugar Mills

Healthcare – Imaging and Medical
Who?
Cardiology Research Hospital Monzino (Milan, Italy)
(hemodynamic, PET and other cardiovascular machines)
How was the customer’s problem solved?

CleanSource 1000iz UPS system
Key Drivers
• Reliability
• Energy efficiency
• Green
Quotable quote
“The flywheel technology is absolutely impressive
and we see on this product the best solution for
green, high quality energy.” (Piantelli Franco, Technical
and Purchasing Department Director, CCM)

Government –
Transportation/Infrastructure
Who?
Tunnel Klimkovice (Directorate of Czech Republic)
(tunnel lighting, air ventilation, traffic controls)

Diesel UPS with total power of 1250 KVA
from CAT genset and essential load of
500 KVA provided by two flywheels
Key Drivers
• Reliability
• Green
Quotable quote
“It is already the third consecutive tunnel
of the new generation which is protected
by NZ2.” (Ivan Urban, Product Manager,
NZ2, Phoenix Zeppelin)

Aviation – Airport Terminals
Who?
Suvarnabhumi Airport (Bangkok)
(two main terminals and infrastructure)

More than 6 MW of CleanSource UPS
Key Drivers
• Reliability
• Green
Unique fact
Airport has capacity to handle more than 45 million
passengers and more than 3 million tons of cargo
per year

Broadcast – Transmitter Site
Who?
WFFF-TV (FOX) and WVNY-TV (ABC) in Burlington, VT
(transmitter site)

CleanSource UPS
Key Drivers
• Reliability
• Green
Quotable quote
“We installed the system six months ago and it was
evident right away we had made the right choice.
…had over 200 power incidents in this timeframe with
absolutely no interruption in service to our viewers.
This machine is just a workhorse.” (Matt Servis, Director,
Engineering, WFFF-TV)

Petrochemical
Who?
Pemex Refinacion (Zaragoza, Tamaulipas; Linarez, Nuevo
Leon; Victoria, Tamaulipas; Gomez Palacio, Durango;
Novoteapa, Veracruz)
(pumping stations)

• 3 CleanSource 900 kVA UPS system
• 2 CleanSource 600 kVA N+1 UPS system
Key Drivers
• Reliability
• Green
Quotable quote
“The lack of consistent, reliable power to support
our operations was an ever present management
headache before we installed CleanSource UPS.
…(have) not experienced any power related
Interruptions and we are very pleased with the
improvement in our day to day operations.” (Mauro Caceres,
General Superintendent, Operations, Pemex Refinacion)

Industrial – Packaging
Who?
Alticor (Ada, MI)
(extrusion lines for packaging of pharmaceutical,
cosmetic, food, tobacco, foil rolling and container
products)

1 MW CleanSource UPS system
Key Drivers
• Reliability
• Green
Unique fact
Packaging facility experienced approximately
30 micro outages in 2006, causing extrusion lines to
go completely offline; lines are now reliably protected
against power disturbances

Industrial – Process Manufacturing
Who?
Albon (Norman, OK)
(machining equipment)

CleanSource 600 kVA UPS system
Key Drivers
• Reliability
Unique fact
200,000 sq ft facility that specializes in machining
and assembly of engine components for automotive
and diesel manufacturers

Industrial – Process Manufacturing
Who?
Fuji Electric Group (Kobe City, Japan)
(manufacturing equipment)

CleanSource DC system
Key Drivers
• Green
Unique fact
Kobe City facility has sensitive manufacturing
equipment in place for building inverters,
inverters for machine tools, UPS
systems and other power supplies

Military
Who?
U.S. Army Communications and Electronics
Command (Fort Monmouth, NJ)
(communications systems)

CleanSource UPS system
Key Drivers
• Reliability
• Green
Unique fact
Customer was able to repurpose battery room and
lower HVAC demands, producing an immediate
cost savings; can now avoid recurring cost and risk
of removing and disposing of lead acid batteries
every three years

Military
Who?
Naval Air Station North Island (Coronado, CA)
(communications systems)

CleanSource 600 kVA UPS system
Key Drivers
• Reliability
• Green
Unique fact
Naval Air Station North Island is a critical
communications hub for the U.S. military

Entertainment – Casino
Who?
Cherokee Nation Casino (West Siloam Springs, OK)
(slot machines)

CAT 900 kVA UPS system
Key Drivers
• Reliability
Unique fact
Customer facility encompasses 50,000 sq ft with
more than 1,000 electronic games and more than
20 table games

Continuous Power Protection Applications
Osaka, Japan: Utility Company
Hong Kong: Utility Company

New York, USA: Radio Station, Empire State Building


Monster.com Data Center
• 6 - Cat UPS 900’s

• Drop over
enclosure
• Protects One Call
server farm
• Purchased 2
additional 900kVA

Shanghai, China: Office Facilities Back-Up

Siemens Call Center
• Custom Containerised Package

• Service Center for Siemens
Medical
• UPS / Transfer Switch / HVAC /
Gen Set / Container Included
• Standard Pre-engineered
Packages Available

VA Medical Center
• Dallas, TX
• UPS 300
• Protecting multiple MRI
systems from voltage
swings and outages
• Severe step load on UPS
• High harmonic load
Agenda
UPS

The Flywheel UPS Family
• Modular Scalable Flexible

• Field Upgradable Grows With Your Needs
• Paralleling Capability for Multi-Megawatt Solutions
1200 kVA
900 kVA
600 kVA
300 kVA
77
The Flywheel UPS Product Family
• Cat UPS 300
– Single Module System (SMS)
• Cat UPS “G” Series

– Multi Module System
• max. 3 flywheels
– Expandable up to 600 kVA per MMS
• Parallel up to 7 UPS systems
– Up to 4,200 kVA in a parallel configuration
• Cat UPS “Z” Series

– Multi Module System
• max. 4 flywheels
– Expandable up to 1200 kVA per MMS
• Parallel up to 7 UPS systems
– Up to 8,400 kVA in a parallel configuration
Z-Series Multi-Module System: 415V / 50Hz

CAT Series 750

Series CAT 750
• 750kVA / 675kW @ 60Hz / 480V
• 625kVA / 625kW @ 50Hz / 400V
• Paralleling support for multi-

megawatt solutions 7 systems in a
Distributed Bypass format
81
2 Sizes of Flywheels – 240kW & 675kW
275kg rotor 770kg rotor

590kg assembly 1905kg assembly
10cm tall 32cm tall
64cm diameter 64cm diameter
7700 RPM 7700 RPM
82
Integrated Solutions - Critical Power Module

What is Critical Power Module?

• Containerised Power Solution
• Includes:-
- Diesel Gen-set
- Flywheel UPS
- ATS

Product Design – Key Features
Cat® Diesel Genset
Automatic Transfer Switch
Cat® Flywheel UPS
ISO Container

Product Design
CPM Typical Single Line Diagram

Integrated Solutions - Critical Power Module

Summary - Benefits
With the Flywheel UPS = No Down Time
1. No more loss of production

• Productivity increased
• Profitability ensured
2. No more wastage of raw material
• Reduced wastage
• Reduced unnecessary cost
3. No more Loss of Man-hours
• No time loss on re-start of processes
4. Equipment protected from Power Issues
• Equipment preserved
• Reduced unnecessary breakdown & maintenance
Discussion
Ricky Goh
Sales Representative for
CAT Electric Power Solutions
TRANSFORMED BY 6 SIGMA Goh_ricky@cat.com Page 91 | CATERPILLAR: CONFIDENTIAL GREEN
Flywheel UPS Reliability
Gen Start Module (GSM) Flywheel
• High Reliability
• Battery Optional AC
• Low Maintenance Voltage In
• Constant current
• Typical Power Draw from UPS is 32A DC Voltage
Out
<8secs Engine
• Provides 1760 Cranking Amps at 24 VDC DC Voltage
Starter
to Genset Starting Motors In
• Increases Engine availability to 99.967%

Gen Set
Batteries

Systems Operations with UPS + GSM
Auto Non-Critical
Transfer Load
Utility Switch
PLN
Cat Flywheel UPS
Start Critical
Cat Signal Load
Gen-Set
Redundant 24 VDC
Starting Power
Operator Interface - Main Panel

Operator Interface - Login/Security

UPS View - Monitoring Display

UPS View - Monitoring Display

Applying Flywheel UPS in Power System

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One powerful future.

Applying Flywheel UPS to improve

Integrated Solutions Provider

TRANSFORMED BY 6 SIGMA Page 2 | CATERPILLAR: CONFIDENTIAL GREEN

TRANSFORMED BY 6 SIGMA Page 3 | CATERPILLAR: CONFIDENTIAL GREEN

UPS = Uninterruptible Power Supply

TRANSFORMED BY 6 SIGMA Page 4 | CATERPILLAR: CONFIDENTIAL GREEN

Why Need UPS?

1. No more loss of production

Typical Systems Operations with UPS

Cat Flywheel UPS

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• Material: 4340 Steel • Diameter: 648 mm (25.5”)

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• ~98% AC-to-AC efficiency

Load Transfer during Power Failure

Power continuity provided by the Flywheel

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Power Conditioning – Voltage Regulation

RMS Voltage sampled

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• UPS controls measure load current harmonics using

• Inverter is controlled to supply harmonic currents while

• Load harmonics don’t appear on the input

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Power Factor Improvement

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Fast Transient Protection: Voltage Window

Incoming Voltage Adjustable Instantaneous

1000% for 10 msec

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• Eliminate Block Loading

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•Foot Print (m²)

250kVA/225 kW Battery-Based UPS 250kVA/225 kW Flywheel UPS

3.7 Sq m (minimal battery) 1.3 Sq. m

7.43 Sq. m. w/ service clearance 2.69 Sq. m w/ service clearance

Financial Return from Flywheel UPS

Potential of lower Capex

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250kVA/225 kW Battery-Based UPS 250kVA/225 kW Flywheel UPS

25 Degrees C Optimal Up to 40 Degrees C

Financial Return from Flywheel UPS

No heavy cooling required - lower utility bill

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» 2 - 4 PM’s / Year » 1 PM / Year

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Financial Return from Flywheel UPS

Lower maintenance and eliminated replacement costs

TRANSFORMED BY 6 SIGMA Page 42 | CATERPILLAR: CONFIDENTIAL GREEN

250kVA/225 kW Battery-Based UPS 250kVA/225 kW Flywheel UPS

~90-94% Efficient 97 - 98% Efficient

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Poorly designed systems can cause a “chain reaction” on efficiency

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Traditional Double Conversion UPS:

CAT Flywheel UPS: