clean energy storage technology advances in
TRANSCRIPT
Clean Energy Storage Technology
Advances in high efficiency energy storage for UPS applications
Advances in high efficiency energy storage for UPS applications
By Johnny GonzalesVice President of Sales & ServicePentadyne Power Corp
The Weakest LinkThe Weakest Link
Traditional Power Quality Configuration
Utility feed
Protectedload
Back-upgenset
ATS
UPS
Batteries
VRLA Batteries
Pros • Proven performance
• Excellent dynamic response
• 5 minutes to >1 hr run time
• Acceptable reliability vs cost
Cons• 2 - 4 year replacement intervals
• Rising costs, longer lead times
• Unpredictable performance
• Temperature and cycling issues
• Health and safety issues
• Environmental impact
Wet Cell Batteries
Pros • Proven performance
• Excellent dynamic response
• 5 minutes to hours of run time
• Higher reliability than VRLA
Cons• Expensive, plus high installation costs
• Rising costs, longer lead times
• Frequent maintenance requirements
• Large footprint, floor loading issues
• Temperature and cycling issues
• Health and safety issues, environmental impact
“Batteries are the primary field failureproblem with UPS
systems” - EPRI
“Lead is ranked 2nd in US for all hazardous
materials and requires proper disposal” - EPA
“Batteries require constant maintenance& have a finite number
of discharges” - EPRI
Narrow
Yes
Yes
Yes
Yes
Environment&
Safety
Operating temp. range Hazardous materials Toxic, explosive gas emissionsDisposal requirementsVentilation requirements
Lifecycle Cost
High
Medium to Large
High
Unpredictable
Low
High
Installation costFootprintMaintenanceLife expectancy Standby costAir conditioning costs
Slow
Speculative
Unpredictable
Low ~2,000 hrs
Reliability
RechargeDiagnostics & monitoringState of charge/backup timeMTBF
Batteries Are the Weakest Link
Unreliable & Dangerous
• UPS lead-acid batteries swell, split, leak acid and emit lead and sulfuric acid vapors
• Also emit explosive gases
Pressure buildup can result in battery
housing explosions
Swelling and splitting creates acid spills and
releases flammable gases
Explosive battery gas emissions literally blew the roof off of this building
Even Happened to Us
Second battery was too swollen to pull out of the case
Swelling reached limit; began to rapidly emit sulfuric acid fumes and
explosive gas
• After 4 yrs, a 0.2 kVA UPS in IT failed
• Sulfuric acid fumes filled the IT office
• UPS diagnostics had reported no faultsor discharges for the 12 months prior
Leading Causes of Dropped Loads
Leading cause of failure: batteries• Corrosion, normal aging process
• Drying out: the most common cause
• Premature failure• Use/# of discharges• Improper voltage charge• Temperature >75°F• Excess charge current• Stained battery terminals
Circuit breaker
UPS component
Logic board
Utility/generator
Other external
Human error
Batteries
Other (<2% each)
Today’s Power Quality Configuration
Utility feed
Protectedload
Optionalbatteries
Back-upgenset
ATS
UPS
Flywheel
Genset Start Reliability
• IEEE Gold Book (Std 493) Appendix L, Table XII:
• Compiled 6 large studies of genset starting characteristics
• Encompassing 25,000 emergency gensets
• Including critical and non-critical sites
• Critical gensets (e.g. at hospitals) are routinely maintained and are load tested every month
• Non-critical gensets are rarely tested or maintained, if ever
• 99.5% start on first attempt
• First attempt start certainty of critically maintained gensets at hospitals, etc. would predictably have much higher dependability
EPRI Utility Power Quality Study
99%of all voltage
sags and outages last less than
10 seconds
• Very brief power interruptions are common, and cause early failure of lead-acid batteries
Flywheels
Pros • Compact footprint/high energy density• Excellent dynamic response• Low maintenance• No HVAC needs• Long design life: 20 years• Much lower own & operate costs
Cons• Short runtime (seconds vs. minutes)• “New” technology• Higher initial cost than VRLAs
Major Flywheel System Benefits
ToCriticalLoad
Static UPS
DC
AC DC
ACFromUtilityGrid
ATS
ToCriticalLoad
Static UPS
DC
AC DC
ACFromUtilityGrid
ATS
Flywheel alone• Transition power to genset• Eliminates batteries• Increases reliability• Significantly reduces lifecycle costs• Eliminates health & safety issues• Eliminates environmental issues
Battery parallel• Transition power to genset• Redundant energy storage• Increases battery life• Enables battery reduction
99% of disturbances< 10 sec. --EPRI
10
Coup de fouet = Whiplash
Float Voltage
Grid Disturbance
0 20
Time (Seconds)
Battery “Whiplash” Prevented
• Flywheel provides voltage support, eliminating battery whiplash
• Increasing battery life and availability
• Improving total system reliability
• Reducing service
w/flywheel
Gen
UP
S D
C B
us V
olt
ag
e
Working in Parallel with BatteriesV
olt
ag
e &
Cu
rre
nt
Po
we
r
UPS, Flywheel & Battery
Time (seconds)
Flywheel Technology Evolution
• Heavy (800 lbs)
• Large wheel
• Mechanical bearings
• Minor service every 6 months, major service every 2-3 years
• High standby power consumption (3,500W)
• Light (50 lbs)
• Compact cylinder
• Full magnetic levitation
• Inspection every year, moderate service every 6 yrs
• Very low standby power consumption (300W)
Flywheel Technology Evolution
• “Low-speed” 7,200 rpm
• More mass means more energy
• Double mass = energy doubled
KE ~ m (rpm)²
• “High-speed” 52,000 rpm
• More speed means more energy
• Double rpm = energy quadrupled
SteelCarbonFiber
Every year
Every 2-3 yrs ($4K)
Every year
Every 3-4 yrs ($2K)
None
Never
None
Never
-20 to 50°C
5.7 sq ft
1,300 lbs
<45 dBA
None
Yes
1-2 hours
-20 to 40°C
10 sq ft
3,800 lbs
<72 dBA
Needs Concrete Pad
No
1-2 days
Operation
Maintenance
EnvironmentalRequirements
SteelCarbon fiber
190 kWb
350–850 Vdc
Symmetrical
300W
250 kWb
400–600 Vdc
Battery-like
3000W
Bearing maintenanceBearing replacementVacuum pump maintenanceVacuum pump replacement
Operating temp. range
FootprintWeightSound level at 1 meterFloor preparationCabinet with castersInstallation & startup time
Maximum output powerVoltage rangeRecharge vs. dischargeStandby losses
Flywheels: Carbon Fiber vs. Steel
Pentadyne Technology Highlights
Flywheel module Rotating group
One Line
Te
mp
era
ture
Se
ns
ors
Po
sit
ion
Se
ns
ors
To UPSBattery Input
AC
Au
x
Ba
ck
up
CO
M
IGBT Power Converter
Remote Monitoring
& Controls
(Optional)
Se
ns
ors
Sp
ee
d
Flywheel Module
Soft Start
DC Monitoring Motor Generator Controls
Power Conversion Module Controller
Magnetic LevitationModule
Flywheel Module Components
Lower Radial Electromagnet
Synchronous Reluctance
4 pole M-G Rotor
Carbon FiberComposite Flywheel
Lower VacuumChamber
Upper VacuumChamber
2” Thick Steel Housing
Molecular Vacuum Sleeve
Motor-Generator Stator
Axial Electromagnet
Upper Radial Electromagnet
Technical Details – Vacuum Sleeve
• Factory-sealed high vacuum
• Patented vacuum sleeve an integral part of the shaft
• Helical grooves draw molecules out of high-vacuum chamber
• No maintenance
• Never needs replacement
NO VACUUM PUMP
Flywheel Cabinet Layout
LCD Control Panel
Power Conversion
Module
Magnetic Levitation Module
Flywheel Module
Flywheel Disconnect
Air Filter (optional)
Casters
Motor-Generator Filter Assembly
Versatile Interface Board
Data Collection Module (optional)
Product Specifications
Parameter Specification
Power Level Up to 190 kW
System configuration Single or unlimited parallel
DC voltage range 350 to 850* Vdc
Standby losses 300 W (same as battery float)
Dimensions (footprint) 25” x 33” x 71” (5.7 sq ft)
Weight 1300 lbs
Sound level <45 dBA @ 1 meter
Operating temperature -4°F (-20°C) to 122°F (50°C)
Seismic certification Zone 4
Mobility Casters
Serviceability Requires only front access
Certification UL & CE
* UL certification requirements have an upper limit of 600 Vdc
End-User Benefits
• <50 kW to several MWs
• Single unit provides up to 190 kWb
• Eliminate or reduce lead-acid battery use
• High power density, lightweight, quiet
• Near-zero maintenance; highest availability
• Very low standby power consumption
• Programmable voltage
• Front serviceable
• Top or side cable entry
• User-friendly
• Rolls into place
• Installs on any floor
5-yearwarranty
5-yearwarranty
>1 Million Operating Hours
• A relatively new, but well-proven technology
• First commercial sales in ‘03
• Product sold by directly by Pentadyne & by some of the world’s leading UPS manu-facturers for more than four years now
• Installed fleet has surpassed 1M hours of operation
• Several early units are well in excess of 30,000 hours
• Per one of our earlier customers – Rick Shipley @ MasterBrand Cabinets – “It’s like a Timex: takes a lickin’ and just keeps on tickin.’”
NASA Service Tech Scott Marabito checks the runtime hours on their flywheel operating since 2004.
Slow
Speculative
Never
~2,000 hrs
Rapid
Accurate
Always
>50,000 hrs
Broad
None
None
None
None
Very narrow
Yes
Yes
Yes
Often
Lifecycle Cost
Reliability
Environment&
Safety
Flywheel vs. Batteries
Low
Small
Very infrequent
20 years
Low to high
None
High
Large to very large
Very frequent
2-4 years
Low
High
RechargeDiagnostics & monitoringKnown state of chargeAvailability interruption
Operating temperature range
Hazardous materials Toxic, explosive gas emissionsDisposal requirementsFire hazard permitting
Installation costFootprintMaintenanceLife expectation Standby costHVAC costs
Bringing It Into Perspective
Lifecycle Cost vs. VRLA Batteries
Flywheels cost 50% more than VRLA batteries, but eliminating battery maintenance and replacement saves more than $100,000/flywheel deployed
over the course of the flywheel’s 20-year design life.
• Application• Cath lab expansion• 500-kVA UPS requirement• Retrofit construction
Do You Have Space Issues?
Scripps Green Hospital – San Diego
• Solution• 500-kVA GE UPS and three flywheels• Fits tight space, eliminates HVAC needs• Eliminated batteries
• Issues• Many premature battery failures
due to very frequent step loading• 350 very brief discharges/week
• 300 sq. ft. UPS room for 150-kVA UPS with batteries• Batteries for 500-kVA UPS would take space away
from cath labs and add $70K in construction costs
Footprint Comparison
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• Floorspace needed by VRLA cabinets for a 300-kVA UPS is nearly double that of a similar capacity pair of flywheels (green). Compared to a one megawatt set of wet cells, the flywheel footprint is nearly 80% less (orange).
• Application• Co-location data center• 80-kVA UPS with expansion plans
NetAlliant Technologies - Chattanooga
• Issues• >100 outages (most brief)/yr• Experiencing battery failures
without warning• Some actually “blew-up”
• Footprint and maintenance considerations
Experienced Battery Failures?
• Solution• 80-kVA Liebert UPS and one flywheel• Fits tight space, eliminates HVAC needs• Eliminated batteries• Lightweight flywheel cabinet rolls into place and bolts on raised floor
• Application• TV broadcast studio and transmitter• UPS in “unconditioned” equipment room
WBRZ Broadcasting – Baton Rouge
• Issues• Equipment room temperature unregulated• Batteries were lasting less than 2 years• Frequent outages due to thunderstorms and
hurricanes
Cooling Constraints?
• Solution• 50-kVA Mitsubishi UPS and one flywheel• Fits tight, unconditioned space (no HVAC needs)• Installed in parallel with existing battery string, which will be phased out• Plans to use another UPS and flywheel at remote digital transmission site
• Application• Supercomputer expansion
DoD Data Center
• Issues• Availability and reliability paramount • Upper floor siting, floor loading issues• Additional space requirement and
floor loading issues would require additional construction cost
• Seeking alternative to wet cell battery plant and associated installation and maintenance costs
Floor Loading Issues?
• Solution• 4 x 625-kVA UPS systems with 20 flywheels• Footprint savings• Eliminates floor loading issues • Eliminates need for batteries• Planning larger flywheel installation next year
Sustainability Concerns?
• Which would you rather dispose of?
• A 20-year-life flywheelwithout hazardous or toxic materials….
Sustainability Benefits
• …or 20 years worth oflead-acid batteries?
During its 20-year design life, each
Pentadyne flywheel mitigates the
dumping of 15,000 pounds of lead
and hundreds of gallons of sulfuric
acid into the world’s ecosystem.
Lead acid batteries also emit
ozone-depleting gases,
contributing to global warming.
An accurate representation of the number of VRLA UPS batteries requiring disposal for the same energy capacity and life of a Pentadyne flywheel
Example – Data Center
• 450-kVA UPS• 3 flywheels (N+1)• Ride-through to genset• Drivers:
• Cut O&O costs• Power quality issues• Reliability• Eliminate batteries
Strataspace 570,000 sq ft Underground Data Center: Kentucky
Example – IT in Manufacturing
GlaxoSmithKline: North Carolina
• One 400-kVA UPS
• 3 flywheels (N+1), battery parallel
• Protecting data center loads
• Drivers:• Short battery life
• Reduce O&O costs
• Battery reliability issues
• Battery maintenance issues
• Space constraints
• Environmental impact
Example – Military
Missle Silos: Hundreds of Sites Nationwide
• VFD energy recycling
• ICBM modernization program
• High inrush power needs
• Poor utility conditions at remote sites
• Pentadyne exclusive supplier• >500 flywheel systems
• DX-A2 rated for national defense use
Award-Winning Technology
• Awards
• 2007 Buildings magazine: Editors’ Choice Top Product Pick
• 2007 EC&M magazine: Power Conditioning Product of the Year
• 2007 SearchDataCenter.com: “Back-up Product of the Year”
• 2006 World Economic Forum: “Technology Pioneer Award”
• 2006 Consulting-Specifying Engineer: “A Perfect 10”
• 2006 Frost & Sullivan: “Product Innovation Award”
• 2005 Frost & Sullivan: “Technology Innovation Award"
Pentadyne Power Corporation
• Company• Founded carbon flywheel technology in 1993
• High-speed flywheel systems that provide a highly reliable DC energy source for critical power and energy recycling applications
• Numerous product and design awards
• Based in Chatsworth, California (Los Angeles area)
• Investors• A venture capital funded company, Pentadyne has
raised $57M+ to date and over $42M has been invested in developing our flywheel technology
Ben Rosen
Distribution Channels
• Emerson Network Power / Liebert: The Americas
• Market segment: Data centers, financial/corporate IT
• Toshiba International Corporation: The Americas
• Market segment: Hospital, broadcast, industrial
• Socomec: EMEA & Asia
• Market segment: All
• EHWA Technologies: South Korea
• Market segment: Data centers, financial/corporate IT, military
• Pentadyne Direct: USA
• Market segment: Department of Defense, initial market seeding
pentadyne.com