GEIndustrial Solutions ES Group / UPS Solutions GE …apps.geindustrial.com/publibrary/checkout/Flywheel-UP... · GEIndustrial Solutions ES Group / UPS Solutions ... Short Term Power

GE Flywheel UPS

GE Industrial SolutionsES Group / UPS Solutions

An Integrated Solution

Using…

Flywheel Energy

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� 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

Key Drivers that Makes GE Flywheel UPS Attractive

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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 ImagingEquipment

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

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Flywheel UPS - Existing Customer Examples

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

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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

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

* TLE MidPower 60Hz available 2017

Series SG MidPower UPS� 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

Parallel Up To 6 Flywheels per UPS Module

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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

Flywheel Energy75” tall

(1905mm)

30” wide

(762mm)

30” deep

(762mm)

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Inside the GE Flywheel Assembly

Redundant Fans

Flywheel Module

DC Breaker

Vacuum Pump

Top or Bottom Cable Entry

IGBT Bi-Directional Converter

Magnetic Levitation Control Module (MBC)

Redundant Power Supplies

Flywheel Controller Module

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

RotorPermanent Magnet

StatorDual Mode Motor/Generator

Hub4340 Aerospace steel

Magnetic BearingsFully active 5-Axis

HousingVacuum environment

Next Generation Flywheel Module Design

Sample Screens of Touch Screen Color GUI

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Flywheel - Simplified Power/Control Diagram

To UPS ModuleDC Input

IGBT Power Converter

Magnetic LevitationController

Soft Start

DC Monitoring Motor Generator Controls

Power Conversion Module Controller

User GUI

3PhaseAC

DC AC

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GE UPS System

Flywheel UPS for Power Anomaly Application Power Protection for short term power problems

Rectifier

AC/DC

Inverter

DC/AC

Utility

AC

Critical

AC Output

GE Flywheel

2 sec. 6 sec. 2 sec. 2 to 15 min.

Utility Outage

Time Line - Utility Outage to Alternate Source Pickup

DCAC

Flywheel Support Time

* Note: Batteries could take 100+ minto recharge, to 95% capacity RP

Will ride-thru short term power issues such as:� Sags� Surges� Spikes� Brownouts� Switching Transients

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GE UPS System

Flywheel UPS for Continuous Power Application Standby GenSet picks up load before Flywheel runtime depleted

Rectifier

AC/DC

Inverter

DC/AC

Utility

AC

Critical

AC Output

Automatic

Transfer Switch

GE Flywheel

Genset Start Signal

2 sec. 6 sec. 2 sec. 2 to 15 min.

Utility Outage

Time Line - Utility Outage to Alternate Source Pickup

DCAC

GenSet

AC

20-50sec Flywheel Support Time

For typical applications where Standby GenSet(s) come online in 10 seconds or less.

* Note: Batteries could take 100+ minto recharge, to 95% capacity RP

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GE UPS System

Rectifier

AC/DC

Genset

AC

Inverter

DC/AC

Utility

AC

Critical

AC Output

Automatic

Transfer Switch

GE Flywheel

Flywheel UPS for Battery Life Extension Application Flywheel extends life of UPS Batteries

� Flywheel absorbs short duration disturbances, reducing battery cycles thus increasing battery life

� Flywheel provides voltage support eliminating whiplash and Coup de Fouetdrop in UPS DC Bus voltage

DC Paralleling Cabinet

VRLA Batteries

RP

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GE UPS System

Rectifier

AC/DC

Genset

AC

Inverter

DC/AC

Utility

AC

Critical

AC Output

Automatic

Transfer Switch

GE Flywheels

Parallel Flywheel Operation

� Parallel for either higher capacity (power), run time or redundancy

� No communication required for paralleling due to “droop” sharing methodology


(see next slide)

Flywheel Energy Flywheel Energy Flywheel Energy

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� 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

ToFlywheels

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GE Flywheel UPS – Why Select GE?

RP

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

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Flywheel vs BatteryComparisons

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Flywheel vs VRLA Battery Comparison

Maintenance

HVAC Costs

Availability (MTBF)

Life Expectation

Max Operating Temperature

Installation Cost

Hazardous Materials

Toxic & Explosive Gas Emissions

Footprint

Diagnostics / Monitoring

Disposal Requirements

OSHA RequirementsOS

Minimal / Annual

None

>50,000 hrs (see next slide)

20 yrs

104 degr F, 40 degr C

Low

None

None

Small

Accurate

None

None

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

Large (V) ; Medium (L-I)

Speculative (V) ; Required (L-I)

Yes

Required Often

GE FlywheelVRLA &Lithium IonBattery

OSHA Requirements None Frequent / Quarterly Reports

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Flywheels vs Batteries – Size, Hazards

Wet Cell Batteries

Flywheels

FlywheelVRLA

Batteries

Wet Cell BatteriesExample: 1200kW

VRLA BatteriesExample: 300kW

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Carbon Footprint / Sustainability

Which is more sustainable

for our planet?

10,000lbs of Lead / Acid 200lbs of Steel

VRLA Battery Plant GE Flywheel

Embedded Carbon Emissions (CO 2 / kg) 1.14 2.70

Energy Storage for 1MW UPS 6 Cabinets/Strings 4x300kw Flywheels

Total Energy Storage Weight (kg) 14,693 1,297

Total Embedded Carbon (kg CO2) 16,750 4,810

15 Year Energy Storage Replacement 3 Times 0 Times

Total 15 Year Lifecycle Embedded Carbon (kg CO2) 67,000 4,810

Utilizing Flywheel energy storage systems reduces the carbon footprint as compared to a

5 minute Battery Plant by an astounding 95%.

1000KW UPS Comparison

$0 $50 $100 $150 $200 $250 $300 $350 $400

Batteries for 500kva UPS

Flywheel for 500kva UPS





15Yr TOC ($K)

Capex Install Yrs 1-4 Maint Yr 5 Repl Yrs 5-9 Maint Yr 10 Repl Yrs 10-14 Maint Yr 15 Repl

15 Year TCO…. Flywheel vs VRLA Batteries

$95K (1 flywheel)

$115K (1 string)

$95K (1 flywheel)

$180K (2 strings)

$190K (2 flywheels)

$380K(4 strings)

Assumptions:1. Annual Maintenance: 1 PM/Yr Flywheel , 2 PM/Yr Batteries2. Runtime: Flywheel 15-30sec support, Battery System, 8-12min support3. Battery Replacements include jars, installation, disposal costs4. Flywheel extra energy costs offset by Battery higher cooling costs

$0 $50 $100 $150 $200 $250 $300 $350 $400 $450







15Yr TOC ($K)

Capex Install Yrs 1-4 Maint Yr 5 Repl Yrs 5-9 Maint Yr 10 Repl Yrs 10-14 Maint Yr 15 Repl

15 Year TCO…. Flywheel vs Lithium Ion Batteries

$95K (1 flywheel)

$139K (1 string)

$95K (1 flywheel)

$205K (2 strings)

$190K (2 flywheels)

$440K(4 strings)

Assumptions:1. Annual Maintenance: 1 PM/Yr Flywheel , 2 PM/Yr Batteries2. Runtime: Flywheel 15-30sec support, Battery System, 8-12min support3. Battery Replacements include jars, installation, disposal costs4. Flywheel extra energy costs offset by Battery higher cooling costs5. Lithium Ion Batteries at 2X VRLA Battery cost

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Flywheel MTBF

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FlywheelRuntime Charts

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TLE Flywheel UPS – 60Hz 480VAC

Enhanced Flywheel Backup Time: TLE UPS, 480V 60HzGE UPS

Models50kva* 80kva* 100kva* 120kva* 150kva* 225kva 250kva 400kva 500kva 750kva 1000kva

UPS kW 50 80 100 120 150 225 250 400 500 750 1000# of

Flywheels ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓

1 113 72 57 45 33 19 16

2 140 111 92 75 48 43 22 15

3 75 68 40 28 15

4 87 55 42 24 15

5 69 55 33 22

6 42 28

* Denoted TLE kva module ratings available in 2017

Standard Flywheel Backup Time: TLE UPS, 480V 60Hz

GE UPS

Models50kva* 80kva* 100kva* 120kva* 150kva* 225kva 250kva 400kva 500kva 750kva 1000kva

kW 50 80 100 120 150 225 250 400 500 750 1000

# of

Flywheels ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓

1 71 44 35 29 22 15 12

2 87 70 58 46 32 28 16 12

3 48 43 26 21 12

4 58 35 28 18 12

5 45 35 23 16

6 28 20

* Denoted TLE kva module ratings available in 2017

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TLE Flywheel UPS – 50Hz 400VAC

Standard Flywheel Backup Time: TLE UPS, 400V 50HzGE UPS

Models60kva 80kva 100kva 120kva 160kva 200kva 320kva 400kva 600kva 800kva

kW 60 80 100 120 160 200 320 400 600 800

# of

Flywheels ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓

1 59 44 35 29 23 17

2 87 70 58 46 36 22 16

3 69 55 33 26 16

4 45 35 23 16

5 45 29 21

6 35 26

Enhanced Flywheel Backup Time: TLE UPS, 400V 50HzGE UPS

Models60kva 80kva 100kva 120kva 160kva 200kva 320kva 400kva 600kva 800kva

kW 60 80 100 120 160 200 320 400 600 800

# of

Flywheels ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓

1 94 72 57 45 32 23

2 140 111 92 71 56 31 22

3 103 83 51 40 22

4 69 55 33 22

5 69 45 30

6 55 39

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SG Flywheel UPS – 60Hz 480VAC

Enhanced Flywheel Backup Time: SG UPS, 480V 60HzGE UPS

Models 50kva 80kva 100kva 120kva 150kva 225kva 300kva

kW 40 64 80 96 120 202 270

# of

Flywheels ↓ ↓ ↓ ↓ ↓ ↓ ↓

1 142 88 71 59 45 22

2 174 139 115 91 54 39

3 81 62

4 80

5

6

Standard Flywheel Backup Time: SG UPS, 480V 60HzGE UPS

Models50kva 80kva 100kva 120kva 150kva 225kva 300kva

kW 40 64 80 96 120 202 270

# of

Flywheels ↓ ↓ ↓ ↓ ↓ ↓ ↓

1 94 58 46 38 30 16

2 115 92 76 60 35 26

3 53 40

4 53

5

6

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SG Flywheel UPS – 50Hz 400VAC

Enhanced Flywheel Backup Time: SG UPS, 400V 50HzGE UPS

Models60kva 80kva 100kva 120kva 160kva 200kva 250kva 300kva 400kva 500kva 600kva

kW 54 72 90 108 128 180 225 270 360 450 540

# of

Flywheels ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓

1 103 79 63 51 35 25 17

2 155 123 101 77 62 48 38 24 17

3 114 91 74 62 44 32 24

4 96 80 61 47 37

5 76 61 49

6 61

Standard Flywheel Backup Time: SG UPS, 400V 50HzGE UPS

Models60kva 80kva 100kva 120kva 160kva 200kva 250kva 300kva 400kva 500kva 600kva

kW 54 72 90 108 128 160 225 270 360 450 540

# of

Flywheels ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓

1 65 48 37 32 23 18 14

2 97 77 64 48 38 30 24 18 13

3 72 57 45 37 27 21 17

4 60 50 37 29 24

5 47 37 30

6 37

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End of Presentation

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External GE Flywheel vs

Integrated FlywheelComparisons

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.

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Flywheel UPS Design Comparison – Power Protection

Line Interactive UPS w/Integrated FlywheelGE Double Conversion UPS w/External Flywheel

Minimal PowerQuality Support

Maximum PowerQuality Support

Extra Protection

Page 32

Flywheel UPS Design Comparison - Technology


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 & LoadExample: 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

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Flywheel UPS Design Comparison – Key Benefits


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.

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Flywheel UPS Design Comparison – Internal 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

AC Flywheel

DC Flywheel

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GEIndustrial Solutions ES Group / UPS Solutions GE …apps.geindustrial.com/publibrary/checkout/Flywheel-UP... · GEIndustrial Solutions ES Group / UPS Solutions ... Short Term Power