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GE Flywheel UPS
Flywheel Energy
Using…
An Integrated Solution
Key Drivers that Makes GE Flywheel UPS Attractive
Page 2
Flywheel UPS - Numerous Great Fit Applications
Page 3
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
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GE Flywheel Module Overview
Max Power Rating:
• 300kW 75” tall Flywheel Energy
(1905mm)
Max Energy Storage Rating:
• Standard Flywheel: 4000kW secs 30” wide
• Enhanced Flywheel: 6000kW secs (762mm)
Rotational Speed:
30” deep
• Standard Flywheel: 24,500-36,750 RPM (762mm)
• 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
Page 6
Inside the GE Flywheel Assembly
Redundant Fans
IGBT Bi-Directional Converter
Vacuum Pump
Page 7
Next Generation Flywheel Module Design
Air Cooled
Sample Screens of Touch Screen Color GUI
Flywheel - Simplified Power/Control Diagram
DC AC
IGBT Power Converter
Soft Start
3Phase
To UPS AC
Module
DC Input
GE UPS System
DC
AC
Time Line - Utility Outage to Alternate Source Pickup
Utility Outage
GE Flywheel
Utility
AC DC
AC
Time Line - Utility Outage to Alternate Source Pickup
Utility Outage
GE Flywheel
Genset
AC GE UPS System
Genset
AC GE UPS System
GE Flywheels Page 14
DC Paralleling Cabinet
Suggested when paralleling 3 or more flywheels To UPS Module
DC Cable Landing Area
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 15
GE Flywheel UPS – Why Select GE?
NOTE: GE UPS Module Warranty is valid for use with Vycon Flywheels only
RP Page 16
Flywheel vs Battery
Comparisons
Page 17
Flywheel vs VRLA Battery Comparison
VRLA &
GE Flywheel Lithium Ion
Battery
OSHA RequirementsOS
Requirements None
None Required Often
Frequent / Quarterly Reports
Page 18
Flywheels vs Batteries – Size, Hazards
Wet Cell Batteries VRLA Batteries
Example: 1200kW Example: 300kW
Wet Cell
Batteries
Flywheels
VRLA
Flywheel
Batteries
Page 19
Carbon Footprint / Sustainability
Utilizing Flywheel energy storage systems reduces the carbon footprint as compared to a
5 minute Battery Plant by an astounding 95%.
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15 Year TCO…. Flywheel vs VRLA Batteries
$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
Batteries for 500kva UPS (4 strings)
Capex Install Yrs 1-4 Maint Yr 5 Repl Yrs 5-9 Maint Yr 10 Repl Yrs 10-14 Maint Yr 15 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
15 Year TCO…. Flywheel vs Lithium Ion Batteries
$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
Batteries for 500kva UPS (4 strings)
Capex Install Yrs 1-4 Maint Yr 5 Repl Yrs 5-9 Maint Yr 10 Repl Yrs 10-14 Maint Yr 15 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
Flywheel MTBF
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Flywheel
Runtime Charts
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TLE Flywheel UPS – 60Hz 480VAC
Enhanced Flywheel Backup Time: TLE UPS, 480V 60Hz
GE UPS
50kva* 80kva* 100kva* 120kva* 150kva* 225kva 250kva 400kva 500kva 750kva 1000kva
Models
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
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 Page 25
TLE Flywheel UPS – 50Hz 400VAC
Enhanced Flywheel Backup Time: TLE UPS, 400V 50Hz
GE UPS
60kva 80kva 100kva 120kva 160kva 200kva 320kva 400kva 600kva 800kva
Models
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
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
Page 26
SG Flywheel UPS – 60Hz 480VAC
Enhanced Flywheel Backup Time: SG UPS, 480V 60Hz
GE UPS
Models 50kva 80kva 100kva 120kva 150kva 225kva 300kva
3 81 62
4 80
2 115 92 76 60 35 26
3 53 40
4 53
6
Page 27
SG Flywheel UPS – 50Hz 400VAC
Enhanced Flywheel Backup Time: SG UPS, 400V 50Hz
GE UPS
60kva 80kva 100kva 120kva 160kva 200kva 250kva 300kva 400kva 500kva 600kva
Models
kW 54 72 90 108 128 180 225 270 360 450 540
# of
Flywheels ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
1 103 79 63 51 35 25 17
3 114 91 74 62 44 32 24
4 96 80 61 47 37
5 76 61 49
6 61
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
Page 29
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.
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Flywheel UPS Design Comparison – Power Protection
GE Double Conversion UPS w/External Flywheel Line Interactive UPS w/Integrated Flywheel
Maximum Minimal
Power Power
Quality Quality
Support Support
Extra
Protection
Page 31
Flywheel UPS Design Comparison - Technology
GE Double Conversion UPS w/External Flywheel Line Interactive UPS w/Integrated Flywheel
High Input Power Factor, 0.98-0.99 Input Power Factor dependent on Input Voltage & Load Constant High Input Power Factor to
Example: 400VAC/0.90pf Load = 0.99pf Input maximize sizing of Input Feeder
430VAC/0.90pf Load = 0.70pf Input
Insensitive to frequency drift by the Issues with frequency drift of generator. Frequency kept at 60HZ. Does not require FW
standby generator. Frequency held Will deplete Flywheel energy if outside preset limits energy to operate when outside preset limits
at 60HZ
Wide Input Voltage Range before Narrow Input Voltage Range (+10, -15%) before Less reliance on Flywheel /Batteries so
switching to DC Energy support switching to DC Energy support component life is extended
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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 Must take down entire UPS System More Maintenance Flexibility
affecting overall UPS operation
No downtime for Flywheel Preventative Maintenance Must use Utility Bypass for Flywheel Zero downtime for PMs No need to go to
Maintenance Bypass.
Add Flywheels for capacity or redundancy at any Must add entire UPS module to get System Cost and Footprint savings
time additional runtime, as Flywheels are
integral
Operate Flywheel in parallel with Batteries for Cannot add batteries Battery Hardening prolongs battery life;
system hardening and extended support time Redundant DC energy storage.
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Flywheel UPS Design Comparison – Internal Flywheel
GE Double Conversion UPS w/External Flywheel Line Interactive UPS w/Integrated Flywheel
AC Flywheel
DC 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. No Maintenance Costs ; No Downtime
8hr downtime during bearing changeout.
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