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GE Industrial Solutions

ES Group / UPS Solutions

GE Flywheel UPS
Flywheel Energy

Using…

An Integrated Solution
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

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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 PLC, Robotics, Short Term Power Quality
Critical Control Improvement; Prevention of
Process Systems Process Downtime
Healthcare Imaging Short Term Power Quality
Equipment Improvement; Prevention of
Ruined Scans
Casinos Operations Continuous Operations for
Support Security and IT Subsystems
during short term power issues
Broadcast Digital Continuous Broadcast TV
Transmitters Operations during short term
power issues

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

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% Parallel Up To 6 Flywheels
 Unity Output Power Factor per UPS Module
 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

Series SG MidPower UPS


 50-300kva Modules, 480/277VAC, UL, 60Hz
* TLE MidPower 60Hz available 2017  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

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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
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Inside the GE Flywheel Assembly

Redundant Fans
IGBT Bi-Directional Converter

Magnetic Levitation Control


Flywheel Module
Module (MBC)

Redundant Power Supplies


DC Breaker

Flywheel Controller Module

Vacuum Pump

Top or Bottom Cable Entry

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Next Generation Flywheel Module Design

Mechanical Battery – stores energy by


spinning a mass, producing high power
output

Rotor Dual Mode Motor Generator – converts


kinetic into electricity with fast recharge
Permanent Magnet
capability

Housing Stator Five-Axis Active Magnetic Levitation –


Dual Mode
Vacuum environment Motor/Generator eliminates any bearing maintenance, no
friction losses.
Hub High Power Density / 300kW
4340 Aerospace steel
Scalable to 6 Units on a UPS

Magnetic 99.4% Efficient


36,750 RPM High Speed
Bearings 20 Year Life / Low Maintenance
Fully active 5-Axis

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

DC Monitoring Motor Generator Controls Magnetic Levitation


Controller
Power Conversion Module Controller

User GUI Page 10


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

Will ride-thru short term power issues such as:


 Sags
 Surges
 Spikes
 Brownouts
 Switching Transients

GE UPS System

Utility Rectifier Inverter Critical

AC AC/DC DC/AC AC Output

DC
AC
Time Line - Utility Outage to Alternate Source Pickup
Utility Outage

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


Flywheel Support Time

GE Flywheel

* Note: Batteries could take 100+ min Page 11


to recharge, to 95% capacity RP
Flywheel UPS for Continuous Power Application
Standby GenSet picks up load before Flywheel runtime depleted

For typical applications where


Standby GenSet(s) come online in
Genset Start Signal
10 seconds or less.
GenSet
AC GE UPS System

Automatic Rectifier Inverter Critical

Transfer Switch AC/DC DC/AC AC Output

Utility
AC DC
AC
Time Line - Utility Outage to Alternate Source Pickup
Utility Outage

20-50sec Flywheel Support Time

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

GE Flywheel

* Note: Batteries could take 100+ min Page 12


to recharge, to 95% capacity RP
Flywheel UPS for Battery Life Extension Application
Flywheel extends life of UPS Batteries

Genset
AC GE UPS System

Automatic Rectifier Inverter Critical


Transfer Switch AC/DC DC/AC AC Output

Utility DC Paralleling Cabinet


AC

 Flywheel absorbs short duration


disturbances, reducing battery cycles
thus increasing battery life

 Flywheel provides voltage support


eliminating whiplash and Coup de Fouet
drop in UPS DC Bus voltage
RP

GE Flywheel VRLA Batteries Page 13


Parallel Flywheel Operation

Genset
AC GE UPS System

Automatic Rectifier Inverter Critical


Transfer Switch AC/DC DC/AC AC Output

Utility DC Paralleling Cabinet


(see next slide)
AC 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 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

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GE Flywheel UPS – Why Select GE?

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
RP Page 16
Flywheel vs Battery
Comparisons

Page 17
Flywheel vs VRLA Battery Comparison
VRLA &
GE Flywheel 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

OSHA RequirementsOS
Requirements None
None Required Often
Frequent / Quarterly Reports

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Flywheels vs Batteries – Size, Hazards
Wet Cell Batteries VRLA Batteries
Example: 1200kW Example: 300kW

Wet Cell
Batteries

Flywheels

VRLA
Flywheel
Batteries

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Carbon Footprint / Sustainability
Utilizing Flywheel energy storage systems reduces the carbon footprint as compared to a
5 minute Battery Plant by an astounding 95%.

1000KW UPS Comparison 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

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

Which is more sustainable


for our planet?

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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
Batteries for 500kva UPS (4 strings)

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

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

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
Batteries for 500kva UPS (4 strings)

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

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

Page 23
Flywheel
Runtime Charts

Page 24
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

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


GE UPS
50kva* 80kva* 100kva* 120kva* 150kva* 225kva 250kva 400kva 500kva 750kva 1000kva
Models
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 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

Standard 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 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
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SG Flywheel UPS – 60Hz 480VAC
Enhanced Flywheel Backup Time: SG UPS, 480V 60Hz
GE 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

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


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

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

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 50Hz


GE UPS
60kva 80kva 100kva 120kva 160kva 200kva 250kva 300kva 400kva 500kva 600kva
Models
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
Page 28
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.

Page 30
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

GE Double Conversion UPS Line Interactive UPS GE Double Conversion Benefit


Dbl Conv Mode Eff up to 97% Line Interactive Eff up to 97% GE Flexibility in Operating Modes maximizes
Eco Mode Eff up to 99% operating efficiency

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

Page 32
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.

Page 33
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. No Maintenance Costs ; No Downtime
8hr downtime during bearing changeout.
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