Clean Energy Storage Technology

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Clean Energy Storage Technology
Advances in high efficiency energy storage for
UPS applications
By Johnny GonzalesVice President of Sales
ServicePentadyne Power Corp
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Traditional Power Quality Configuration
ATS
Protected load
UPS
Utility feed
Batteries
Back-up genset
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VRLA Batteries

• Pros
• Proven performance
• Excellent dynamic response
• 5 minutes to gt1 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

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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

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Batteries Are the Weakest Link
High Medium to Large High Unpredictable Low High

• Installation cost
• Footprint
• Maintenance
• Life expectancy
• Standby cost
• Air conditioning costs

Lifecycle Cost
Slow Speculative Unpredictable Low 2,000 hrs

• Recharge
• Diagnostics monitoring
• State of charge/backup time
• MTBF

Reliability
Narrow Yes Yes Yes Yes

• Operating temp. range
• Hazardous materials
• Toxic, explosive gas emissions
• Disposal requirements
• Ventilation requirements

EnvironmentSafety
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Unreliable Dangerous

• UPS lead-acid batteries swell, split, leak acid
  and emit lead and sulfuric acid vapors
• Also emit explosive gases

Explosive battery gas emissions literally blew
the roof off of this building
Swelling and splitting creates acid spills and
releases flammable gases
Pressure buildup can result in battery housing
explosions
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Even Happened to Us

• 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

Swelling reached limit began to rapidly emit
sulfuric acid fumes and explosive gas
Second battery was too swollen to pull out of the
case
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Leading Causes of Dropped Loads
Circuit breaker UPS component Logic
board Utility/generator Other external Human
error Batteries Other (lt2 each)

• Leading cause of failure batteries
• Corrosion, normal aging process
• Drying out the most common cause
• Premature failure
• Use/ of discharges
• Improper voltage charge
• Temperature gt75F
• Excess charge current
• Stained battery terminals

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Todays Power Quality Configuration
ATS
Protected load
UPS
Utility feed
Back-up genset
Flywheel
Optional batteries
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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

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EPRI Utility Power Quality Study

• Very brief power interruptions are common, and
  cause early failure of lead-acid batteries

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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

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Major Flywheel System Benefits

• 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

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Battery Whiplash Prevented
Float Voltage
Grid Disturbance
UPS DC Bus Voltage
Coup de fouet Whiplash
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0
Time (Seconds)

• Flywheel provides voltage support, eliminating
  battery whiplash
• Increasing battery life and availability
• Improving total system reliability
• Reducing service

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Working in Parallel with Batteries
UPS, Flywheel Battery
Voltage Current
Power
Time (seconds)
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Flywheel Technology Evolution
KE m (rpm)²

• High-speed 52,000 rpm
• More speed means more energy
• Double rpm energy quadrupled

• Low-speed 7,200 rpm
• More mass means more energy
• Double mass energy doubled

• Light (50 lbs)
• Compact cylinder
• Full magnetic levitation
• Inspection every year, moderate service every 6
  yrs
• Very low standby power consumption (300W)

• Heavy (800 lbs)
• Large wheel
• Mechanical bearings
• Minor service every 6 months, major service every
  2-3 years
• High standby power consumption (3,500W)

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Flywheels Carbon Fiber vs. Steel
Steel
Carbon fiber
250 kWb 400600 Vdc Battery-like 3000W
190 kWb 350850 Vdc Symmetrical 300W

• Maximum output power
• Voltage range
• Recharge vs. discharge
• Standby losses

Operation

• Bearing maintenance
• Bearing replacement
• Vacuum pump maintenance
• Vacuum pump replacement

None Never None Never
Every year Every 2-3 yrs (4K) Every year Every
3-4 yrs (2K)
Maintenance

• Operating temp. range
• Footprint
• Weight
• Sound level at 1 meter
• Floor preparation
• Cabinet with casters
• Installation startup time

-20 to 40C 10 sq ft 3,800 lbs lt72 dBA Needs
Concrete Pad No 1-2 days
-20 to 50C 5.7 sq ft 1,300 lbs lt45
dBA None Yes 1-2 hours
EnvironmentalRequirements
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Pentadyne Technology Highlights
Flywheel module
Rotating group
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One Line
Flywheel Module
IGBT Power Converter
Soft Start
To UPSBattery Input
Sensors
Temperature
Sensors
Speed
Position
Sensors
Magnetic Levitation Module
DC Monitoring
Motor Generator Controls
Power Conversion Module Controller
Remote Monitoring Controls (Optional)
AC Aux Backup
COM
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Flywheel Module Components
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Technical Details Vacuum Sleeve
NO VACUUM PUMP

• 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

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Flywheel Cabinet Layout
Flywheel Disconnect
LCD Control Panel
Versatile Interface Board
Data Collection Module (optional)
Motor-Generator Filter Assembly
Magnetic Levitation Module
Power ConversionModule
Flywheel Module
Air Filter (optional)
Casters
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Product Specifications
UL certification requirements have an upper
limit of 600 Vdc
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End-User Benefits

• lt50 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
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gt1 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 worlds 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 _at_
  MasterBrand Cabinets Its 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.
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Bringing It Into Perspective
Flywheel vs. Batteries

• Installation cost
• Footprint
• Maintenance
• Life expectation
• Standby cost
• HVAC costs

Low Small Very infrequent 20 years Low to
high None
High Large to very large Very frequent 2-4
years Low High
Lifecycle Cost

• Recharge
• Diagnostics monitoring
• Known state of charge
• Availability interruption

Slow Speculative Never 2,000 hrs
Rapid Accurate Always gt50,000 hrs
Reliability
Very narrow Yes Yes Yes Often
Broad None None None None

• Operating temperature range
• Hazardous materials
• Toxic, explosive gas emissions
• Disposal requirements
• Fire hazard permitting

EnvironmentSafety
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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 flywheels 20-year design life.
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Do You Have Space Issues?
Scripps Green Hospital San Diego

• Application
• Cath lab expansion
• 500-kVA UPS requirement
• Retrofit construction

• 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

• Solution
• 500-kVA GE UPS and three flywheels
• Fits tight space, eliminates HVAC needs
• Eliminated batteries

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Footprint Comparison

• 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).

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Experienced Battery Failures?
NetAlliant Technologies - Chattanooga

• Application
• Co-location data center
• 80-kVA UPS with expansion plans

• Issues
• gt100 outages (most brief)/yr
• Experiencing battery failures without warning
• Some actually blew-up
• Footprint and maintenance considerations

• 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

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Cooling Constraints?
WBRZ Broadcasting Baton Rouge

• Application
• TV broadcast studio and transmitter
• UPS in unconditioned equipment room

• Issues
• Equipment room temperature unregulated
• Batteries were lasting less than 2 years
• Frequent outages due to thunderstorms and
  hurricanes

• 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

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Floor Loading Issues?
DoD Data Center

• Application
• Supercomputer expansion

• 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

• 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

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Sustainability Concerns?

• Which would you rather dispose of?
• A 20-year-life flywheelwithout hazardous or
  toxic materials.

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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 worlds 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
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Example Data Center
Strataspace 570,000 sq ft Underground Data
Center Kentucky

• 450-kVA UPS
• 3 flywheels (N1)
• Ride-through to genset
• Drivers
• Cut OO costs
• Power quality issues
• Reliability
• Eliminate batteries

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Example IT in Manufacturing
GlaxoSmithKline North Carolina

• One 400-kVA UPS
• 3 flywheels (N1), battery parallel
• Protecting data center loads
• Drivers
• Short battery life
• Reduce OO costs
• Battery reliability issues
• Battery maintenance issues
• Space constraints
• Environmental impact

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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
• gt500 flywheel systems
• DX-A2 rated for national defense use

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Award-Winning Technology

• Awards
• 2007 Buildings magazine Editors Choice Top
  Product Pick
• 2007 ECM 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"

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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

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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

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Thank you!
pentadyne.com