Professional Documents
Culture Documents
1
Traditional Power Quality Configuration
ATS
Protected
load
UPS
Utility feed
Batteries
Back-up
genset
The
The Weakest
Weakest Link
Link
the event of a brief utility power disturbance, the UPS gets power from a string of
lead-acid batteries connected to its internal DC bus. If the disturbance lasts longer
than a few seconds, the ATS starts the genset and the load is transferred from
battery power. When the ATS detects the return of proper utility power, it switches
back to the normal configuration and the lengthy process of bringing the batteries
up to a full state of charge begins.
2
Leading Cause of Dropped Loads
Circuit breaker
UPS component
Logic board
Utility/generator
Other external
Human error
Batteries
Other (<2% each)
Problem is, batteries are the leading cause of dropped load incidents. As the weakest
link in the chain, many facilities opt for a redundant string of batteries to hedge their
bets. But the bottom line is that having two weak links in the UPS chain isnt much
better than one.
3
Unreliable & Dangerous
Each Pentadyne flywheel replaces the use of 40 lead-acid batteries. Each of those
batteries contain six cells. When there is an issue with any one of those 240 cells,
the whole string fails. While battery monitoring devices can make interpretive
guesses at which battery or cell might fail next, its not until you hit those 240 cells
with full load that you will know for sure whether the string will work or fail. As one of
our customers puts it: Battery failure is not an option. Nonetheless, it happens all
the time.
4
A better way
The Pentadyne flywheel offers a better way. First introduced in 2003, the
installed fleet of Pentadyne systems have amassed 4 million hours of
reliable operation at customer sites. Mean time between dropped loads has
proven out at a million hours more than 100 years. Dropped load MTBF for
battery strings is about 10,000 hours (around once a year), and just barely
over 2,000 hours for individual jars according to UPS industry reports.
5
Todays Power Quality Configuration
ATS
Protected
load
UPS
Utility feed
Back-up
genset
Flywheel Optional
batteries
Todays power quality configuration uses one or more flywheels to serve as the
primary energy storage device. Most sites choose to permanently rid themselves of
their battery headaches. But the flywheel can be used in parallel with a redundant
battery string for particularly critical applications. The flywheel responds to ALL
power disturbances, whether sub-second or to bridge to a smooth handoff to the
generator. In such configurations, the batteries are isolated from all cycling. With no
cycling, batteries can actually begin to approach their life claims and battery
maintenance is held to a minimum.
6
Battery Whiplash Prevented
Float Voltage
Grid Disturbance
Gen
99% of disturbances
< 10 sec. --EPRI
0 10 20
Time (Seconds)
7
Critical Need: Storage vs. Generation
8
Genset Start Reliability
The bottom line is that: 1) Genset start reliability is far higher than that of batteries.
2) Without cooling, theres no such thing as 15 minutes of battery backup time. With
todays servers and rack densities, you have less than 60 seconds to have the
genset online and powering the cooling systems, otherwise thermal server crash is
inevitable.
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One Line
Flywheel Module
Soft Start
To UPS
Battery
Input
Temperature
Sensors
Sensors
Position
Sensors
Speed
DC Monitoring Motor Generator Controls Magnetic Levitation
Module
Power Conversion Module Controller
Remote Monitoring
Backup
AC Aux
COM
& Controls
(Optional)
The Pentadyne flywheel connects into the DC bus of the UPS just like a
battery cabinet, and it draws its 250 W float charge from the DC bus just
like a battery cabinet.
10
Flywheel Technology Evolution
Carbon
Steel Flywheel Technology
Fiber
Evolution
KE ~ m(rpm)
Low-speed 7,800 rpm High-speed 52,000 rpm
More mass means more energy More speed means more energy
Double mass = energy doubled Double rpm = energy quadrupled
With flywheels, if you double the mass, you double the energy storage. But
double the spin rate and you quadruple energy storage. Thats why it makes
sense to make the wheel smaller and lighter for a more compact footprint
and less floor-loading, but spin it faster for greater energy density. With this
relatively light mass, you can float it in a magnetic containment field and
eliminate mechanical bearings that need very costly replacement every 2-3
years and incur downtime lasting the better part of a day. That and other
innovations make this carbon-fiber-based flywheel 10x more energy efficient
than steel flywheels.
11
Flywheels: Carbon Fiber vs. Steel
Carbon fiber Steel
Footprint 5.7 sq ft 10 sq ft
Weight 1,300 lbs 3,800 lbs
Environmental Sound level at 1 meter <45 dBA <70 dBA
Requirements Floor preparation None Needs concrete pad
Cabinet with casters Yes No
Installation & startup time 1-2 hours 1-2 days
12
Less is More
Flywheel module
13
Full Magnetic Levitation
NO MECHANICAL BEARINGS
Pentadynes patented 5-point
magnetic levitation system fully
floats the spinning mass
No bearings, no contact
No wear, no friction, no heat
No costly maintenance
Extremely strong and robust
Originally designed for hybrid vehicle
energy storage (i.e., to be driven over
potholes all day)
14
Vacuum Sleeve
15
A Closer Look Inside...
Upper Radial
Electromagnet
Upper Vacuum
Chamber
Axial
Lower Vacuum Electromagnet
Chamber
Molecular
Carbon Fiber Vacuum Sleeve
Composite
Flywheel
2 Thick Steel
Motor-Generator Containment Vessel
Stator
Synchronous
Coolant Reluctance 4 pole
Passages M-G Rotor
Lower Radial
Electromagnet
Patented
16
Flywheel Cabinet Layout
Flywheel
Disconnect
LCD Control Panel Versatile Interface Board
(optional)
Data Collection Module
(optional)
Motor-Generator
Filter Assembly
Magnetic Levitation
Module
Power
Conversion
Flywheel
Module
Module
Coolant
Air Filter (optional) Pump
Casters
The Versatile Interface Board provides dry contacts for integration into
monitoring systems. The Data Collection Module stores about 12 months
worth of operational and self-diagnostics data. The coolant pump shown is
normally off. It turns on for 10-15 minutes when a significant discharge event
has occurred, heating up the motor-generator. Its a very heavy-duty pump,
but the actual duty cycle is exceptionally light, perhaps only a few hours per
year. As such, the pump requires no maintenance for the 20-year life of the
system. The fluid itself is a vegetable oil based coolant, called Paratherm.
Its very stable no fluid changes are recommended and non-toxic. In fact,
its even kosher-ratedyou can put it on your salad.
17
Footprint Comparison
Floorspace needed by 5-minute VRLA cabinets for a 400-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).
VRLA VRLA FW FW FW FW FW FW FW
access
access
If you are tight on floorspace, the Pentadyne flywheel delivers vastly more reliable
energy storage in half or less the footprint of batteries. And since it doesnt need
temperature control like batteries, you can stick it in an electrical room and recover
the conditioned space for more core business uses.
18
Floor-Loading
With only the weight of a comparable capacity 5 minute VRLA battery cabinet,
the Pentadyne flywheel imposes no floor-loading issues. This enables siting on
upper level floors. It can even be rolled across and mounted on unreinforced raised
flooring, no concrete pad is needed as is the case with all the alternatives.
19
Shipping & Installation
Installation is simple. Since the Pentadyne flywheel weighs only 1300 lbs,
there are no floor-loading issues, no need for a concrete pad. It even mounts
directly on raised flooring. The system has casters to roll the unit into place.
UL-required seismic mounting is also very simple, with bolting supplied for
both raised and standard flooring. Leveling feet are provided to align the
flywheel cabinet(s) to the UPS cabinet (precise leveling of the flywheel is not
needed). Complete installation and commissioning takes only an hour or two
vs. a day or two for legacy steel flywheels.
20
Green Technology
Lead is ranked 2nd in
Elimination of Hazardous Materials US for all hazardous
materials and
No lead mining, smelting, transport, etc. requires proper
disposal - EPA
No lead disposal
No sulfuric acid disposal
No greenhouse gas emissions
No disposal/replacement after only a few years of service
Lasts 20+ years
Energy Reduction
Only 250 W float charge
1/10th that of other flywheels
Annual savings
20,000 kWh/unit deployed
26,000 lbs of carbon emissions/unit deployed
Rapid recharge in seconds
No cooling requirements
21
Sustainability Benefits
Each Pentadyne flywheel cabinet deployed will save the mining, smelting, refining,
transporting and manufacturing of more than 15,000 pounds of virgin lead (UPS
batteries do not use recycled lead) as well as the costs, energy use and hazards of
recycling that that lead into other product uses. Most of the mining of virgin lead
takes place in foreign nations that have little regard for the health and safety of the
people doing this work.
22
The OTHER Green Advantage
Each Pentadyne flywheel will save more than $100,000 in operating costs over that
of our nearest competitors product. Compared to lead-acid batteries, the savings
per cabinet are more than $150,000. The above cost comparison is inclusive of
operating energy costs, maintenance and HVAC energy use, but not inclusive of
ancillary equipment costs, such as HVAC equipment, acid-spill containment, health
& safety equipment, floorspace, fire hazard permitting, explosive gas sensors, etc.
23
Nearly 4 Million Operating Hours
Pentadyne has sold and shipped more than 750 flywheels worldwide. The installed
fleet has amassed nearly 4 million hours of operation in commercial settings. So
while the product has been shipping for only 5 years, it is a very well-proven source
of reliable clean energy storage.
24
Product Specifications
Parameter Specification
Power Level Up to 190 kW
System configuration Single or unlimited parallel
DC voltage range 350 to 850* Vdc
Standby / Heat Diss. <250 W / <900 BTU/hr
Dimensions (footprint) 25 x 33 x 71 (5.7 sq ft)
Weight 1300 lbs
Sound level <45 dBA @ 1 meter
Operating temperature -4F (-20C) to 122F (50C)
Seismic certification Zone 4
Mobility Casters
Serviceability Front access only
Certification UL & CE
* UL certification requirements have an upper limit of 600 Vdc
A quick review of the specifications. Again, note the extremely low energy
consumption, very small footprint, near silent operation and seismic zone 4
certification (the heart of the Pentadyne flywheel was originally designed for
hybrid vehicle applications, i.e. to be driven over potholes all day, so seismic
shaking is a non-issue with this small-mass system).
25
End-User Benefit Review
26
Pentadyne Overview
Los Angeles
LABJ
Business Journal
#1 FASTEST
GROWING
PRIVATE
COMPANY
2008
Pentadyne has sold and shipped 750 of its cleantech energy storage
systems. These products operate in the diverse, large-scale UPS market
where each unit mitigates the use of hundreds of hazardous lead-acid
batteries, inclusive of battery replacements. The hazmat-free Pentadyne
clean energy storage system is a proven product enjoying rapidly growing
demand in the UPS and energy recycling markets. In the UPS sector,
Pentadyne is an OEM supplier of flywheel energy storage systems, which
are sold by GE, Toshiba and Emerson Network Power (the latter markets
our product as the Liebert FS).
27
Example Small Colocation
NetAlliant: Tennessee
150-kVA UPS
1 flywheel
No batteries
Protecting server loads
Ride-through to gensets
Drivers:
Short battery life
Batteries had dropped load
Other bad experiences with batteries
Reliability
>300 utility incidents since installation
Flywheel has never let them down
NetAlliants President John Smith echoes the sentiments of most UPS users
when he says, I hate batteries, theyre nothing but trouble. Before installing
a Pentadyne flywheel, two of the VRLA batteries in the string at this
Chattanooga colo didnt just fail during an outage, they actually blew apart,
dropping the server loads and leaking acid. Fortunately, no one was nearby
when it happened. Unfortunately, Smith lost several clients due to the
dropped load incident. Theyve seen more than 300 power disturbances
since the flywheel was installed back in January of 2006. Of course, the
Pentadyne flywheel has never once let them down.
28
Example Data Center
Strataspace 570,000 sq ft Underground Data Center: Kentucky
450-kVA UPS
3 flywheels, no batteries
Ride-through to genset
Drivers:
Cut O&O costs
Power quality issues
Reliability
Eliminate batteries
This massive underground center near Louisville, Kentucky, has had three
Pentadyne-made Liebert FS flywheel units operating for the last couple years
without any batteries. Theyve never seen a load interruption since.
29
Example Research Data Center
This R&D center in Omaha chose to eliminate battery costs, headaches and
poor reliability by stringing half a dozen Pentadyne flywheel systems on each
of their four 750-kVA UPSs. They have N+1 redundancy and extended
flywheel running time. Of course, unlike battery sets, if one or more flywheel
systems in the string were ever to fail, the remaining units would carry the
load, albeit for slightly less total duration.
30
Example - Transportation
50kVA UPS
1 flywheel
Protecting radar and
other critical loads
Battery parallel
Flywheel is first line
of defense
Ride-through to genset
Drivers:
Reliability issues
Maintenance issues
Norman Y. Mineta San Jos International Airport serves the Silicon Valley and
Greater San Francisco Bay Area. The airport moves about 10 million passengers
per year. The Pentadyne system there operates in parallel with a redundant set of
UPS batteries. In this configuration, the Pentadyne system is the first line of defense
against all power issues, isolating the batteries from any such events.
31
Example Casino
Cache Creek Casino: California
1000-kVA UPS
5 flywheels (and plans for 5 more)
Parallel with 3-minute batteries
Protecting electronic gaming
Drivers:
Reduce maintenance
Increase reliability
Reduce number of batteries
Reduce O&O costs
Extend life of redundant batteries
Environmental responsibility
Cache Creek Casino outside of Sacramento is one of the largest Native American
gaming facilities in the United States. Situated in a rural area, they were at the end
of a PG&E utility line and often suffering very poor power quality and reliability.
Frequent power interruptions were killing their battery sets at an alarming rate. They
now use a bank of five Pentadyne-made Liebert FS systems on their 1 MVA Liebert
610. Because the FS array can smoothly roll off voltage into a battery set if the
generators could not come online, this enables the use of a 3-minute battery set
something you could never do with batteries alone due to coup de fouet issues.
32
Example Laboratory Equipment
150-kVA UPS
Ride-through to genset
No batteries
Drivers:
Frequent power quality
issues
Batteries had dropped load
Reduce O&O costs
Eliminate batteries
Significantly reduce
maintenance
Unconditioned space
33
Example - Broadcast
34
Example Hospital
Heart catheterization lab equipment is notorious for pulse loads that UPS
systems just cant rectify quickly enough, so energy for those sub-second
inrushes have to come out of the UPS energy storage. With hundreds of
those occurring every week, its no wonder that cath labs, MRIs, CT
scanners and other imaging equipment burn through so-called 10-year
VRLA batteries in just 12-18 months. Flywheels, on the other hand, are
completely unaffected by such frequent cycling.
35
Example Hospital
The 500+ bed Sparrow Hospital in Lansing, Michigan, has more than a half-
dozen larger-scale Liebert UPSs and a total of 18 Pentadyne-made Liebert
FS flywheel systems on loads ranging from a large data center to medical
diagnostic equipment.
36
Example Manufacturing
37
Example Education
Two different school districts, located just a few miles apart in the state of
Washington, each use a Pentadyne flywheel without batteries to ensure
continuity of their centralized server banks. Other educational facilities using
Pentadyne flywheels include several universities, including one in Nebraska
that has 24 Pentadyne-made Liebert FS units in a battery-free configuration.
38
Recap: Value, Performance
The award-winning Pentadyne flywheel uses a carbon fiber mass to deliver a small
footprint, high energy density and to enable magnetic levitation that eliminates bearing
failures and maintenance. Its intelligent design also eliminates the mechanical vacuum
pump as another point of failure and maintenance. With only 10 or less hours of
downtime service over its 20-year design life, the Pentadyne flywheel delivers
amazing uptime availability: 99.994%. Its exceptional energy efficiency reduces own
and operate costs radically over batteries and other flywheels while its technological
achievements, proven in nearly 4 million hours of commercial site operation, delivers
two orders of magnitude greater reliability.
39