Electrifying innovation changing the future of mobility - BENNING
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10 / 2 018 Customer Magazine informative · up-to-date · pioneering Electrifying innovation changing the future of mobility Photo: © Scharfsinn/Shutterstock.com Rapid-charging modules for E-mobility 14 28 – 17 31 Secure offshore power supplies 123– –16 5 Greater efficiency for the NY metro 17 – 31 30 19 www.benning.de
POWER news 10/2018 Safe power supplies for Editorial offshore wind farms Dear reader, The UK is planning to build the world's largest battery power supply BENNING greatly contributes to energy transition: network, consisting of 45 battery storage systems with a total capacity of more than two gigawatts, helping balance any fluctuations It supports offshore wind farm projects throughout Europe with in electricity production and demand, so that a constant and stable secure power supply systems and customised services. power supply is maintained – an important step towards better man- agement of the transition to renewable energy. In parallel with the installation of the battery power supply network, one of the largest networks of rapid-charging stations for electric vehicles will be created. The UK power network will experience additional strain due to the electrification of road vehicles, these storage systems will help by reacting flexibly and compensating for any fluctuations. BENNING is also committed to making sure that the use of electric cars, trucks and buses becomes central to a smart, resource-conserving urban lifestyle. For this purpose, we have Energy transition is an issue that affects developed the HPC rapid-charging BELATRON modular range whose advantages we will us all. At the UN Climate Change Con- be highlighting in this issue of POWER news. ference in Paris in 2015, the Assembly You can also read about how BENNING uses highly efficient modular power systems to adopted a climate agreement that pro- contribute to CO2 savings and greater efficiency in other areas, e.g. the modernisation of a vides for global warming to be limited power station in the UK, and the expansion of the Ukrainian mobile network or the moderni- to at least two degrees and ideally to sation of the New York metro. 1.5 degrees Celsius. At the same time, I hope you enjoy reading this issue and look forward to your feedback. CO2 emissions are to be significantly reduced. Yours, Stephan Ratermann e-mail: s.ratermann@benning.de To achieve this goal, we want to implement telephone: +49 2871 93 0 a gradual transition from conventional energy sources to fully renewable ones. This article describes the way the offshore wind industry Contents is contributing to the latest trends and devel- opments and the role of BENNING in this 3–5 Safe power supplies for offshore wind 22 Energy Technology List Certification for farms the ENERTRONIC modular SE regard. Contributing to the energy revolution: BENNING’s modular UPS systems have Europe-wide support for offshore wind received an award for their particularly high farm projects energy efficiency. Promotion of wind energy 6–9 Modular power protection in industrial 23 – 25 IABG certification for earthquake safety applications in the maximum danger zone 19” modular rectifier plug-in unit with Technical and economic advantages of Evidence of superb design: The UC-HE In addition to the study of sustainable tech- 4 modules TEBECHOP 3000 HDI modular technology in the design and cabinet system, especially developed for use nologies, the promotion of wind energy is of and remote monitoring unit operation of UPS systems in earthquake zones, has been certified by Industrieanlagen-Betriebsgesellschaft mbH particular importance when it comes to the MCU 2500 10 – 13 Power supply systems and services for (IABG). sustainable implementation of the energy the Ukrainian telephone network For more than 20 years, BENNING Ukraine 26 – 29 New Drive Motors for historical transition. has provided highly efficient power supplies Kaiserwagen As the construction of larger wind farms however, high-voltage direct current (HVDC) for reliable, energy-efficient operation Retrofit: BENNING has carried out a rotor- turns out to be fairly complex in rural areas, transmission is used, as this allows a lower stator configuration for the historic Wup- 14 – 17 Highly efficient, fast-charging module the focus is placed on the development of loss of energy and thus more efficient energy pertal Suspension Railway Kaiserwagen. for electric vehicles BELATRON modular – the new high-performance 30 – 31 Increased safety for one of the world's Offshore Wind Farms (OWF), which are con- transmission. charging module for constructing high availability, largest underground networks structed in coastal areas (e. g. in the North economical electric vehicle charging stations Individual product solutions and engineering and Baltic Seas, the Irish Sea or the Iberian Increase in capacity services make New York's rail transport 18 – 21 Built to last for a power plant’s lifetime Atlantic coast) and supply energy to the safer and more efficient. BENNING contracted to supply UPS systems to one of the UK's largest and most energy-efficient 32 Fairs, events and exhibitions coast via submarine cables to feed into the While the first OWF received substantial sub- fired coal power stations 2018 general power grid. sidies from the government, the first projects Publication details are currently being implemented without BENNING Elektrotechnik und Elektronik Liability and Copyright Picture credits For transmission distances of less than 30 state funding. This is a clear sign that the off- GmbH & Co. KG’s client magazine All texts are protected by copyright. The © BENNING Elektrotechnik und Elektronik industrieblick, Jakub Jirsák, Kadmy, publication, adoption or use of texts, pic- GmbH & Co. KG / Manuel Adorf, mariana_designer, kilometres, the principle of alternating current shore wind industry has established itself in Publisher: BENNING Elektrotechnik und tures or other information is subject to the © Anatoliy Sribny Max Topchii, Natalia Bratslavsky, newb1, transmission is generally used. For longer recent years as a new and strong industrial sector in Europe. Elektronik GmbH & Co. KG, written agreement from BENNING GmbH. © IABG Nick Moulds, Petrovich12, Pixel Embargo, Münsterstrasse 135-137, 46397 Bocholt No liability is accepted for any guidance, © Oleksandr Ananyev rabbit75_fot, royyimzy, scharfsinn86, references, recommendations or evalua- © Uniper Sergey Novikov, sirikornt, sk_design, distances and high wind farm performance, Design und Production: Advertising Agency tions. In spite of making every effort to © WSW Wuppertaler Stadtwerke GmbH Tobias Arhelger, Torbz, Varunyu, Paus Design & Medien GmbH & Co. KG, carry out a correct presentation and © arsdigital, beermedia, brianwhittaker, Vera Kuttelvaserova / Fotolia.com Brinkstegge 13, 46395 Bocholt checking of the subject matter, errors or Christian Delbert, cphotos100, © buffaloboy, Scharfsinn / Shutterstock.com 2 | BENNING | POWER news | 10/2018 mistakes in interpretation remain possible. DamienGeso, envfx, Gorodenkoff, BENNING | POWER news | 10/2018 | 3
Especially in Germany, the offshore sector is Not only the number of wind turbines, but Secure power systems in the offshore wind energy sector in terms of in the ascendancy. At the end of 2017, a total also their average power has significantly in- safety and efficiency. BENNING is continually of 1,196 offshore wind turbines were con- creased to 10 MW. At the same time, the For almost 15 years now, BENNING has seeking to optimise service performance nected to the grid in 20 OWFs with a total voltage level and thus the use of DC connec- proven to be a reliable designer and manu- from planning through to maintenance in a capacity of around 5,387 MW. But that is not tions has increased – as a result of the larger facturer of flexible and, above all, safe power targeted fashion. all: According to the plan, this figure is to be amounts of energy, some of which are trans- supply systems in the offshore sector. It sup- increased to 10,700 MW by 2025 – and ported over very long distances. plies both rectifier systems and UPS systems BENNING’s extensive service package also other European countries also wish to follow with batteries, which are primarily used on includes the Hotline support service for its suit. The Netherlands, for example, plans to Artificial energy islands offshore platforms where permanent avail- customers. On request, BENNING also pro- expand its offshore capacity from 1,120 MW ability of critical loads (e. g. switchgear for vides employees who specialise in offshore currently to 7,000 MW by 2030. Several European energy companies are cur- high voltage, communication and safety sys- operations for on-site deployment. This en- rently working on a major project which is tems) must be ensured by means of uninter- sures continuous operational safety of the Over the past five to ten years, a large num- significantly contributing to the implementa- ruptible power supplies. wind turbine. ber of OWFs have already been built and put tion of the goals of the UN Climate Change BENNING also offers tailor-made solutions A small but important contribution on the way into operation – especially in European coun- Agreement. It consists of several man-made for the wind turbines themselves, especially to the energy transition. tries such as Great Britain, France, Germany North Sea islands, on which various wind in transition pieces. The systems used here or the Netherlands. Most of these wind farms farms are connected to generate electricity must meet the highest requirements in terms contact: Bram Slaager have a total capacity ranging between for the surrounding countries. of EMC, vibration and climatic influences. telephone: +31 30 63 46 010 300 and 700 MW. By the year 2027, they should be able to e-mail: slaager@benning.nl produce sufficient energy to supply approx. Customised service A single wind turbine has an average power 80 million households. There are also central output of 10 MW and is connected to a central facilities such as accommodation for techni- BENNING provides its customers with an ex- Scan the QR code for platform (called hub) where all the energy is cal and operational personnel as well as an perienced team of competent experts whose further information accumulated and routed to the mainland. airport and water port close to these hubs. aim is to maximise the use of power supplied A B The high wind farm capacities of the artificially constructed energy islands require high-voltage direct current (HVDC) transmission. This ensures a highly efficient and low-loss energy transport over long distances. C D Redundant and modular power supply system with rectifier, inverter and DC/DC converter 4 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 5
Modular power protection in industrial applications The principle of modularity provides significant technical and economic benefits in the design and operation of UPS systems. Modular power protection and conversion technology, partic- ularly in the form of UPSs, has long been used in commercial applications, but take-up in industrial applications has, to date, been relatively slow. ENERTRONIC modular SE, BENNING’s UPS system is scalable and can 40 kW modules increase in size in line with load requirements This relatively slow uptake is due, in part, to Determination of functional Such a system could, for example, be in- power. Because of its experimental nature, a new drug. This decision now fundamentally a limited understanding of the “ilities” (“Avail- characteristics creased or decreased in size (see “scalability” the directors of our fictitious company restrict changes the design brief of the power pro- ability”, “Reliability”, “Scalability”, “Flexibility” article) to optimise TCO or additional mod- the project’s budget and because it does not tection system because if a power problem and “Maintainability”) commonly associated At the initial design stage of a power protec- ules could be added to it to introduce parallel have a production line, the UPS system is not causes the production line to be stopped with modular technology and how the vari- tion system, the designer will prioritise the redundancy (i.e. N+n) if maximised system “business critical”, making TCO a greater mid-batch, the entire batch must be ous “ilities” complement each other. most important aspects of the required availability became a requirement. consideration than system availability. To scrapped, costing the pharmaceutical com- system and will most likely compromise on Finally, it would allow for power capacity to meet this design brief a modular UPS sys- pany tens of thousands of pounds. The fourth of five articles within our 'ility' se- other design aspects. For example, if the be relocated from system to system if the tem, “rightsized” to the initial critical load by ries focuses on flexibility. We will define this load is considered to be business critical the needs of the critical load(s) across numerous using two 40 kW modules, is installed (see The design brief is now to maximise system in the context of the increasingly important designer will prioritise availability above TCO. systems ever needed to change. phase 1). availability and an additional 40 kW module and popular modular technology and discuss With the above “ideal world” we can define is added to the modular UPS (see phase 3) how truly flexible systems allow system de- Such prioritisation is not a problem if the “flexibility” as a system’s ability to adapt to Assuming that the company’s experimental to add parallel redundancy and thereby meet signers to design power protection systems needs of the site and/or critical load are guar- the ever-changing needs of the site/critical production line is an initial success, directors the new design brief of maximum availability. capable of adapting to the potentially chang- anteed to never change over the working life load. High levels of system flexibility help de- want to see how easily production capacity ing needs of a site and/or its critical load. of the system (typically 20-25 years), how- signers to “future-proof” their design and can be increased on the experimental line, As a result of increasing sales, the pharma- ever, we live in an ever-changing world and below we will consider a practical example to adding 50% capacity to the production line. ceutical company opens up a new production Flexibility such guarantees can rarely be given. The see how the inherent flexibility of rack- This increases the production line power re- facility in a town, which is a 30-minute drive danger, therefore, is that a system that was mounted modular UPS helped to future- quirement by 30 kW from 60 kW to 90 kW. away, and decides to move the new drug’s In previous articles within this series we have initially designed to meet one set of site/crit- proof a system and thereby provided numer- This challenge is overcome by simply adding production line to the new production facility. defined modularity and discussed how mod- ical load needs may no longer be suitable if ous financial and operational benefits to the one additional 40 kW module to the modular The drug production line’s modular UPS is ular UPS systems can be designed to either the needs of the site/critical load ever system operator. UPS system (see phase 2) to accommodate only 3 years old and rather than investing in a maximise system availability or minimise total change. If this situation ever occurs it may be the increased load and still meet the initial de- completely new UPS system the directors de- cost of ownership (TCO). We must now con- an expensive problem to correct. An example of a highly flexible system sign brief of lowest TCO. cide to relocate it to the new facility. However, sider how we can design a single system that design the downtime on the production line must be is flexible enough to have the highest avail- In an ideal world, a system would be de- The directors – who are delighted with the minimised and the time needed to decom- ability or lowest TCO with the ability to switch signed with the capability to quickly and Let us assume that a pharmaceutical com- performance of the now larger experimental mission, de-install, physically relocate, re-in- between the two depending upon the pre- easily adapt to the prevailing needs of the site pany decides to start up an experimental production line, decide to turn it into a real stall and recommission the existing UPS is vailing needs of the site/critical load. and/or critical load. production line that needs 60 kW of UPS production line and begin serial production of considered to be too great. 6 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 7
Modular power protection Power [kW] 200 kW (n+1) installed power 180 requested power new old location location 160 160 kW (n+1) 160 kW (n+1) 160 kW (n+1) 140 Transfer 120 120 kW (n+1) 120 kW 100 90 kW (n+1) 90 kW (n+1) 90 kW (n+1) 90 kW 80 80 kW 60 60 kW 40 kW 40 30 kW 20 Time 0 Location A Location A Location A Location A Location B Location A Location B Location A Location B Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Phase 6 The solution is to install and commission an The above example shows the flexibility of a Modular systems with modules that have the Conclusion empty modular UPS cabinet at the new pro- true modular UPS. In this example, we have inbuilt intelligence to be parallel redundant duction facility (see phase 4). seen a simple, cost effective: (e.g. N+1) when the size of the load means With industrial power protection systems they can be; or parallel capacity (i.e. N+0) having a design life of >20 years, one of the When the production line is switched off at • Increase in system capacity when they need to be, enable automatic, greatest challenges faced by system design- the old facility, the four UPS modules are • Conversion from a TCO priority to an avail- real-time flexibility and ensure that the critical ers is how to future-proof their design by en- then simply switched off, removed from the ability priority design load is always supplied with the highest level abling it to adapt to the potentially changing original modular UPS cabinet, driven by car • Relocation to new premises of protection possible. This capability auto- needs of the site and/or critical load. to the new production facility, fitted into the • Reduction in system capacity and conver- matically maximises system availability. Rack-mounted modular UPS systems can new modular UPS cabinet and switched sion back to a TCO priority design be quickly and easily reconfigured to allow back on (see phase 5). Because the new Reduction of power consumption the power protection system to adapt to production facility was only a 30-minute drive Inbuilt intelligence for true flexibility site/critical load changes and can prioritise away, the whole process took less than Similarly, modular systems with modules that either highest availability or lowest TCO 90 minutes in total. The example above needed the pharmaceu- have the inbuilt intelligence to use only the depending upon the prevailing needs of the The pharmaceutical company now decides tical company to make decisions and take required number of UPS modules necessary site/critical load. to start up another experimental production physical actions to adapt the system to the to supply power to the critical load by putting Rack-mounted UPS modules with user con- line on the original site and this line now changing needs of the site/critical load. “excess” modules into a “sleep mode” en- figurable inbuilt intelligence will automatically needs 30 kW of UPS power. In most cases this is perfectly acceptable, able the system to automatically operate as further enhance system flexibility without Again, because of its experimental nature, however, there may be occasions when it efficiently as it can whilst ensuring that the removing ultimate control from the system contact: Alexander Proemel the directors restrict the project’s budget and would be beneficial if the system itself were critical load continues to receive the required operator. telephone: +49 2871 93 238 because it not a real production line, and intelligent enough to make decisions and level of protection. The next, and final, article in the “ilities” series e-mail: a.proemel@benning.de therefore not “business critical”, TCO is a take automated actions to maximise system will discuss “maintainability” and how select- greater consideration than system availability. availability or minimise TCO. If the critical load increases, a “sleeping” ing the right UPS topology will reduce servic- Of course, such decision-making capability module will automatically be returned to full ing costs, minimise “local” spare parts hold- To meet this design brief a single 40 kW mod- must be user configurable to ensure that the service and if the critical load decreases fur- ings and enable rapid “first line” fault Scan the QR code for ule is fitted into the original modular UPS sys- system operator retains ultimate system con- ther then another module will automatically rectification, all of which will ultimately max- further information tem cabinet and the whole “experimental pro- trol, but such inbuilt intelligence will further be sent to “sleep”. This capability automati- imise system availability and minimise total duction line” cycle starts again (see phase 6). enhance system flexibility. cally optimises system TCO. cost of ownership. 8 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 9
Photo: © Oleksandr Ananyev Photo: © Anatoliy Sribny Power supply systems and services for the Ukrainian telephone network The rear cabinet series has a 48 V / 216 kW telecommunications system with TEBECHOP 13500 BENNING Ukraine has been supplying the Ukrainian telecom- modules consisting of module cabinets, mains supply fields as well as battery and load output fields, including a monitoring system. The front contains the battery system, along with battery connection munications market with high-efficiency power supplies boxes. for energy-saving, reliable operation for over twenty years. Photo: © Oleksandr Ananyev At the beginning of the new millennium, Ukrainian telecommunication operators Over 500 DC systems for Vodafone between the two companies. Since 2005, Virtually all the regions of the Ukrainian there was a surge in development in the chose products and services from Vodafone Ukraine has received more than 500 Vodafone network are now equipped with telecommunications market in Ukraine, BENNING. At that stage, the company Vodafone, one of the largest telecommunica- DC systems with associated distribution sys- BENNING telecommunications power sup- attributable to the economic progress of had already accrued ten years’ experi- tions network providers in Ukraine, also uses tems. These conform to the relevant interna- plies – and Vodafone Ukraine is currently the country. This was also reflected in ence in the Ukrainian market and nur- know-how from BENNING for power supplies tional and regional standards and are perfectly using BENNING solutions for new mobile cell high demand for uninterruptible power tured trust from a large number of cus- for 3G and 4G telecommunications systems. tailored to the strict individual requirements of sites that are to be erected. The power sup- supplies for setting up network infra- tomers with its bespoke product The positive experiences since the start of the the Ukrainian telecommunications system, plies delivered are based on SLIMLINE, structures. Despite the high competition solutions, high standards of quality and collaboration have served to underpin the which repeatedly experiences network out- TEBECHOP 12000 and TEBECHOP 13500 SE in that market sector, many high-profile reliable support. good relationship that continues to exist ages, especially outside major cities. series rectifiers. 10 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 11
... Turnkey Service High-efficiency power supplies BENNING power supply system BENNING has delivered battery-powered for telecommunication applications AC and DC power supplies to many mobile phone and landline operators around the world for decades. In recent years, it has made particular investments in the develop- ment of high-efficiency power supplies for energy-saving, reliable operation. The latest circuit topologies and state-of-the-art electrical components support a very compact and reliable design of system. Proactive Service – Technical On-Site Service Rectifier series INVERTRONIC compact, TEBECHOP 13500 SE, modular, single phase inverters – 48 V - 250 A (300 A) 19” Sub-rack with 5 inverters Power capacities up to several hundred kilo- Largest system in the Ukraine on-board control system and extensive mon- maintenance work, as well as training for developed the state-of-the-art ENERTRONIC watts are covered, depending on customer re- itoring and diagnostic functions (remote Vodafone Ukraine service technicians. As Modular SE UPS system, the cooperation will quirements and purpose. The modular tech- The telecommunications system in Kharkiv, monitoring) for preventative early detection. BENNING has highly qualified personnel and be intensified even further. The new high-tech nology of the power supply systems also a large city in the east of Ukraine, is not only technical resources, it is in a position to re- product was unveiled in Ukraine at Elcom provides customers with a quick and easy op- the biggest one in the country with a capacity Individual turnkey services spond quickly at any time to requests from Ukraine 2017, an international trade fair for tion for capacity scalability (pay as you grow). of 48 V and 14,000 A, it is also one of the customers from a wide range of sectors and power engineering, electrical engineering, en- biggest in the whole of Europe. It consists of However, central to the service portfolio pro- to offer bespoke solutions. ergy efficiency and automation. Furthermore, each of the systems has an indi- TEBECHOP 13500 rectifier modules, vided for Vodafone Ukraine are not only prod- vidually developed DC distribution unit, an on- TEBEVERT DSP power inverter modules and uct solutions, but also various individual Vodafone Ukraine requires optimum technical author/contact: Andrij Piatachenko line monitoring system (TCP-IP and SNMP four distribution cabinets. These are respon- turnkey services. In addition to the develop- solutions and services, and not only for 48 V telephone: 0038 044 501 40 45 Scan the QR code for protocol), as well as a temperature compen- sible for the power supply to the entire ment, manufacture, installation and start-up DC power supplies. As BENNING Elek- e-mail: a.piatachenko@benning.ua further information sation system for gentler charging of batteries. 3G and 4G network and include both an of the systems, this also includes service and trotechnik und Elektronik GmbH & Co. KG has 12 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 13
Photo: © buffaloboy/Shutterstock.com Highly efficient, fast-charging module for electric vehicles With the BELATRON modular series, BENNING provides equipment suppliers and operators of EV charging stations with high-performance charging modules and systems which combine the highest level of system availability with maximum cost-efficiency. Photo: © Scharfsinn/Shutterstock.com The German automotive industry is 19” module (87.5 kW) going to invest around 40 billion euros in e-mobility by 2020. This should make the use of electric vehicles a key feature of a smart, resource-friendly urban lifestyle. There is a clear need for optimisation, espe- cially with regard to the charging infrastruc- Input per module: Output per module: 3 x 400 V / 50 Hz 200 V to 950 V ture. According to a recent study, about 3 x 150 A (max.) max. 100 A 25 percent of all potential car buyers are con- cerned about not finding an e-charging sta- Block diagram: combination of rectifier and tion in the vicinity if needed. DC/DC converter in the 19” module (87.5 kW) of the BELATRON modular 19” module (87.5 kW) In particular, the idea of experiencing this on the way to work or on holiday, was unwel- come. Consequently, the installation of fast- PN: Mr. Erfen, could you briefly explain what PN: Before going into more detail, can you PN: With this equipment range, BENNING is charging systems will be the high-priority makes the new BELATRON modular fast please explain to our readers what are the entering a completely new market segment. task in the near future. charging module stand out? most important benefits of this new range of That’s a major risk for the company and its devices? potential customers, isn’t it? The challenge is to design the interfaces be- Erfen: With pleasure. BELATRON modular is tween electric vehicles, charging devices and a highly efficient modular system for effective Erfen: Each 87.5 kW module has freely con- Erfen: We do not see it that way. For more power grids as open systems. This would installation of DC charging stations. figurable interfaces and is therefore an ideal than 80 years, BENNING products have im- enable a wide variety of companies to collab- building block for the installation of charging proved safety and efficiency and contributed orate and jointly develop product modules for The three-phase fast charging modules can systems at fuel stations and motorway ser- to better utilisation of energy resources. Ever a common platform. be flexibly combined and are suitable for vice areas, for example. The modules are since it began, the company has been pro- charging a wide variety of vehicle types such therefore aimed, in particular, at companies ducing smart solutions for the conversion of A key component in this context is the newly as cars, trucks and buses. that plan and install the charging infrastruc- electricity into multi-purpose or storable en- developed BENNING HPC rapid charging tures. By opting for charging modules of the ergy. Today, BENNING is known worldwide module the BELATRON modular. POWER With the different configurable power ratings BELATRON modular series, they will provide fu- as a ‘quality leader’ for reliable smart-effi- news took the opportunity to discuss this (e. g. 150 kW or 350 kW), vehicles with both ture e-filling station operators with tailored con- ciency AC and DC power supplies for the with Reinhard Erfen, Key Account Manager 400 V and 800 V batteries can be charged figurations that combine maximum system telecommunications, power plant technol- BELATRON modular system cabinet of the E-Mobility Division at BENNING. efficiently. availability with extremely efficient operation. ogy, medical and IT industries. 350 kW / 875 VDC 14 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 15
2 x 175 kW / 875 VDC Transformer Module 1 (10 kV . 20 kV) Sec.1: 3 x 400 V And it’s not really a new market segment for 175 kW Pri.10 kV / 20 kV us. BENNING has been supplying chargers Module 2 @ for forklift trucks for almost 50 years now. 875 VDC Sec. 2: 3 x 400 V Public mains The name BELATRON is synonymous with high-quality, robust and highly efficient charg- ing systems for lead and lithium batteries. Module 3 PN: At whom is the newly developed product aimed? 175 kW Module 4 UC system cabinet with distribution and @ Erfen: With the BELATRON modular series, overvoltage protection 875 VDC W 600 mm x D 800 mm x H 1800 mm BENNING is providing equipment suppliers and operators of EV charging stations with high-performance charging modules and sys- 350 kW / 875 VDC tems that are specifically tailored to the ex- tremely high requirements of fast-charging op- Transformer eration. In addition to the cost-efficiency, these also offer maximum operational safety, relia- Plug & play technology ensures quick and easy Module 1 (10 kV . 20 kV) bility, energy efficiency as well as easily con- exchange of modules figurable User Space at the installation site. Pri.10 kV / 20 kV Sec.: 3 x 400 V Module 2 PN: You have mentioned cost-efficiency as a The power module components consist of a Photo: © Scharfsinn/Shutterstock.com key feature. This becomes evident when you redundant control unit, a three-phase rectifier Public mains consider the system total operating costs. and a DC/DC converter. Rectifiers and con- These include, among other things, the in- verters are implemented in a 3-level IGBT 350 kW Module 3 vestment costs, the energy costs as well as technology, ensuring low power input distor- @ maintenance and service costs. How does tion and active power factor correction at all 875 VDC the BELATRON modular meet these require- times. While the harmonic content of the ments exactly? mains power consumption (THDi) is 3%, the Module 4 UC system cabinet with distribution and input current is sinusoidal with cos ϕ of overvoltage protection Erfen: Each 19” power module is stand- nearly 1. W 600 mm x D 800 mm x H 1800 mm alone and highly efficient. Due to the highest module efficiency of 97% the ongoing oper- PN: The module is offered not only as a ating costs are minimised without compro- stand-alone unit, but also as an integrated mising the voltage quality. system in a cabinet housing. To what extent The block diagrams demonstrate how to use the 87.5 kW modules does the system design you develop affect as a basis to configure different DC charging systems the costs of rented areas or new buildings where the relevant equipment is installed? fuels. It is the top-priority task of the operator PN: You mention short repair times. Could Erfen: BENNING has always invested a potential downtime and ensure long-term Charging power characteristics Erfen: The charging system has an output of of an EV filling station to ensure that all EV you briefly explain how these are achieved? great deal of effort in maintaining the highest cost-efficiency. Thus, our customers are well approx. 729 kW/m². Since the air flow is dis- charging stations are available for operation service standards for its customers. Our cus- prepared for the challenges of today and the [kW] charged through the system roof, its installa- on a permanent basis. How do you meet this Erfen: The modular component concept is tomers value the reliable, globally oriented opportunities of tomorrow. tion is extremely space-saving. The systems requirement for maximum product availability? the basis for a significant reduction in instal- service structure that provides the best pos- 400 A ent can be easily placed ‘back to back’ on a wall lation and assembly times as well as for more sible support for their respective require- PN: Mr. Erfen, thank you for the detailed and very interesting conversation. curr Charging power ing or in a corner. Erfen: In the new BELATRON modular se- user-friendly and efficient maintenance activ- ments. Charg A ries, BENNING combines the advantages of ities in subsequent operation. All settings and nt 200 g curre Optionally, a rear ventilation system can be maximum reliability and shortest repair times service work can be configured and under- In anticipation of future requirements, the ser- Chargin ent 100 A Charging curr integrated. These possibilities ensure a high (MTTR) in a product that meets the highest taken from the front. vice department has been greatly expanded contact: Reinhard Erfen degree of flexibility and save a lot of space, requirements regarding the availability and The ‘hot swap’ capability allows each mod- over the past few years. We are talking about telephone: +49 2163 500 994 which in turn leads to a reduction in costs in quality of a safe and reliable power supply of ule to be replaced in less than ten minutes Service 4.0 which is offered as a proactive e-mail: r.erfen@benning.de Battery charge voltage [V] terms of rented areas or building invest- EV charging systems. which equates to a maximum availability 360° service. ments, for example. By using high-quality components and their of 99.9999%. generous performance rating in the critical BENNING 360° services encompass reliable The characteristics show the linear change of PN: The goal is to achieve a fast charging path, the design of the BELATRON modular PN: You mention quick replacement on site. maintenance and spare parts management, the charging power in relation to the battery time of approx. 20 minutes for electric vehi- system is optimally adapted to the harsh Is the technical support provided for a large with individual service contracts, which help Scan the QR code for charging voltage at different charging currents cles, which is still relatively long as compared conditions of rapid charging with high cur- number of scattered locations not a critical safeguard the business and production pro- further information of 100 A, 200 A and 400 A. to the refuelling process with conventional rents and voltages. factor? cesses of our customers, as well as prevent 16 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 17
Built to last for a power plant’s lifetime BENNING contracted to supply UPS systems to one of the UK's largest and most energy-efficient fired coal power stations. Uniper's power station in Ratcliffe-on-Soar is a 2,000MW coal-fired power station, For both large projects, BENNING proposed which can meet the electricity needs of approximately two million homes. Commis- new redundant systems, incorporating effi- sioned in 1970, the power station has four coal-fired boilers made by Babcock & cient and digitally controlled solutions, which Wilcox, each of which drives a 500-megawatt (MW) Parsons generator set. provide a high level of availability, whilst min- In addition to the plant's enormous capacity, it is also the first power station in the imising risk and cost in maintaining the UK to be fitted with Selective Catalytic Reduction technology (SCR), which reduces equipment. the emissions of nitrogen oxides through the injection of ammonia directly into the flue gas. Project one - 'critical supplies' upgrade In April 2016, Ratcliffe Power Station's lead Ratcliffe Power Station appointed BENNING It is crucial for power plants to have back up electrical engineer contacted BENNING to for two contracts and some additional sys- power systems in place that can start and enquire about a small inverter system. When tems: control their operation if the mains supply is visiting the site, it became clear that the interrupted. plant's UPS systems for ‘Critical Supplies’ re- • The first contract was to replace the old To achieve this most effectively, BENNING quired an upgrade. station and coal battery charger systems / designed two rectifier/charger systems for rectifiers which support critical power plant the site’s critical supplies. Accordingly, two BENNING was identified as the right partner systems. The new systems were to include 1000A, 240VDC station charger systems for this project because of its specialisation additional capacity and be relocated within (A+B) were supplied and installed in the in providing robust, industrial-scale modular the building. power station and one 400A, 240VDC power solutions. charger system is installed in the coal plant. • The second contract was to replace the ex- The coal plant charger/rectifier, which feeds In contrast to power solutions for the com- isting site instrument, computer, measur- batteries within the coal plant area of the mercial sector, BENNING's industrial grade ing, recording and regulating device UPS / power station, has a future capability of 400A solutions achieve a prolonged lifetime and inverter/converter systems with a set of at 240VAC, which was de-rated at delivery higher availability by over-specifying compo- modular UPS systems. to 200A to match the incoming AC supply. nents and developing hardware that is de- All three systems were designed to use an signed to withstand the harsh conditions • In addition, BENNING won orders to re- identical voltage so that they can be coupled faced in the environment of industrial-scale place multiple smaller emergency lighting if needed during maintenance or in emer- applications such as dust, temperature chan- systems with modular UPS system de- gency situations, increasing the power ges or water ingress. signs. plant's high availability level. UPS subsystem for instrumentation 18 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 19
... advantages thanks to modularity Easy module swap due to hot plug technology and automatic module configuration The two 1000A, 240VDC station chargers provide the power station with a fully redun- dant N+N system (A+B), which ensures a high level of availability. The systems, which needed to be positioned in a new location within the building, were not only designed but also manufactured, installed and com- missioned by BENNING. One challenge was to correctly position the systems over the cable tunnels, however, the team took all client specifics into consideration, ensuring that the systems were perfectly levelled, aligned and positioned over the cable tunnels in their new location. Hier steht jetzt noch Blindtext als Project two - UPS & inverter systems Beispiel für die Bildunterschrift ENERTRONIC modular SE Following the success of the first "critical sup- 40 kW module, developed for plies" upgrade program contract, BENNING the most demanding requirements was asked to take part in the bidding pro- cess for replacing 13 separate UPS/inverter systems across the entire Ratcliffe-on-Soar site. Most systems were at the end of their life and an appropriate, future-proof replace- modules, which can simply be added or re- • Modules interchangeable with other sys- this project." According to the loads these is a modular, transformerless three-phase reduce running costs and environmental im- ment needed to be found. During survey vis- moved from the larger UPS chassis unit, tems: Modules can be swapped between supported, these systems were: output UPS system based on IGBT/MOSFET pact, while modular design allows for rapid its with Uniper's team, BENNING were able which has no single point of failure. systems and spare parts can be kept to a • 1 x Station Instrument UPS 30kVA N+N semiconductor and DSP processor technol- repair and pay as you grow system scalability to assess the exact requirements of the site minimum due to their interchangeability system with N+1 on each side and dual ogy. It has been designed to provide the through the installation of additional parallel and gain an appreciation of the level of criti- Key benefits of BENNING's suggested battery strings highest level of protected power availability connected modules. cality involved. Closely working with the lead modular system are: • Expandability and flexibility: The UPS sys- • 1 x Coal Plant UPS 20kVA N+1 using sta- for critical loads within the utilities, oil, gas, engineer throughout, BENNING recommen- tem can grow with power requirements, as tion battery set transport and other high-demand industries. BENNING completed the positioning, instal- ded a modular approach for the new sys- • Increased availability: Units can be easily modules can simply be added to achieve a • 1 x FDG UPS 7.5kVA n+1 using dual bat- As previously introduced, the truly modular lation and SAT/commissioning of all of the re- tems. This modular approach is well-estab- added or replaced, as none represent a higher capacity, giving operators a great tery strings design means that each ENERTRONIC mod- maining UPS systems within the completion lished in the commercial sector, when looking single point of failure deal of flexibility • 1 x Communications UPS 7.5kVA N+1 ule contains its own rectifier, inverter, con- target of November 2017. at smaller scale data centre UPS systems, for using three battery strings troller and static bypass switch, ensuring that example. However, its advantages have not • Reduced MTTR: It only takes a few min- • UPS black start function allows station to • 1 x IT infrastructure UPS 25kVA N+1 using there is no single point of failure within the author/contact: Dirk Meyer found their way into industrial environments utes to remove or swap modules, all of initiate a recovery procedure following an single battery strings UPS system. This, coupled with a modular, telephone: +49 2871 93 261 yet, as these environments require longer which can be done whilst the overall sys- extensive loss of supply • 4 x Instrumentation UPS 20kVA using sta- hot-swappable design ensures a high system e-mail: d.meyer@benning.de UPS lifetimes, greater installed system com- tem is online and running tion battery sets MTBF and low MTTR. A manual bypass plexity, and rugged system hardware. According to Uniper’s Lead Engineer Christo- • 4 x Computer UPS 20kVA using battery switch is provided for maintenance pur- BENNING is the only manufacturer to meet • Simple spare holding: Due to their small pher Howe, “BENNING were the only indus- sets poses. The provided system also included these unique industrial requirements whilst size, UPS modules can be easily lifted and trial supplier of such modular technology, 2 x100% rated 12-15 Year design life VRLA providing a highly functional modular system carried by one person, while spare mod- and this coupled with the flexibility of a mod- The fully installed and commissioned station batteries. Scan the QR code for architecture. Rather than a monobloc sys- ules can be stored to facilitate quick re- ular system, led to the decision to employ UPS system comprises a dual redundant Low input harmonic distortion and high effi- further information tem, the UPS is built out of smaller units, or placements BENNING as the partner of choice to deliver ENERTRONIC modular SE UPS range, which ciency, even at partial load, significantly 20 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 21
“We are proud to be included in the ETL. This Energy Technology List is evidence that we offer our Certification for the customers highly efficient product solutions that contribute to a reduc- ENERTRONIC modular SE tion of ongoing operating costs and IABG certification lower CO2 emissions.” for earthquake safety The modular UPS systems in the ENERTRONIC modular SE David Whitlow, Managing Director range developed by BENNING have received a commendation BENNING UK in the maximum danger zone for their particularly high energy efficiency. The UC-HE cabinet system specifically developed for use in seismic areas has been certified For more than 80 years, BENNING prod- by Industrieanlagen-Betriebsgesellschaft mbH. ucts have stood for maximum security, This is testament to the excellent design work efficiency and optimised resource utili- sation. created on PC-based simulation technology. The company has now received a special commendation for its efforts – the inclu- sion of the ENERTRONIC modular SE UPS systems in the Energy Technology y n c List (ETL) for Enhanced Capital Al- y Effi cie Energ lowances (ECA). This is official confir- Natur al R CO2 mation of the particularly high energy e so ur c The need to consider earthquake risks Highest safety standards es efficiency of this BENNING UPS range. ENERTRONIC modular SE,40 kW Module IT Series is almost everywhere. Currently, more than 2.7 billion people live in an earth- The highest safety standards must be met, quake-prone area. If you take a look at although a classification into different priority The ETL certificate has been awarded by there is a load increase. Therefore, the sys- If maximum profitability and energy efficiency the earthquake zone map, you will see levels is also necessary. The failure of the Carbon Trust, an organisation founded tem has the capability to automatically main- are of greater importance than the voltage that many densely populated cities such telecommunications system, for example, by the British government for the reduction tain the highest system availability, while en- and frequency quality, it is possible to oper- as Los Angeles, Shanghai, Tokyo, Lima poses a much lower risk than a blackout of of greenhouse gases. suring the lowest operating costs. ate in “Super Efficiency Mode”. This allows or Istanbul are located in seismogenic the pump system that supplies the cooling the supply of the load to be achieved via the zones. In this case, we are talking about circuits. The ECA system supports companies in in- Combined with the repair and maintenance static bypass, as long as the voltage and/or Category 4 hazard zones, based on US vesting in energy-efficient equipment and benefits of true “hot swap” modularity, frequency of the supplying network lie within UBC standard classification. If a major In order to meet the variety of high demands, machinery which allows them to receive through which a whole UPS module can be the preset tolerance ranges. earthquake occurs in one of these re- BENNING has developed an individually con- financial benefits. Tax exemptions enable replaced in just a few minutes, this results in gions, it can cause severe damage to figurable cabinet system that can be perfectly the total cost of the new asset or machine a UPS system with 99.9999% availability. As soon as one of these values leaves its buildings, infrastructure or technical adapted to the different earthquake cate- to be offset against the taxable profit for range, automatic and uninterrupted switch- plant - affecting, among other things, gories and safety requirements. It is available the full financial year in which the purchase Minimising Operating Costs ing into double conversion operation takes transport, industry, healthcare system or in the following versions: UC (Standard), was made. place. At the same time, the load receives energy supply. UC-LE (Light Earthquake Resistant), UC-ME Thanks to the “pay as you grow” scalability complete protection against harmful network (Middle Earthquake Resistant) and UC-HE Maximum Energy Efficiency and very high operating efficiency, even at influences. On average, large earthquakes with a mag- (Heavy Earthquake Resistant). partial load, the actual operating costs of the nitude of 6.0 and higher occur about three The energy optimisation mode, selectable ENERTRONIC modular series are kept to a contact: Dirk Meyer times a week - nearly 100 earthquakes a year In comparison to conventional designs that and configurable by the user, automatically minimum, without compromising on network telephone: +49 2871 93 261 cause structural damage, according to re- seek to achieve the necessary earthquake minimises the total cost of ownership (TCO) quality. Every UPS module therefore repre- e-mail: d.meyer@benning.de cent statistics from the National Earthquake resistance of housing through high rigidity, while maximising system availability. sents a highly efficient, serial online UPS Information Centre (NEIC). This unpredictabil- the new UC cabinet variants are charac- (VFI-SS-111). ity makes it necessary to protect electrical terised by a cutting-edge approach. This ap- An intelligent algorithm determines the The supply of the critical load via the rectifier equipment by using UPS systems for bridg- proach and the use of high strength steel number of modules required for safe oper- and inverter of the ENERTRONIC modular SE ing any power outages and network failures, allow a structure to perform well-defined ation and switches all other modules to hi- also eliminates all voltage and frequency for example. movements without weakening the cabinet bernation mode. System efficiency is max- fluctuations of the national grid and thus Scan the QR code for system. A construction method that has also imised by making the latter available only secures the operation of loads sensitive to further information An individual configurable But how are the UPS and power plants pro- found its way into the automotive sector, for when they are really needed, e.g. when interference. UC-HE cabinet system by BENNING tected against the impact of an earthquake? example. 22 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 23
... certified by IABG Specific simulation options The cabinet system development process has also changed. The method used in the past was to first produce drawn construc- Photo: © IABG tions as test objects and then to expose them to extensive tests. If the expected as- sumptions were not confirmed, the engineers Seismic verification, would repeat the process chain (Design > vibration test and Construction > Tests) until the target was certification by IABG achieved. An integral part of the state-of-the-art con- struction processes at BENNING, however, is computer-aided development with specific simulation options, which are carried out be- fore the actual hardware tests. This makes acceleration-frequency-diagram the development process significantly shorter [m/s2] response spectrum – 5 % damping and more efficient. TRS_x TRS_y BENNING has also developed a simulation TRS_z tool which can determine the cabinet require- RRS_xy ments prior to the construction stage in order RRS_z to select a suitable cabinet. Finite element method Computer-aided simulations are used to check the load limits using structural and dy- namic calculations based on the finite ele- ment method (FEM). This results in a stan- dard-compliant analysis and calculation of the deformations or stresses of a cabinet [Hz] frame during the construction. In addition, physical properties of the cabinet system can TRS = transmissed response spectrum (x-axis, y-axis, z-axis) be visualised, and potential weaknesses can RRS = required response spectrum (xy-axis, z-axis) Example construction earthquake cabinet UC-HE UPS-System ENERTRONIC I in seismic design UC-HE be precisely located for targeted optimisation H 2200 x W 800 x D 800 mm H 2200 x W 800 x D 800 mm measures. Stringent requirements fulfilled The construction of a test housing and the struction exceeds all normative requirements rectifier system, which supplies the pumps of ferent is the system casing, i.e. the enclosure. a welded structure and the other has a ment increases without resonance. The verification of the calculations in the com- in terms of earthquake resistance, even in the the internal cooling circuit, ensures maximum Due to this technical and functional analogy, bolted structure. During an earthquake, the higher the attenuation factor of the device, pany's own environmental laboratory do not worst-case scenario. safety and therefore chooses an housing cer- a technician can find his/her way around a structural elements in the bolted housing the lower its response curves. take place until the simulation process has tified to the highest earthquake categories for servicing task faster. This provides the highest move relative to each other, causing friction been successfully completed. Here, so- Maximum cost-efficiency this area. In this way, both power supply sys- level of safety with maximum cost-efficiency. and noise, such that the seismic energy author/contact: Stefan Kleefeld called vibrating tables are used, which mimic tems used are provided with the optimal pro- dissipates much faster than in the welded telephone: +49 2871 93 358 the vibrations and shock loads caused by an Another decisive advantage arises from the tection that complies with the cost-efficiency Seismic switchgear terminology housing. The bolted cabinet will thus dampen e-mail: s.kleefeld@benning.de earthquake. fact that all four cabinet system versions de- and safety requirements. On the other hand, the energy faster than the welded one, thus In addition to its own test results, BENNING veloped by BENNING are based on the same this provides for easy and quick maintenance The damping characteristic of a switching reducing the time required to build up seis- has had the current UC-HE cabinet design design principle. Suppose, for example, that because the base frame of the cabinet con- device limits the overall gain that it experi- mic response. The damping properties of a certified by a recognised testing laboratory, in earthquake zone 2, a rectifier system in struction as well as the arrangement of the ences during resonance. Suppose, for exam- system are indicative of the system's ability Scan the QR code for the IABG (Industrieanlagen- Betriebsgesell- UC-ME design is used to secure the telecom- power and functional elements are identical ple, that two cabinets are identical in design, to dissipate earthquake energy. Without at- further information schaft mbH), with the result that this con- munications system. At the same time, the in both systems. The only thing which is dif- assembly, and weight, but one cabinet has tenuation, the resonance gain of the equip- 24 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 25
Reduction of headway Photo: © WSW Wuppertaler Stadtwerke GmbH. WSW Mobil GmbH aims to replace all 27 old vehicles with 31 new vehicles by spring 2019. These should achieve a higher average speed thereby reducing the rush hour head- way from three to two minutes. As in the case with the power increase, the requirements for the mains voltage have also changed: All new vehicles and the his- Historical wheel set of the Kaiserwagen toric Kaiserwagen are no longer designed for a mains voltage of 600 V, but, rather, for Original design: Rotor and field coil 750 V DC. from 1900 New Drive Motors for historical Kaiserwagen BENNING carried out a rotor-stator re-build on the historic Kaiserwagen of the Wuppertal suspension railway to ensure that it can continue to be used for round trips and festivities Data capture in BEM test bay in the future. The Wuppertal suspension railway is con- To date, the Kaiserwagen has been pre- Historically, the Kaiserwagen has been configuration needed to be implemented. As and implemented the appropriate solution sidered one of the longest engineering served for posterity, surviving the two world powered by four 25 kW series motors using part of the modernisation, this represents a strategies using its technical know-how and landmarks in the world. On the route of a wars as well as several generations of older 600 V DC, whilst the new 'Generation 15' ve- particularly complex and costly process, extensive experience in the repair, construc- 13.3-kilometre long railway system, it trans- cars. In addition to the regular transportation hicle series will only use 750 V DC mains volt- which can only be professionally fulfilled by tion and reconstruction of electric motors. ports around 70,000 passengers a day services, it is not only used for round trips, age for the three-phase asynchronous motors, very few companies. The customer was WSW Mobil GmbH as the through the capital of Bergisches Land. but also as a venue for birthdays, anniver- to allow a headway of only two minutes (see How and where does one start if no technical operator of the Wuppertal suspension rail- A special highlight is a ride in the nostalgic saries or weddings, for example. info box at top right). documents are available, only an outdated, way. ambience of the historic Kaiserwagen. To ensure that 'the good parlour of Wuppertal', albeit functional, sample frame, which was Kaiser Wilhelm II and his wife Auguste Vik- as the historic car is commonly called, is also Adaptation to the new operating system used back in 1900 to support the suspen- Rotor-stator configuration toria made the inaugural trip through the available for rides and festivities in the future, sion railway? Wupper Valley in 1900 - about two and a it must be adapted to meet the increased To ensure that the engines of the Kaiserwagen As part of the rotor-stator configuration, fol- half years after the start of construction of mains voltage requirement of the new gener- can be adapted to the voltage requirements of A challenge facing the BENNING electrical lowing successful assembly of the sample the suspension railway. ation of cars. the new operating system, a new rotor-stator machines (BeM) department, who developed rack on BENNING's own test station, Historical running gear, disassembled for data capture 26 | BENNING | POWER news | 10/2018 BENNING | POWER news | 10/2018 | 27
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