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9 / 2 017 Customer Magazine informative · up-to-date · pioneering Thinking ahead, acting sustainably Efficient UPS system for Sydney’s Metro 28 – 31 Smart telecom power supply 12 – 16 Nature and technology in harmony 17 – 19 www.benning.de
POWER news 9/2017 Editorial Dear Readers, Driverless cars have been a hot topic in the transport industry for some time. Technologies such as assisted parking, accidental lane Modular power protection change warning systems and tailback systems are already being fit- ted to vehicles as standard and initial prototype driverless cars have in Industrial applications also been successfully tested, although they are not ready for mass production just yet. This may still be on the horizon for roads, but it is already maturing The principle of modularity provides for rail transportation. Many cities are using driverless overground and significant technical and economic underground trains which are making a major contribution to taking the load off road traffic and Sydney will soon have Australia's first fully-automatic underground system. To ensure it benefits in the design and operation carries passengers safely and smoothly, it is using BENNING high-availability power supply of UPS systems. systems. To discover what financial and environmental benefits this brings, see this edition of POWER news. You can also read how BENNING's products are making Washington's Metro rail system Modular power protection and conver- safer and dramatically reducing energy consumption at one of Germany's largest semi-au- sion technology, particularly in the form tomated textiles logistics centres. of UPSs, has long been used in com- I hope you enjoy reading it and look forward to hearing what you think. mercial applications, but take-up in Yours, Stephan Ratermann industrial applications has, to date, been ENERTRONIC modular SE, relatively slow. 20kW and 40kW modules e-mail: s.ratermann@benning.de telephone: +49 2871 93 0 Contents 3–7 Modular power protection 22 – 23 Highly efficient and effective test and This relatively slow uptake is due, in part, to in Industrial applications diagnostic solution for photovoltaic systems a limited understanding of the “ilities” (“Avail- The principle of modularity provides significant in accordance with international standards technical and economic benefits in the design The installation tester and I-V curve tracer ability”, “Reliability”, “Scalability”, “Flexibility” and operation of UPS systems. BENNING PV 2 is an efficient diagnostic tool and “Maintainability”) commonly associated to ensure that initial operation tests, mainte- with modular technology and how the vari- 8 – 11 BENNING develops innovative OEM nance tests and performance assessments of power adaptor for medical technology ous “ilities” complement each other. photovoltaic systems are carried out quickly For more than 30 years, the name BENNING and reliably. has represented high-performance OEM power supplies specially designed for the 24 – 25 Investing in new pyrolysis process The third of five articles within our 'ility' series tough demands of the medical technology reduces turnaround times significantly focuses on availability and reliability. We will sector. It takes just 36m³ of space to strip electric motor windings quickly, non-destructively review the technical and mathematic back- 12 – 16 The Next Generation: and efficiently. grounds and explain how both terms SLIMLINE Telecom power supply systems BENNING is just starting to deliver a new 26 – 27 Significant energy savings thanks to relate to the increasingly popular modular generation of highly efficient telecom power highly efficient LIONIC® energy systems technology. supply systems with a performance range of BENNING supplies highly efficient lithium-ion 2 – 400 kW. energy systems to one of Germany’s largest semi-automated textile logistics centres. Scalability 17 – 19 Hydroelectricity – Nature and Technology in Harmony 28 – 31 Support for the largest traffic project At the Bavarian Hydroelectric Power Station at in Australia Power protection systems for industrial ap- Leipheim, modular power supply systems are Australia's first fully automatic underground plications are typically expected to have an being installed to provide an uninterrupted railway system opens in 2019, with BENNING’s power supply for all power station functions. ENERTRONIC modular SE UPS systems operational life of 20-25 years, so ensuring 20 – 21 Emergency power supply for the heavy rail ensuring that the signalling system the size of the system is correct at the time never stops working. of installation is very important. rapid transit system in Washington 30 BENNING UPS systems set to provide 32 Fairs, events and appointments more safety for one of the busiest metro rail 2018 systems in the United States. If the installed system proves to be under- Publication details sized at some point in its operational life then BENNING Elektrotechnik und Elektronik Liability and Copyright errors or mistakes in interpretation re- © MEV Verlag GmbH / www.mev.de an expensive system upgrade or replace- GmbH & Co. KG’s client magazine All texts are protected by copyright. main possible. © chombosan, chungking, Destina, ment may be required (i.e. a capital expendi- ture, or “Capex”, problem). The publication, adoption or use of texts, eplisterra, ghazii, Gina Sanders, Ingo Publisher: BENNING Elektrotechnik und pictures or other information is subject Picture credits Bartussek, JEGAS RA, kuosumo, Elektronik GmbH & Co. KG, to the written agreement from BENNING © BENNING Elektrotechnik und Elektronik lhboucault, Mirko, newb1, Paul, pixs:sell, Münsterstrasse 135-137, 46397 Bocholt GmbH. No liability is accepted for any GmbH & Co. KG / profit_image, Ramona Heim, RobbinLee, guidance, references, recommendations © Bayerische Elektrizitätswerke GmbH Sashkin, Scanrail, Sergey Nivens, Design und Production: Advertising Agency or evaluations. In spite of making every © Drägerwerk AG & Co. KGaA, Lübeck serkat Photography, tanarch, Witthaya, Paus Design & Medien GmbH & Co. KG, effort to carry out a correct presentation © GS-Gabelstapler Service GmbH. WrightStudio / Fotolia.com Brinkstegge 13, 46395 Bocholt and checking of the subject matter, © KIMA 2 | BENNING | POWER news | 9/2017 BENNING | POWER news | 9/2017 | 3
modular power protection [%] Efficiency [%] Output power Efficiency for different output powers Normal Operation SE Operation Bypass Operation Typical transformerless UPS efficiency curve BENNING’s UPS system is scalable and can increase in size in line with load requirements If, however, the installed system proves to be ership is minimised, is to ensure that the that supplies a critical load that may well • Power losses ing efficiencies of >95% are achieved with maintenance recommendations and hence oversized then initial Capex would have been system is always “right-sized” and scalable change significantly over time. loads above 17% and the optimum efficiency ongoing maintenance costs before purchas- wasted, the system will be running at less systems enable this. If the critical load is 100kW, for every 1% re- (>96%) is achieved when the load is between ing the system. than optimum efficiently and maintenance The problem is that these three elements duction in operating efficiency there will be an 35% and 60%. costs will be higher (i.e. an operational ex- Total cost of ownership (TCO) are all interconnected and a balance needs additional 1kWh of wasted energy. Because System “right-sizing” penditure, or “Opex”, problem). to be struck between all three elements if the the power protection system is in operation • Ongoing maintenance costs Both Capex and Opex problems can have a For a power protection system the three lowest overall TCO is to be achieved. 24 hours/day, 365 days/year there will be For consistency across the articles in the significant impact on total cost of ownership. main elements affecting cost of ownership 24kWh wasted each day or 8,760kwH All power protection systems contain electri- “ilities” series, we will revisit the examples Ever changing site equipment (critical load) are: Considering each element in turn: wasted each year or 175,200kWh wasted cal and mechanical components that have a seen in the “Availability v Reliability” article, technology and operational requirements 1. Up-front capital cost (purchase price); over the 20 years operational life. With this finite useful working life and will require rou- i.e. we will assume that the system design makes predicting what the system load will 2. Power losses (a function of system effi- • Up-front capital cost in mind: tine maintenance and/or replacement if the critical load is 120kW and that N+1 parallel be, and hence what the system size should ciency); power protection system is to achieve the redundancy is required. However, as it is not be, over a 20-25 year period almost impos- 3. Ongoing maintenance costs. If the lowest cost system is purchased the 1. Care should be taken to ensure that the required availability levels for its 20 years’ op- good practice to operate a UPS continuously sible. To err on the side of caution, almost all lowest up-front capital cost will have been power protection system is sized to erational life. at 100% load we will assume an operational systems are oversized at the time of initial in- It goes without saying that everyone wants achieved. However, if the system is of an ensure it operates on the optimum point If, as suggested above, the lowest cost sys- load of 80% (i.e. 96kW). stallation, which is good news for the system to minimise the total cost of ownership (TCO) older, less efficient, technology then the on the efficiency curve; tem uses the lowest cost (and hence prob- manufacturer but bad news for the system for their power protection system. However, system running costs may be higher than ably the lowest quality) components then Example 1: 120kW, 1+1 parallel redundant operator as they will probably have wasted to achieve this it is necessary to first under- necessary. 2. System operating efficiency is more likely to the maintenance costs for the system over system using modular-block topology. Capex at the initial system purchase and will stand what the key elements affecting the affect TCO than the up-front capital cost. its operational life will probably be higher as be wasting Opex every year the system is in total cost of ownership are, and then to Furthermore, the lowest cost system may the components will need to be main- In this example, we are using two 120kW operation. understand how they can be optimised for a also have the highest ongoing maintenance Almost all modern “transformerless” UPS tained/replaced more frequently. With this in UPS cabinets. If the critical load is 96kW then The only way to ensure that Capex and Opex power protection system that may have an costs because it probably uses low quality have an efficiency curve that is relatively flat. mind, it is always worth asking the power each UPS cabinet will be 40% (48kW) are optimised, and hence total cost of own- operational life of more than 20 years and (i.e. cheap) components. In the figure above, we can see that operat- protection system supplier for their ongoing loaded. 4 | BENNING | POWER news | 9/2017 BENNING | POWER news | 9/2017 | 5
modular power protection Modular block architecture Modular block architecture Mains Mains UPS 1 / 40kW 120kW 120kW UPS 1 / 120kW UPS 2 / 40kW Critical Critical load load UPS 2 / 120kW UPS 3 / 40kW UPS 4 / 40kW 1+1 Parallel redundant configuration 3+1 Parallel redundant configuration Example 1: 120kW, 1+1 parallel redundant Example 2: 120kW, 3+1 parallel redundant system using modular-block topology. system using modular-block topology. The system will be perfectly “right-sized” and then the new 125kW load will mean that If, however, the critical load is 60kW then loaded and either the N+1 parallel redun- icantly affect the system total cost of own- the system will be operating in the optimum each UPS cabinet will be 34% (41.6kW) each UPS module will be 37% (15kW) loaded dancy will be lost or an additional 40kW UPS ership and all three of these elements must part of the efficiency curve. Both Capex and loaded so the system will be oversized, so the system will be oversized and Capex module must be installed. be jointly considered. Opex are optimised. significant additional Capex would have been will have been wasted on purchasing a Because the system cabinet was correctly Installing a rack-mounted modular UPS If, however, the critical load is 60kW then each wasted on purchasing a system that is too system that is too large but Opex will still be sized at installation and there is a “spare” slot cabinet with one or more empty slots at the UPS cabinet will be 25% (30kW) loaded so large and Opex may be being wasted as OK as the system will still be operating on a available to accommodate an additional UPS time of initial installation will future proof the system will be oversized, Capex will have the system may not be operating at optimum good part of the efficiency curve. However, module and because the system is rack- the installation for very little increase in the been wasted on purchasing a system that is efficiency. because the system is rack-mounted modu- mounted modular the installation of the addi- initial capital cost of the system. too large and Opex will be being wasted as lar the system operator has two options: tional module is quick, easy and relatively the system will be operating less efficiently. Example 2: 120kW, 3+1 parallel redun- inexpensive, thereby Capex and Opex con- The next article in the “ilities” series will dant system using rack-mounted mod- 1. Continue to operate the system with all tinue to be optimised. discuss “flexibility” and how the selection of If, the critical load suddenly needs to increase ular topology. 4 modules and benefit from N+2 parallel the right UPS topology can give parallel to, say, 125kW then the system will be over- redundancy; Conclusion redundancy, changes in system capacity loaded and either the N+1 parallel redun- In this example, we are using a single cabinet and the ability to rapidly locate critical power dancy will be lost or an additional 120kW capable of housing five 40kW UPS modules 2. Remove one of the modules from service A system that is perfectly sized for the load protection capacity wherever needed. UPS cabinet must be installed (assuming that but fitted with only four modules. There is, (either switch it off or physically remove it from day one and can increase or decrease the site infrastructure can accommodate an- therefore, one “spare” slot for an additional to create a second “spare” slot) to operate its capacity in sympathy with the critical load contact: Alexander Proemel other cabinet). In the worst case, the system 40kW module. If the critical load is 96kW the system on a better part of the effi- will achieve the lowest total cost of ownership telephone: +49 2871 93 238 will need to be replaced with another, more then each of the 4 off 40kW UPS modules ciency curve. If a module is removed each (TCO) for the system over its operational life. e-mail: a.proemel@benning.de powerful, system. will be 60% (24kW) loaded. The system will of the remaining three modules will be be perfectly “right-sized” and the system 50% (20kW) loaded. The up-front capital cost of the system, If the site infrastructure can accommodate will be operating on the optimum part of the whilst important, is not the most important Scan the QR code for another 120kVA UPS cabinet, making the efficiency curve. Both Capex and Opex are If, the critical load suddenly needs to increase element in TCO. System operating efficiency further information system a 2+1 parallel redundant system, optimised. to, say, 125kW then the system will be over- and ongoing maintenance costs both signif- 6 | BENNING | POWER news | 9/2017 BENNING | POWER news | 9/2017 | 7
The newly developed M7.3 Plus power supply BENNING develops innovative OEM unit has three output connections (see image left). power adaptor for medical technology It is used e.g. in a respiratory device such as made by company Dräger (see image below). cm For more than 30 years, the name BENNING has represented 18 ox. appr high-performance OEM power supplies specially designed for the tough demands of the medical technology sector. The average life expectancy in Germany continues to increase. In 2000, it was around 77 years. This has risen to over 81 years since then. The development is largely a result of the advances in medical technology with innovative devices and machines ensuring that patients receive increasingly safe, efficient and comfortable care. One of the effects is a significant decrease in the workload of hospital staff. Medical technology is subject to stringent Tailor-made solutions safety standards. An essential requirement here is a guaranteed uninterrupted power Optoelectronics is just one area where supply. Fluctuating power and power out- BENNING power supplies are used. In order ages may result in interruption of medical to be able to use high-sensivity scanning care with potentially severe consequences electron microscopes for research purposes, for patients. power supplies are required not to produce mechanical vibrations in the NF range. Even For more than 30 years, BENNING – one of the smallest mechanical vibrations can lead the leading producers of synchronised OEM to blurry and distorted images being Photo: © Drägerwerk & Co. KGaA, Lübeck. All rights reserved. power supplies – has been developing high- recorded by the microscope. performance power supply units specially designed for the tough demands of medical BENNING also produces reliable power sup- technology applications. plies for use in the dental technology field. These products stand out for two reasons. Fitted with a high-power pulse (36 V and Firstly, their high quality and excellent reliabil- 50 A for 10 seconds) and a graduated over- ity meet both national and international safety load profile, dentist chair motors can quickly (EN 60950, UL/CUL 1950 and IEC 60601-1) and safely bring patients of any weight class and (EN 55022-B) EMC standards. into the right position. Secondly, the hardware and software are tailored to the individual requirements of Other uses include heart-lung machines, each customer, which means that each MRI, dialysis systems, anaesthetic systems power supply unit has its own specific lay- and respiration systems. For the last men- out and software design. According to the tioned systems, BENNING developed the technical specifications provided, the unit is 250 watt M7.3 Plus power supply with its fitted with the appropriate interfaces; AC compact two-part structure, combining inno- and DC outputs; as well as the control, reg- vative and reliable hardware and software in ulation and monitoring software necessary the smallest confined space. The M7.3 Plus for reliable operations. builds upon the well-established 8 | BENNING | POWER news | 9/2017 BENNING | POWER news | 9/2017 | 9
Photo: © Drägerwerk & Co. KGaA, Lübeck. All rights reserved. The compact two-part structure of the M7.3 Plus combines innovative and reliable hardware and software in the smallest confined space. Passive cooling is used so that it emits zero noise. M7.3 Classic with a range of additional fea- High degree of flexibility Constant dialogue contact person is assigned who coordinates any special or complex requirements individ- author/contact: Dirk Petrich tures to set it apart from its predecessor. the hardware and software development. ually and to find appropriate solutions. telephone: +49 2871 93 401 For example, an additional battery connec- Charging performance has been doubled so All of the specified characteristics contribute Intensive discussions are held with everyone Results of the development process are usu- e-mail: d.petrich@benning.de tion has been integrated that is particularly that the higher battery capacities can be to optimising the quality of treatment and involved to ensure that all customer-specific ally presented in form of initial prototypes important while transporting patients, e.g. charged within a reasonable amount of time. safety of patients. These properties are the requirements are included in the develop- and then further enhanced in close cooper- when moving from the operating theatre to The use of lithium batteries should be pos- result of close and trusting collaboration with ment process. ation with the customer until a completely re- the intensive care unit. The use of a redun- sible in the near future. Until then, a combi- producers of medical devices. liable system that meets the specific require- dant battery system represents an addi- nation of lead and NiHM batteries can be From the planning phase until the start of A key advantage of this is that with BENNING’s ments and standards is ready to go into tional safety mechanism for the respiratory used to increase flexibility. Just like its pre- series production, BENNING maintains a decades of experience, the company knows production. Scan the QR code for device in case the first battery fails or runs decessor, the M7.3 Plus works without a fan dialogue with them. Throughout the devel- the high standards and requirements of the further information out of power. so that it emits zero noise. opment and production processes, a direct medical sector very well. This allows to discuss 10 | BENNING | POWER news | 9/2017 BENNING | POWER news | 9/2017 | 11
The Next Generation: SLIMLINE Telecom power supply systems BENNING is just starting to deliver a new generation of highly efficient telecom power supply systems with a performance Stefan Kleefeld, range of 2 – 400 kW. Sales The average German household has 10 devices on line at any time. In modern as flexibility and modularity are also highly im- switching centres or MSCs) through base [l] Comparing Volumenvergleich volumes society, everyone normally has access online for communications or business portant. These form the basis for a significant station controllers (BSCs) right up to the in- of derSLIMLINE SLIMLINE purposes at all times. reduction in installation and assembly times dividual base transceiver stations (BTS). So generations Generationen Being ‘Always In Touch’ means always having Internet access, with broadband and simpler and more efficient maintenance our power supply systems protect all the 1,5 networks spreading globally using wireless technology (LTE, in future 5G). The in subsequent operation. BENNING meets transmission technology involved (LTE, 4G, telecommunications systems required need power supplies that are always op- these requirements with its modular concept VOIP, TV, Server, etc) against any mains sup- erational and reliable. in our new SLIMLINE telecoms power sup- ply deviation . ply. At the same time, we are cutting the time 1,0 For decades, BENNING has been supplying power supplies for operating IT, communica- and costs required to install or maintain PN: Could you tell us something about mobile phone and landline operators world- tions and industrial technology systems reli- power supplies at communications sites re- power density? wide with battery-backup AC/DC power ably. What are the main things the market gardless of whether they are new ones or ex- 1,5 l 1l supplies and has invested particularly in wants from the new development of the isting conversions. Kleefeld: To build complete power supply developing highly efficient power supplies for SLIMLINE Series for the telecommunications systems, individual modules are available 0,5 reliable, energy-saving operations. sector? PN: You said the equipment was developed with a power output of 2000 W. Compared specifically for use in the telecommunications with our previous SLIMLINE SE models, we POWER News talked with Stefan Kleefeld, Kleefeld: BENNING develops feature rich market. What are the fields in which the new have succeeded in increasing power density BENNING’s product manager, about the next power supply solutions to give network op- system is normally used? by 50%. Our 19“ 1HU equipment rack can 2 kW 2 kW generation of intelligent power supplies. erators precisely what they need. Current accommodate either six rectifier modules or 0 ‘must-haves’ include maximum operating re- Kleefeld: Our new SLIMLINE range covers five 48 V rectifier modules at 2000 W and one PN: Mr Kleefeld, BENNING is seen as one of liability, maximum energy efficiency and max- the whole spectrum of mobile phone appli- MCU module, giving a power of 10 kW or SLIMLINE SE SLIMLINE SLIMLINE 2000 today’s leading suppliers of high efficiency imum available ‘user space’. Features such cations, from switching centres (mobile 12 kW per 1U of rack space. SLIMLINE System 48 V/4 kW and MCU, battery and load distribution [%] SLIMLINE System, 48 V/22 kW and MCU 12 | BENNING | POWER news | 9/2017 BENNING | POWER news | 9/2017 | 13
[%] ... SLIMLINE – smart, flexible and efficient Efficiency factor/level PN: What other advantages does your new PN: You mentioned the term ‘MCU’ a num- SLIMLINE telecom power supply offer – in ber of times. What does this module do? terms of flexibility in particular? Kleefeld: For the comprehensive control and Kleefeld: Thanks to their hot plug technol- monitoring functions for these systems, we ogy, all modules can be replaced without in- provide our remote monitoring system MCU terruption to the clients load. The equipment (monitoring control unit). For low-power units, Output rating [%] racks with their corresponding number of this is usually installed as a module in the rec- rectifier modules, and the battery and user tifier equipment rack; for higher-power sys- SLIMLINE SE SLIMLINE distribution systems allocated, create a com- tems, it can be installed in the power supply plete modular SLIMLINE power supply sys- cabinet door. tem ensuring maximum flexibility. There are The efficiency factor of the new SLIMLINE rectifier module has been signifi- If a mobile device or computer is available, the system can be configured also add-on battery and load distribution sys- PN: As you said earlier, high-energy effi- The new SLIMLINE MCU module has a 1.8" cantly increased and already achieves 97% at 50% of output performance. easily via a network connection and an Internet browser. tems available at different power ratings. ciency is one of the ‘must haves’. What are Display on the front, a USB 2.0 interface (e.g. The distribution systems are also designed the advantages of the new range compared for a WLAN stick, etc) and an ethernet port. as 19” plug-in units and comprise one or with the previous one specifically? three height units, depending on power out- Kleefeld: It is true that the MCU monitors take up more space and cost more. If it things looking with the MCU unit installed in can be connected both via the RS 485 inter- put. Kleefeld: Our new series of highly efficient a system and controls it appropriately – for does fail, of course, a signal is sent so we the racks? face or via the network. A modem connec- rectifiers reduces AC-DC conversion losses power management, for example; but the can plan to replace the MCU as soon as tion, which is supplied via an RS 232 inter- PN: Can the new SLIMLINE be fully flexible, by up to 30%, reducing the actual rectifier system is in fact designed in such a way possible. Kleefeld: If you look closer at the MCU mod- face, and the 12 V power supply has also bearing in mind there may be very different physical size by approximately 50% at the that the power supply continues to operate ule, you will notice that no less than five com- been added. performance criteria with very special require- same time. reliably even if the MCU fails. The rectifiers PN: With the rectifiers, you have managed to ponents are integrated in just one sixth of the ments? What is particularly impressive is that the continue to supply the system and batteries double the power density for each individual 19“ width, which were still separate in the The system configuration can be set up via SLIMLINE range operates at > 97% effi- so that performance remains at 100%. So, height unit. In parallel with this, how are previous model and took up extra space, e.g. the colour display or,if a mobile device or a Kleefeld: Yes, we have solutions to meet ciency in the 50–90% load range. This failure of the MCU is not critical to the pro- an SMNP adapter and the Modbus, which computer is available, then it can be config- every need. Our SLIMLINE PSU 4000 power means major savings in most facilities cess – and there is no need for the ured easily via a network connection and supply system, which is the smallest in telecommunications that service providers MCU to be redundant. Quite power terms, has up to two 48 V/2000 W use in the field. the opposite, in fact: it rectifier modules and one MCU, plus the bat- would merely tery and load distribution system, all in a sin- We have an optional active power manage- gle 19“ 1HU equipment rack. ment system that determines what the load is at any time and connects or discon- For the mid-performance range – which in- nects the rectifier modules cludes, for example, mobile phone base sta- accordingly, this will al- tions – system performances of 10 kW (with ways ensure the maxi- an MCU module) or 12 kW can be achieved mum system efficiency within a single height unit using just one without compromise to 1U rack, fully equipped with rectifiers. redundancy. Connecting a second rectifier rack in parallel PN: We see the MCU is can increase power to 22 kW – including an not redundant. What MCU module. Special battery and user dis- happens if it fails? tribution systems are available for all power ranges, ensuring flexible and compact space-saving systems. Even higher power outputs, which central hubs and distribution stations need for ex- ample, can be produced by connecting a number of equipment racks in parallel. In this way, output power ratings of up to 400 kW are possible. Such systems are then installed in the special BENNING UC cabinets, which can also accommodate batteries and distri- bution. The 19“ 1HU equipment rack can hold either six rectifier modules or five 48 V rectifier modules (offering 2000 W) 14 | BENNING | POWER news | 9/2017 and one MCU module. BENNING | POWER news | 9/2017 | 15
... SLIMLINE – smart, flexible and efficient 6 x relay contacts 4 x analogue inputs (TTUI) 4 x digital inputs Redundant supply Expansion slot Hydroelectricity – Nature and Technology in Harmony At the Bavarian Hydroelectric Power Station at Leipheim, modular power supply systems are being installed to provide an uninterrupted power supply for all power station functions. The SLIMLINE MCU 3000 Module can contain as many as five components integrated in just one sixth of the 19“ width, which were still separate in the previous model and took up extra space. the Internet browser also. No additional soft- existing infrastructure and what challenges points. As it is equipped with the MCU mon- ware is required. does this mean to power supply manufactur- itoring and controlling unit, this power supply Photo: © KIMA ers like BENNING in the future? system is already meeting tomorrow’s com- PN: You said the system is modular in terms munications challenges today. of both rectifier systems and distribution. Kleefeld: As 5G will probably use frequen- How will you cope with future power up- cies between 300 MHz and 300 GHz, the PN: You mentioned the large number of grades? short wavelength means it can carry signifi- widely distributed transmission cells and the cantly more data; but it also reduces the op- resulting new or upgraded communications Kleefeld: The system is easily scalable, of erating range. This means that instead of hubs. How will these affect network opera- Environmentally-friendly power sup- course and can grow in line with customer having a few dozen transmitter masts in an tors’ operating costs as a whole? ply technology from Westmü nsterland requirements – from 2–400 kW. Through urban area, we might need to install and con- being highly modular, we will be able to plan, nect hundreds of small transmitter cells. So, Kleefeld: As it will take 1000 times less en- KIMA Gesellschaft für elektronische Leipheim Hydroelectric configure and deliver customer-specific sys- on the one hand, we need to supply power ergy to send each transmission and so the Steuerungstechnik und Konstruktion mbH power plant tems in a matter of weeks from 2018. reliably to hundreds of small transmitter cells operating cost per megabyte will fall. Within [English: “Company for Electronic Control needing power supply systems with low rat- total operating costs (total cost of owner- Technology and Design Ltd”] was founded PN: If we look at the economics, operating ings; on the other hand, communication ship), maintenance and service costs will ac- BEW (Bayerische Elektrizitätswerke GmbH) generates around 1.1 billion kWh of en- in1987 in Gronau and, with more than 100 costs should be considered, as well as en- hubs will provide high-speed connections count for a much greater percentage. vironmentally-friendly power per year using renewable hydroelectricity, making it employees, provides engineering services ergy efficiency. What opportunities does the between individual mobile phone stations Multiplying the transmission cells required one of Bavaria’s leading operators of hydroelectric power stations. All 36 of the hy- in the field of control and regulation tech- new generation offer for making savings? and providers’ core networks. If these break means operators’ service and maintenance droelectric power stations BEW operates are exclusively ‘run-of-river’ plants. As nology. down, whole regions may crash, so these costs will soar if no quick and simple service the water never stops flowing, these are designed for continuous operation, pro- Kleefeld: The rectifier modules are identical hubs must be particularly protected against options are available. Integrated service func- viding sustainable power around the clock and making a major contribution in the KIMA develops customised applications – and mutually compatible, so they can be mains failures. tionalities could be used to extend the main- transfer to alternative energy sources. from initial engineering right through to easily exchanged in all available systems. The tenance cycle. commissioning – for a wide variety of pro- advantage for our customers is simple stock- At the same time, if we look at what is hap- cesses in manufacturing and process keeping and logistics because only one type pening in the Internet of Things, it is clear that PN: Mr Kleefeld, many thanks for this infor- Top priority must be given to a reliable power Comprehensive Modernisation technology. KIMA supplies complex con- of module needs to be kept for all the sys- process reliability, for example, in relation to mative interview. We look forward to further supply for the technical systems inside the trol and regulating systems worldwide to a tems. Industry 4.0, will depend on reliable data innovative developments from your engi- power plant that are critical for its operation, To achieve this, a wide-ranging initiative was wide variety of industrial sectors, such as The bright, high-contrast display of the MCU communications much more than today. So, neers. i.e. its internal power requirements. All the set up in order to update the equipment for cement, food processing, hydroelectricity is also programmed as a signalling unit. If any a modular scalable DC power supply can regulation and control functions for the vast the electrical and control systems within the and environmental technology, including problem occurs, it lights up all in red and is provide the basis for covering these widely author/contact: Stefan Kleefeld number of actuators in the power plant and power plants. redundant, high availability/safety-related highly visible from a distance. ranging performance requirements within the telephone: +49 2871 93 358 particularly for the turbine units that lie at its control systems. overall infrastructure. e-mail: s.kleefeld@benning.de heart, are based on gathering data seam- After an intensive planning phase, BEW im- PN: The next generation of mobile phone net- lessly from a large number of measurement plemented the resulting strategy for the first works is already on the drawing board. 5G With our SLIMLINE power supply system for points. time in 2012 at the ‘run-of-river’ hydro power BENNING and BEW had already worked to- mobile phone networks with up to 10 GB/sec indoor and outdoor operations, BENNING is One of BEW's most ambitious aims is to plant at Rhien, owned by Rhein-Main-Donau gether for over 30 years. Throughout this offering approximately one hundred times the already offering a flexibly scalable system, Scan the QR code for achieve an unmanned operating regime that AG. Following a competitive tender process, time, BENNING had demonstrated how ro- data rates of the current 4G-LTE networks. which can currently be used to upgrade LTE further information is remotely monitored at minimum cost, day BENNING was selected as the partner of bust, reliable and efficient its equipment is in What does this technology mean for the mobile phone stations, hubs and distribution and night. choice for the power supply systems. a number of different projects. 16 | BENNING | POWER news | 9/2017 BENNING | POWER news | 9/2017 | 17
̈tswerke GmbH Photo: © Bayerische Elektrizita The equipment was started up in BENNING's test area, and was subjected to extensive tests by KIMA's staff. Since entering into service in 1961, the two Kaplan turbines with a maximum joint output of 9,370 Kilowatts, have generated an av- erage of around 50 mil- lion kWh of power per year. Compared with con- ventional power gener- ation, this means elim- inating roughly 35,000 tonnes of carbon diox- ide emissions a year. User-friendly equipment Meanwhile, this system design with high pack- has now been installed ing density. at the hydroelectric power plant. The automation project was started at the technically authorised that, based on com- damage to the critical and costly engineering able, these systems supply the loads and Remote Access Function Plans for Further Collaboration Leipheim site, owned by Obere Donau Kraft- prehensive tests, the modular industrial type systems. provide the charging current or float voltage werke AG (ODK). Modernising the ‘run-of- rectifier, the TEBECHOP 3000 HDI could for the batteries that were also supplied by In order to enable a fully-automated, un- There are already plans to continue the part- river’hydro power plant, situated directly on cope with the loads occurring in the power BENNING won the order in May 2017, BENNING. This ensures that, if the mains manned operation of the ‘run-of-river’ power nership, which demonstrates the power plant the Danube in the Swabian rural district of plant, particularly in the event of an emer- thanks to a product that was both technically supply fails, the batteries are available at full plant, it is necessary to have remote access operator is confident in BENNING’s supply of Günzburg, will be carried out working with gency shutdown. and commercially credible. Roughly two capacity and that the various loads receive a to all the technical systems in the power both products and services. tried and tested partners, as in the additional months later, the client gave the go-ahead to reliable power supply during the transition plant. hydroelectric power plants on the Lech, Iller In this scenario, an emergency shutdown commence manufacture and in November, period, without any interruption in power. The power supply system is therefore author/contact: Claus Kirmaier and Danube rivers. means that as there is suddenly no generator as soon as it was accepted at the plant, it equipped with the BENNING MCU (multi- telephone: +49 8332 936363 load on the turbine units, they overspeed was commissioned on-site. The modular rectifiers and inverters supplied point control unit) enabling connection via e-mail: c.kirmaier@benning.de The company responsible for implementing when the load is removed, so that frequen- are specifically robust systems designed for Profibus to the BEW state-of-the-art central the extensive modernisation measures is cies of over 70 Hertz may occur initially be- Maximum Availability industrial applications. Maximum equipment control room, providing reliable, problem-free KIMA Automatisierung of Gronau which has fore the automatic frequency controls react availability is achieved by means of parallel remote access from the control room to the already undertaken a number of power plant to mitigate the enormous release of kinetic The in-house power supply developed switching of power supply modules fitted entire power supply system and the whole of modernisation projects in collaboration with energy. by BENNING includes rectifier systems with hot plug-in technology providing n+1 or the plant’s technological systems. BENNING (including those at Offingen, Gun- It is precisely at the beginning of these un- (110V/100A) of type TEBECHOP 3000 HDI, n+2 redundancy. In addition, the perfor- delfingen and Faimingen). planned operating conditions that it is abso- DC/DC-converters (110V/24V) in the series mance of the system can be flexibly adapted Thanks to the highly efficient data capture lutely vital to have an secure power supply for TEBECHOP HDDC and power inverter sys- at any time by adding or removing plug-in and the actuation technology via remote Scan the QR code for In the system used by BEW, BENNING had the internal requirements of all the significant tems of the INVERTRONIC compact type modules, without causing any interruption to management, the system is always under further information to demonstrate before the project could be technical systems in the plant to prevent (230 V/20 kVA). When mains power is avail- the supply to the consumers load. complete control in 'unmanned' mode. 18 | BENNING | POWER news | 9/2017 BENNING | POWER news | 9/2017 | 19
Emergency power supply for the heavy rail rapid transit system in Washington 30 BENNING UPS systems set to provide more safety for one of the busiest metro rail systems in the United States. The Washington heavy rail rapid transit A static UPS system is not only intended to represent safety and cost-effectiveness. The system is one of the busiest rail systems ensure a continuous and uninterrupted sup- equipment combines excellent output char- in the USA, covering a total area of ply to connected equipment, but also to acteristics and high voltage stability, even around 1,500 km² including Washington achieve a considerable improvement in volt- under heavy load fluctuations, with an input DC, as well as surrounding areas in age and frequency quality compared to the power factor ≥ 0.99 and minimal current dis- Maryland and Virginia. It is predicted normal power supply system. By 2021, vari- tortion. The product line has a comprehen- that the region around the American ous lines of the rail network should be sive set of reporting and monitoring func- capital will enjoy strong growth in the equipped with appropriate systems to ensure tions, and can be controlled both remotely coming decades, therefore the govern- a reliable and uninterrupted electricity supply via the customer’s network and from the dis- ment has formulated a strategic plan to the rail signalling system, control centres play on the system. called Momentum as a long-term vision and stations. for the future. This plan is intended to Redundant and scalable ensure that the rail network will continue Six UPS systems per year to meet the needs of the region, whilst Should the client wish to have the UPS sys- maintaining its competitiveness. As a leading quality supplier of industrial tem expanded in the future, for example, to power supply systems worldwide, BENNING scale up output capability for increased load Modernisation programme was awarded the contract to supply specially or for redundancy purposes, up to eight units configured UPS systems based on the of the ENERTRONIC I product line can be Momentum describes the need for a modern ENERTRONIC I type for various rail lines in used in parallel. As a series production range, and efficient transit system which, in the Washington in late 2016. Over the next five the ENERTRONIC I rectifier consists of an long-term, will be able to ensure a safe and years, six UPS systems will be delivered and IGBT semiconductor rectifier bridge with ENERTRONIC I 120 kVA reliable rail service for all passengers. put into operation each year, making 30 units power factor correction (power factor = 1). with optional IP21 cabinet To achieve this goal, a modernisation pro- in total. In accordance with the special customer re- gramme for the rail system has begun in In order for the highly customer-specific re- quirements in this case, BENNING has pro- order to, amongst other things, gradually quirements to be met as closely as possible, duced a thyristor rectifier with additional replace the existing emergency power supply BENNING and the client have been in close THDi filters, which reduce distortion to less with a modern and efficient system. contact from the outset. The specific product than 12%. It is designed in such a way that it duration allows great efficiency under partial selecting the system. For example, there was author/contact: Dietmar Papenfort Due to the high loads placed on the public specifications were jointly established and can simultaneously supply the full load and loads and very low THD with non-linear a lot of brake dust in the air at sites where the telephone: +49 2871 93 237 power supply (caused by disturbance effects the technical planning agreed. The delivery recharge discharged batteries within around loads. This also provides excellent dynamic system was to be installed. This largely con- e-mail: d.papenfort@benning.de from large-scale consumers, connections in and launch dates were set at an early stage 12 hours after a power outage to approxi- response with load changes. sists of fine dust which, because of its small peak usage periods and lightning strikes) it to ensure that the installation and commis- mately 95% of the battery capacity. particle size and chemical composition, could contact: Kiran Karuman is not possible to avoid voltage dips, over- sioning process would be as short and The consumers load will be automatically lead to breakdowns. The system cabinets de- telephone: +1 214 553 1444 voltage and transient currents in the public seamless as possible. The first successful Ideal for non-linear loads switched to the bypass network or a parallel veloped by BENNING have special air filter e-mail: k.karuman@benning.us mains electricity supply. Accordingly, robust system tests took place in the first quarter of system if the supply is no longer guaranteed devices to prevent the infiltration of the finest uninterruptable power supplies (UPS) can be 2017 with the first delivery taking place just In the inverter, the dc current is converted by the inverter within the prescribed toler- particles into the system. deployed to guarantee the supply to critical a few months later. into a three-phase alternating current using a ances. This is another product feature that serves to consumers (e.g. process control computers, sinewave generated from pulse width mod- meet high customer requirements during de- control rooms or SCADA systems), all of Maximum safety ulation through an IGBT semiconductor and Robust system engineering manding 24/7 operations and continually en- which require an independent electrical output isolation transformer. The high-switch- sures reliable operation of the heavy rail rapid Scan the QR code for supply that does not suffer from any disrup- The robust three-phase ENERTRONIC I 3-3 ing frequency compared to the basic fre- The resistance of the UPS systems to envi- transit system in the political capital of the further information tion in the public network. UPS systems ensure high availability and quency and optimum regulation of the pulse ronmental conditions was a decisive factor in USA. 20 | BENNING | POWER news | 9/2017 BENNING | POWER news | 9/2017 | 21
Highly efficient and effective test and diagnostic solution for photovoltaic systems in accordance with international standards * The installation tester and I-V curve tracer BENNING PV 2 is an efficient diagnostic tool to ensure that initial operation tests, maintenance tests and performance assessments of photovoltaic systems are carried out quickly and reliably. Optional accessories Numerous photovoltaic systems, especially in the private sector, are becoming out- for BENNING SUN 2: dated and not effective anymore. But how will you know, if a PV system is still safe Mounting bracket and yields the anticipated returns? (top) To be on the safe side, an expert solar engineer should be called in. By performing tests in accordance with DIN EN 62446 (VDE 0126-23) and DIN EN 61829 (VDE 0126-24), Optional accessories customers are given both a safety inspection and report regarding the quality and for BENNING PV 2: efficiency of the existing PV system. Shoulder bag Scope of delivery of BENNING PV 2 (bottom) The construction of low-voltage systems has In the heyday of PV systems, solar module factor, the lower the efficiency, since a part Software and accessories a PV module retainer for the BENNING SUN 2, been determined by particular specifications and manufacturers promised low power losses of the generated power is lost to the internal a 40 m measuring line reel (BENNING TA 5) guidelines for many decades now. Introduced for a period of up to 20 years. If there is a de- resistance of the solar cell. For crystalline The PC software BENNING SOLAR Manager and an AC/DC current clamp adapter approximately ten years ago, the EN 62446 viation in the quality and efficiency assess- solar cells, values between 0.75 and 0.85 are can be used for generating complete test (BENNING CC 3) suitable for DC and AC standard defines the minimum requirements for ment, a warranty claim can be proven, doc- achieved; for amorphous cells the filling fac- reports and documentation in accordance current measurement up to 40 A. BENNING PV 2 documentation, commissioning and periodic umented and requested. tor is between 0.5 and 0.7. The filling factor with DIN EN 62446 (VDE 0126-23) and photovoltaic installation tester and tests of the grid-connected PV systems. is thus a key indicator that provides a quality DIN EN 61829 (VDE 0126-24). The I-V and With its PV installation testers and curve I-V curve tracer However, similar standards and regular mon- Range of additional features assessment at first glance. power curves determined are converted to measuring devices, BENNING is ideally itoring were given short shrift in the past, also STC conditions and compared to the nominal placed for the needs of a solar energy spe- due in part to the lack of awareness of private In 2011, BENNING launched BENNING PV 1-1, To ensure that a characteristic curve is manufacturer specifications via an integrated cialist during the installation, maintenance PV system operators. one of the first PV installation testers for stan- recorded correctly and can be subsequently PV module database. and servicing of a photovoltaic system. dard-compliant, quick and easy testing of analysed, the ambient conditions should be If the solar energy specialist is using a smart- Older PV systems often deliver less power PV generators. Today, BENNING PV 2 is an taken into account. A combination and wire- phone or tablet with an Android operating sys- Please do not hesitate to contact us if you than the cost-efficiency calculation promised. all-in-one commissioning tester and supple- less coupling of BENNING PV 2 with the tem and NFC technology, he can download and have any further queries about the testing In order to detect a decrease of power in ments the PV check with an additional I-V irradiation and temperature measuring device use the free app "BENNING PV Link" from the and measuring equipment. good time and to be able to initiate counter- curve tracer and power curve. BENNING SUN 2 is therefore necessary. Playstore. With this "Android device" the expert measures, the proper method would be to In addition to the measurements of the no- Supplementary data on solar irradiation, can select data from the NFC chip integrated author/contact: Tobias Enck have the PV characteristics measured by a load voltage, the short-circuit current and the module temperature and ambient tempera- into the BENNING PV 2. The app can display telephone: +49 2871 93 111 corresponding specialist. In the event of qual- insulation resistance, the display shows the ture are essential because they directly im- and compare a characteristic curve with the e-mail: t.enck@benning.de ity and efficiency losses, the BENNING PV 2 current and the voltage in the "Maximum pact the PV module performance. STC data via the integrated module database. combined with an irradiation and tempera- Power Point" (the point of maximum power ture sensor, can record the actual electrical on the electrical curve) of the solar string. A new feature compared to its predecessor, In addition, there are other accessories avail- values and document them using the BENNING PV 2 calculates the filling factor as BENNING PV 1-1, is the ability to provide able that offer a practical range of additional BENNING SOLAR Manager PC software. a measure of the solar cell quality based on separated and continuous insulation resis- features. This includes, for example, a shoul- The software is based on a comprehensive the current and voltage values. tance measurement. BENNING PV 2 per- der bag for the PV measuring devices, which module database. It compares the measured forms a “preliminary check” before each au- allows greater freedom of movement in the BENNING SOLAR Manager for the as- values converted to STC (Standard Test The ideal solar cell is a constant current tomatic test procedure in order to prevent solar field and in a PV plant. Scan the QR code for sessment of BENNING PV 2 measure- Conditions) with the nominal manufacturer source up to its maximum voltage and the fill- damage (e.g. due to power surges) that could The product range also includes a two- further information ment results and characteristic curves specifications. ing factor is equal to one. The lower the filling destroy the measuring device. channel temperature sensor with suction cup, * BENNING PV 2 and BENNING SOLAR Manager are 22 | BENNING | POWER news | 9/2017 expected to be available in English from 06/2018. BENNING | POWER news | 9/2017 | 23
Investing in new pyrolysis process reduces turnaround times significantly It takes just 36m3 of space to strip electric motor windings quickly, non-destructively and efficiently. Maintaining electrical equipment often involves replacing parts. Apart from se- rious ageing, this may be due to dam- age, such as a short circuit in the wind- ings or a short circuit to earth from the rotor or stator winding. Using modern insulating materials and winding de- signs, replacement windings can also be The loading capacity of the floor is designed for made to increase efficiency or improve machine components weighing up to 35t. operating characteristics. When reconditioning electric motors and hauling the pyrolysis process, facing all the depending on the type of winding, there is irregularities occur, they immediately get an chamber on a system of rails manoeuvring it Regular testing drives, it is crucially important to remove any challenges this involved. also a possibility that the copper winding can alert on their mobiles. The process parame- with the aid of two lasers to ensure it is posi- damaged items quickly and with care. One be reused, reducing costs and turnaround ters are displayed at the installation itself and tioned accurately to the nearest millimetre. To ensure the pyrolysis oven continues to op- of the processes used when replacing wind- Challenges overcome time to the customer significantly. in the offices of the specialist department in The whole placement process can be moni- erate economically and in accordance with ings is pyrolysis, which is the careful removal charge via a computer connected to the LAN. tored precisely via a special sensor system. the law in future, as well as the operational of the existing winding using controlled heat. The process starts by determining the tem- The challenge to the equipment designer lay The information and signals required are dis- safety examination cycle, there are also emis- During this process, insulating materials and peratures and times which can vary, depend- not only in the pyrolysis process itself but also Working with the installation manufacturers, played very clearly and inform the plant op- sions tests conducted by the TÜV [German any existing varnish or epoxy resin are care- ing on the type of winding, the weight and in the so-called ‘thermal afterburning’ re- we designed the process and equipment to erator about the correct position of the vehi- Technical Inspection Agency] and the test re- fully and slowly “burned off” out of the lami- size of the component involved. The heating quirement which, as the name indicates, the actual physical environment. As well as a cle inside the oven chamber. sults are verified officially. nation bundle. When done correctly, the ex- process inside the installation is carefully con- takes place after the main process. This en- capacity of 36 m³ (dimensions of 4 x 3 x 3 m isting stator or rotor laminations can be used, trolled, with precisely adjusted oxygen levels sures that statutory limits are observed and – L x W x H), the loading capacity of the floor BENNING also invested in a suitable towing This investment has enabled BENNING to re- so the winding can be replaced quickly, effi- inside the chamber. There are two major fac- no prohibited emissions escape into the en- was designed at a generous 35t for individual truck from a well-known German manufac- duce turnaround times for overhauling elec- ciently and cost-effectively. tors to consider here: first, the electrical con- vironment, for example. machine components. turer. This is battery-operated and was trical equipment considerably. ductor used (e.g. copper wire) should then adapted for the operating conditions so that, Successful new strategy be able to be removed from the winding eas- Continuous monitoring The unit is housed in a separately con- for example, it can handle a load of up to 30t author/contact: Matthias Loerwink ily without damaging the lamination; and sec- structed building for which all the particular without problems. It needs very little space telephone: +49 2871 93 318 BENNING has used pyrolysis for many years. ond, the temperature in the oven must not in Thermal afterburning involves temperatures requirements of this process have been during manoeuvring activities and, due to the e-mail: m.loerwink@benning.de However, at the same time as we were mov- any way affect the other components, like the up to 850 °C. This extreme heat puts great taken into careful consideration. The entire narrow wheelbase of approximately 1500mm, ing into the large drive unit market, we re- lamination insulation. These specific require- stresses on the materials used and sensor system was built below ground level so the it is very easy to position. alised that we needed to make the plant ments must be met continuously throughout systems employed. oven chamber can be loaded at ground level larger and optimise the process involved. As a process lasting 18–24 hours. To monitor and control the processes a data as it is necessary to manoeuvre individual The plant was commissioned subject to an crane capacities had increased from 40t to The oven is heated by two gas burners with logger has been installed. This system can components weighing up to 30t. approval procedure under the Federal Emis- 120t, the processing capacities clearly finely graduated adjustment in combination be used to record and document the tem- sions Protection Control Act, which had to be needed to be adapted to accommodate with air circulation being controlled via a perature, gas consumption and oxygen A ‘customised’ trailer with hydraulic height agreed with various authorities. This means these weights. Our electrical machines de- speed-regulated drive. As well as the ad- content in the combustion chamber, as well adjustment eliminates the need to load and that this project involves not only the man- partment responded by installing a new vantage that the process parameters can as throughout the whole process of after- unload the oven slowly using a mobile crane. agers responsible within the particular de- Scan the QR code for state-of-the-art balancing unit (which can be controlled precisely, this also minimises burning. And BENNING's standby staff can While the trailer moves on its own wheels partment, but also management for Environ- further information balance components up to 50t) and by over- the installation’s energy requirements. And, monitor the process easily because, if any outside the oven, it is carried into the oven ment and Safety at Work representatives. 24 | BENNING | POWER news | 9/2017 BENNING | POWER news | 9/2017 | 25
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