From: Hoping for the Best, Planning for the Worst
Flywheel Eases Backup Headaches at Bayer Pharmaceutical
The technology for the use of a UPS (uninterrupted power supply) to protect critical manufacturing and data systems continues to improve. Batteries have a solid reputation in the industry, but newer flywheel systems are also finding acceptance. These systems use kinetic power cell technology to store and deliver power to critical loads during power fluctuations or interruptions.
In the case of Bayer Pharmaceutical in Berkeley, CA, the company chose a Caterpillar 1,200-kVA flywheel UPS system to protect crucial atmospheric controls when the plant switches from its primary power sources to onsite diesel-generated electricity. In manufacturing, the plant’s sterile-fill facility needs ultra pure water and must maintain a constant flow of clean air. A momentary power outage or sag can allow atmospheric air into their system, causing contamination, and both lost production time and money.
The system proved itself during its first week of service, when dual utility feeders experienced significant voltage fluctuations as utility crews performed work on their grid. Power in the sterile fill facility remained constant, but other equipment in the plant sustained interruptions.
The flywheel systems have some advantages over batteries because they need only a third of the space required by a battery-powered static UPS system, and in Bayer’s case, the company didn’t want to worry about batteries malfunctioning in a room warmer than 77°F. Space and weight were additional factors. Caterpillar’s systems are offered as 300-kVa modules that require 14 square feet, and weigh 4,475 pounds. A typical battery system of the same power would require 40 square feet, and weigh 13,000 pounds.
Caterpillar rates its systems at 98% efficiency, and that can provide a significant cost advantage compared to the 94% efficiency of a typical battery-based unit. When combined with the reduced maintenance cost of flywheels compared with periodic battery replacements, Bayer expects to see significant savings in the total cost of ownership over the life of the UPS.
September-October 2009
From: Hoping for the Best, Planning for the Worst
Flywheel Eases Backup Headaches at Bayer Pharmaceutical
The technology for the use of a UPS (uninterrupted power supply) to protect critical manufacturing and data systems continues to improve. Batteries have a solid reputation in the industry, but newer flywheel systems are also finding acceptance. These systems use kinetic power cell technology to store and deliver power to critical loads during power fluctuations or interruptions.
In the case of Bayer Pharmaceutical in Berkeley, CA, the company chose a Caterpillar 1,200-kVA flywheel UPS system to protect crucial atmospheric controls when the plant switches from its primary power sources to onsite diesel-generated electricity. In manufacturing, the plant’s sterile-fill facility needs ultra pure water and must maintain a constant flow of clean air. A momentary power outage or sag can allow atmospheric air into their system, causing contamination, and both lost production time and money.
The system proved itself during its first week of service, when dual utility feeders experienced significant voltage fluctuations as utility crews performed work on their grid. Power in the sterile fill facility remained constant, but other equipment in the plant sustained interruptions.
The flywheel systems have some advantages over batteries because they need only a third of the space required by a battery-powered static UPS system, and in Bayer’s case, the company didn’t want to worry about batteries malfunctioning in a room warmer than 77°F. Space and weight were additional factors. Caterpillar’s systems are offered as 300-kVa modules that require 14 square feet, and weigh 4,475 pounds. A typical battery system of the same power would require 40 square feet, and weigh 13,000 pounds.
Caterpillar rates its systems at 98% efficiency, and that can provide a significant cost advantage compared to the 94% efficiency of a typical battery-based unit. When combined with the reduced maintenance cost of flywheels compared with periodic battery replacements, Bayer expects to see significant savings in the total cost of ownership over the life of the UPS.