case study: recent microgrid installation in wadeville · • electrical, fluid, and mechanical...

Case study: Recent Microgrid

Installation in Wadeville

Louis Shaffer

Distributed Energy Segment Leader EMEA

How well do you know Eaton?

Eaton has beenPowering business worldwide for over 100 years

• Electrical, fluid, and mechanical power management

• $20.4bn turnover in 2017

• 96,000 employees

• 4 key sectors

Eaton Electrical:

Energizing a world

that demands more Expertise from seven core

technology platforms

Backup

power

protection

Control

and

automation

Structural solutions

and wiring devices Engineering

services

Lighting

and

security

Power distribution and circuit protection

Solutions for

harsh and hazardous

environments

Data centers Industrial Utility Commercial Machine building Residential

Lighting and securityImproved efficiency, comfort and safety in the home and the workplace

Recessedlighting

Ambientlighting

Emergency lighting

Outdoorlighting

Fire systems

5

Solutions for harsh and hazardous environmentsDelivers reliability and safety to prevent production interruptions

EnclosuresIndustrial control

and switchgear InstrumentationLighting

Commercial outlet boxes, wiring and fittings

Hazardous

area

communications

6

Power distribution and circuit protectionDelivers reliable, efficient and safe power where it is needed

Panelboards and

switchboards

LV/MV

switchgear TransformersFusesCircuit

breakers

7

Backup power protectionMaximizes reliability and continuous uptime to prevent business interruptions

Uninterruptiblepower systems

Surge protection and power factor

correction

Power distribution units (PDUs)

Transferswitches

Parallelingswitchgear

8

Control and automationImproves operating efficiencies and enablesequipment to run at peak potential

LV/MV motor control centers

Variable frequency

drives

Contactors and starters

Automationand

sensors

Panel wiring

solutions

Interconnectivity and I/O

9

Eaton in Africa

800 employees

200k ft2 of manufacturing space in South Africa and Morocco

BBBEE Level 1 certification for Wadeville, South Africa Manufacturing

Engineering Services: Study|Design|Build|Support

IEC and UL approved productsHistorical brands in Africa since 1927

http://images.google.com/url?q=http://www.mgeops.com/var/ezwebin_site/storage/images/company/1866-16-eng-GB/company_medium.gif&usg=AFQjCNHd-ytKPmchrajnSS9GxZNX-b8Euw

http://images.google.com/url?q=http://www.mgeops.com/var/ezwebin_site/storage/images/company/1866-16-eng-GB/company_medium.gif&usg=AFQjCNHd-ytKPmchrajnSS9GxZNX-b8Euw

Why Microgrids - and Why Now?

Africa has a tremendous

growth opportunity

by delivering reliable,

sustainable, and affordable energy

for all

Increasing access to

energywill deliver improved education, health and

disposable income

ANGOLA

NAMIBIA

SUDAN

ETHIOPIA

KENYA

ZAMBIA

TANZANIA

EGYPT

LIBYAALGERIA

MALINIGER

NIGERIA

CHAD

BOTSWANA

IVORYCOAST

MAURITANIA

C.A.R.

D.R. CONGO

CAMEROON

GABON

SOUTHAFRICA

MOROCCO

GUINEA

SIERRA LEONE

LIBERIA

SENEGAL

TUNISIA

GH

AN

A

ZIMBABWE

99.8%

51.8%

35.1%

25.2%

30.9%

86.3%

100%

79.8%

66.4%

50.2%

64.5%

87.0%

98.9%

28.2%

25.4%

5.3%

13.4%

82.8%

<1

175

184

98

135

8

National Urban Rural Pop’n w/o Access (m)

Rate of electricity access

SOURCE: IEA, Energy Access Outlook 2017

North Africa

West Africa

East Africa

Central Africa

Other Southern Africa

South Africa

Good news is the exponential drop in cost of Solar & Storage

• Solar is abundant and low cost energy – and storage makes it available when needed

Microgrid Use Cases:

• Steady Grid – few outages, good quality• Increase use of renewables• Reduced risk (Resiliency or “UPS”)• Cost reduction (e.g. Peak Avoidance)

• Intermittent Grid – availability / quality issues• Reduced downtime and/or diesel reduction

• No Grid, i.e. Remote • Primary Power / Diesel reduction

• WBCSD C&I whitepaper with more details: https://www.wbcsd.org/Clusters/Climate-Energy/REscale/Resources/Microgrids-for-commercial-and-industrial-companies

Microgrids: Multiple Applications

Eaton has > 10 years experience building Microgrids

Power Xpert Energy Optimizer TM

Simple, scalable, adaptable…

Power Xpert Energy Optimizer TM

Power Xpert ®

energy

optimizer

Microgrid

Energy

System

Fuel Cell Engine Generator Energy Storage Photovoltaic Controllable Loads

To Upstream Grid

IEC-61850

Local Controller -

Fuel Cell

To Upstream Control

Local Controller -

Gen Set

Local Controller -

Load

System Controller

PCCBreaker/Recloser

HMI

LocalController -

Energy Storage

Local Controller -

PV

Modular Design reduces Engineering

Case Study

Wadeville South Africa

Microgrid

Eaton’s Wadeville facility: Key Challenges

Cost of

electricity

Unreliable

energy supply

Due to ageing infrastructure experiencing an

increase in load shedding due to:

• Cable faults &

• Scheduled maintenance of the grid

As a manufacturing plant we are face increasing;

• Energy charge impacted by seasonality and

peak time

• Network demand charge

Wadeville Electricity Cost by month

• Rates higher in Winter (June-August)

• Peak rate charges significant part of bill

Note – values (SAR) normalized, not actual

Eaton’s Wadeville facility:

Three main use cases

Peak shaving• Reduced demand /

peak charges• Maintains constant

demand day or night• Reduced energy

charges

Integrated PV• Reduced PV variation

with energy storage• Reduces utility demand• Improved overall

power quality

Islanding• Continuous operation of

manufacturing even when the utility is down

• Mission critical operations continue

• Minimize backup fuel consumption

Smart controller

Eaton’s Wadeville facility:

Key Elements of the microgrid

application

• Utility Grid

• 400 kVA Genset

• 200 kW PV Array

• Battery Storage 275 kW / 200KWh

Sources

• 50 – 375 kVA (30 min readings)

• 70 kW compressor

Loads

25© 2018 Eaton. All Rights Reserved..

Diesel

Genset400 kVA

4 x 50 kW

Inverters

Photovoltaic232 kWp

6.6 kV Utility

XIRIA E

6.6 kV/400 V

2 x 500 kVA

Loads

50 – 375 kVA

(30 min avg.)

275 kVA

XST PCS

275 LARGE

xStorage Building

Battery Storage200 kWh Nissan Second Life

CX Power

Distribution

Centre630 A, 32 kA

Eaton’s Wadeville facility:Key hardware components for the microgrid

application


Eaton’s xStorage using 2nd Life

Batteries

(Can be done with new cells as well)

1 Battery String =

12 modules12 modules connected via BBM

BBM connector Casing BMS

“xStorage can

expand the

useful life

of electric

vehicle

lithium

batteries and

therefore

reduce the

need to use

additional

resources

from the

planet to

produce new

batteries”

-

Nissan


xStorage for C&I

Racked solution: Up 96kWh per rack


Eaton’s Wadeville facility:Energy consumption pattern over a typical

day

Energy

consumption on

site mostly

from 7.30am to

5.30pm


Eaton’s Wadeville facility:Solar matches the bulk of the demand

Peak Rates

Energy

consumption on

site

Renewable

energy

generation

from PV


Eaton’s Wadeville facility:Applying Storage reduces demand at peak

times

Energy

consumption on

site

Renewable

energy

generation

from PV

Battery

Storage energy

profilePeak Rates


Eaton’s Wadeville facility:Reduced consumption when costs are

highest

Peak Rates

Energy

consumption on

site

Resulting

energy

consumption

from the grid


Eaton’s Wadeville facility: 40%

SavingsAll but Service charges reduced

Energy

charge

reduction

of:

31% Standard

65% Peak

-81% Off

Peak

Demand

charge

reduced by

33%


• Africa must increase electrification and improve

power reliability at reasonable cost

• Microgrids enhance the reliability of existing

grids and allow the rapid access to power where

the grid can’t reach

• The rapid drop in the cost of renewables and

storage enables a rapid expansion of distributed

and lower cost power generation

• Eaton’s Wadeville Microgrid demonstrates

how a simple, cost effective, modular system

addresses the unique challenges in the region

Microgrids: Building a resilient, cost effective power future for Africa

Questions?

For more – see www.Eaton.com/MicrogridsVideo: https://www.youtube.com/watch?v=dTXJE2s9zlU

http://www.eaton.com/Microgrids

https://www.youtube.com/watch?v=dTXJE2s9zlU

case study: recent microgrid installation in wadeville · • electrical, fluid, and mechanical...

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