Download - DRUPS System – Mike Dawson & Euro Diesel
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Overview
Alleviating power problems at NXP Semi-Conductors Stockport by
the introduction of a diesel rotary UPS System
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Contents
• Background – The power related issues experienced at NXP Stockport
• The Solution - Installation of a diesel rotary UPS system
• The UK power security landscape – The National Grid
• How It Works - How a DRUPS operates
• Conclusions – Next steps
• Q and A
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Background – The power related issues experienced at NXP
Stockport
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2006/7
• The site is served by two incoming 11kV supplies from Electricity North West.
• Frequent power disturbances in the form of voltage and frequency excursions resulting in drop out of
process equipment, scrappage and delays in production.
• UPS system identified as the solution to ensure site maintains business continuity and is protected from
poor quality supply.
• Critical loads are not centralised but distributed around the site off various substations. Decision was taken
that the entire site would be protected by UPS.
• Project launched to evaluate the cost to the business of poor quality power compared with costs for a UPS
system. Concluded there was a business case.
Background
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2008
• Evaluation of UPS technologies concluded a
rotary based system is the optimum solution.
• EURO-DIESEL selected to build a UPS power
house comprising 3 x 2000 kVA diesel rotary UPS.
With provision for a future 4th machine.
Background
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2016
• UPS system has been in service since 2009 and has fulfilled its brief, eradicating historical power issues
on site and helping to make NXP Stockport one of the most successful plants for NXP globally.
• Noticeable improvement in equipment uptime. Power supply is constant and smooth, particularly
beneficial for Switch Mode Power Supplies.
• Latest project recently concluded, installing a fourth machine due to site load increase over time.
Today
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Sweating the asset
The power available from the UPS system on site is contracted in to National Grid power reserve schemes.
NXP participate in revenue generating schemes that call upon the output from the embedded site
generation capacity, at times of peak electrical demand on the grid.
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The Solution - Installation of a diesel rotary UPS system
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EURO-DIESEL
• Established 1989
• HQ in Liege Belgium
• Manufacturing facilities in Belgium & Germany
• 75 million EUR Turnover
• Offices worldwide
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EURO DIESEL UK & IRELAND
Cirencester
Sales, service, warranty and application
engineering.
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Portfolio
• GENSETS: 500 - 3000 kVA
• DRUPS: 300 - 3000 kVA
Full Turnkey Solutions
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Power House
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Power House
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The power security landscape - The National Grid
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The National Grid – The job of providing electricity
Available power from generators
• Load is changing constantly
• Available power is changing constantly
• Impractical to store electricity
Consumer demand
National Grid
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4th April (0730am to 0830am)
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21st century challenges in keeping Grid stable
Renewable power sources are increasingly contributing
- Unpredictable, offering little or no system inertia
Less spinning reserve in the grid
- Driven by efficiency improvements
- Fossil fuel power stations taken off line
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• Failure of hardware
• Accidental power interruptions
• Effects of down stream switching
Local DNO Distribution Issues
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The potential consequences
1. Spikes
2. Frequency Deviations
3. Sags
4. Outages
5. Harmonics
6. Transients
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Wednesday 28th May 2008
• Both Sizewell B and Longannet power stations fall
off line within minutes of each other
• Hundreds of thousands of homes and businesses
across London, Cheshire, Merseyside and East
Anglia lost power
• National Grid issue Demand Control Imminent
(DCI) warning
What if this scenario occurred today, how would we cope?
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The future UK Power Landscape
National Grid are excellent at what they do, providing a relatively robust and
reliable power supply 365 days of the year.
However circumstances beyond their control; lack of government direction on
Nuclear power, closing down of fossil fuel power stations to meet emissions
commitments and the ever increasing amount of renewable energy adds up to an
uncertain future……be prepared!
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How It Works - How a DRUPS operates
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Power Conditioning from a UPS
DIRTY INTERRUPTIBLE POWER CLEAN UNINTERRUPTIBLE POWER
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Most common approach diesel generator set back up
Site Load
• Typically 10 to 20 Seconds interruption to site loads.
• Only addressing one issue – Outages
Diesel Generator Set
Mains Supply
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Introduce a UPS System
Site Load
• Without break in supply to the site load
• Incoming power source is “conditioned”
Diesel Generator Set
Mains Supply
UPS
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Battery UPS systems
• Lead Acid Batteries require lots of space, not favoured from an environmental perspective, high operational cost due to plant replacement cycle and high cost of consumable energy in maintaining acceptable battery room temperatures.
• 500 kWe requires 7 Tons of batteries
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A Rotary UPS system
Site Load
“NO-BREAK” Diesel Rotary UPS
Mains Supply
• Without break in supply to the site load, Incoming power source is conditioned
• No requirement for diesel generator set
• The UPS has the benefit of improving site power factor – reducing energy bills
• No Batteries!
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Rotary NO-BREAK KS® System
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Simple Layout
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Building a NO-BREAK KS® System
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NO-BREAK KS®
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Used in dual mode
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Assisted engine starting
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System Configurations
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Typical Scope
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Multiple Machines
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Ring Configuration
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Outdoor Enclosure Options
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Summary
• First evaluate the business case.
• Consider not only the direct benefit in business continuity but also the indirect
benefits such as power factor correction, improved equipment life as a result of a
cleaner power source, and revenue from National Grid schemes.
• Arrange for EURO-DIESEL to visit your facility and provide a free initial assessment .
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Questions ?