HITZINGER GmbH 1 Agenda Company History, Organisation, Profile - - PowerPoint PPT Presentation
HITZINGER GmbH 1 Agenda Company History, Organisation, Profile and Global Network NBDK IT Power Systems Mechanical, Features and Benefits NBDK IT Power Systems Electrical Operation and Energy Flow NBDK IT Power
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Mechanical, Features and Benefits
Electrical Operation and Energy Flow
Control and Monitoring
System configuration
Hitzinger & On site service / maintenance / repair
Summary and References
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In June 1946, Dipl. Ing. Walter Hitzinger,
installations and repairs located in Linz.
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Today, more than 230 highly skilled employees develop and produce high tech products in state-of-the- art technology in 3 production plants with a total area of 18.000 m² . Hitzinger Products are:
Asynchronous Alternators
Systems
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3.1 Quality Management 1.3 Customer Service Management 3.3 Plant Management 1.3.1 Technical Support 1.3.2 Customer Service 3.3.1 Production Management 1.0 IT Management
1 Managing Director Sales & Logistic 3 Managing Director Technical (QMB)
3.3.2 Process Planning Management 1.1 Sales Management 2.1.1 Human Resource Management 3.2 Projektmanagement 1.2.1 Mechanical Strategic Purchasing 1.2 Purchasing & Logistics Management 1.2.3 Warehouse Management 3.4 Research and Development Management 3.5 Technical Management 3.5.3 Electric Design Management 3.5.2 Mechanical Design Management 1.2.2 Electrical Strategic Purchasing 1.2.4 Shipping Management 3.5.4 Electronic Management 3.5.6 Test Bay Management 2.0 Management Assistance 2.0 Management Assistance 4.0 Administration 1.1.3 Order Management 2.1 Financial & Accounting Management
2 Managing Director Commercial
2.1.2 Controlling 2.1.3 Accounting 1.1.1 Sales Management 1.1.1.1 Business Area 1 Alternators VG 1.1.1.3 Business Area 3&4 Diesel Gen sets & Dynamic UPS systems VA & VV 1.1.1.2 Business Area 2 Airport Equipment & Converters VF & VU 1.1.1.4 Product Management
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10 20 30 40 50 60 2004 2005 2006 2007 2008 2009 2010 2011 2012 Forecast 2013 Year Reihe1
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Sales Personnel Management & Administration 5% Research & Development Skilled workers Apprentices 6 % Engineers 15% 6% 8% 60 %
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Mechanical, Features and Benefits
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To save money! Mains failures – even for milliseconds – can cause production and supply outages and subsequent financial problems. These sectors are plastic industry and semiconductor production, data centers, airports, hospitals and so on. To prevent standstill or losses of production! The increasing percentage of automation in modern production processes demands more than ever high-quality and absolute reliable and uninterruptible power supply to avoid production outages. To be independent from extern influences! Nowadays, a high-quality power supply system often has to be more than what can be provided by local grid providers. Certain sensitive economical fields need, more than ever, a constant mains supply quality. These fields are, for example: hospitals, airports, semi-conductor production plants, the chemical industry, data processing centers, telecommunications, plastics-technology, computer-controlled industrial plants,…
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A Hitzinger DDUPS system is a high-quality and permanent solution concerning clean power supply of your consumers. Hitzinger Diesel UPS systems enable you to prevent production
A Hitzinger UPS system is a tailor made solution and guarantees a fast ROI.
That„s why we are sure that our no-break systems NBDK & NBDD are the best solution for our costumer„s power supply problems .
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TECHNOLOGY SHIFT: Away from:
Towards:
Diesel remains the common component Redundant Power feeds are prone to common mode failure and thus
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Why these Technologies? Kinetic energy storage:
Alternators and Generators:
struggle to match.
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Solution Class Power Circuit Components Ride through Energy Storage Power Generation Power electronics Rotating Electric Machine Batteries Kinetic Energy Diesel Dynamic No Yes No Yes Yes Hybrid (Rotary) Yes Yes No* Yes Yes Static Yes No Yes Yes Yes * Optional ** Depending on power capacity
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Hitzinger Dynamic Diesel UPS systems
short duration disturbances or outages.
disturbances or outages. Hitzinger delivers the smallest foot print 2500 kVA unit on the market.
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KIN module operation WHY USE A KIN MODULE?
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More Scalability: Solutions for all size applications Choose from a wide range of capacities and performance Rating (kVA) Model 150 NBDK 1/10-150 250 NBDK 1/10-250 350 NBDK 1/10-350 500 NBDK 1/10-500 625 NBDK 1/10-625 800 NBDK 1/10-800 1000 NBDK 1/10-1000 1250 NBDK 1/10-1250 1500 NBDK 1/10-1500 1750 NBDK 1/10-1750 2000 NBDK 1/10-2000 2500 NBDK 1/10-2500
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Operation Tolerance Operation Tolerance
Static +/- 1% During mains operation = mains frequency Dynamic Changing from mains to diesel operation Load transfer 100% +/- 1% At change of nominal load, cos φ = 0,8 +/- 10% Static during diesel engine
+/- 0,5% Voltage recovery time 0,3 s Short circuit at the input +/- 10% After short circuit shutdown < 10% Voltage recovery time 0,3 s Mains shutdown at nominal voltage +/- 10% Voltage recovery time 0,3 s Other tolerance values are available on demand!
Voltage Frequency Guaranteed values
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Advantages
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Reliable… … usage:
… handling:
… design:
Hitzinger UPS systems are worldwide in operation for more than 40 years.
Advantages
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Economic…
Advantages
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Maintenance friendly…
Advantages
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Extremely available…
maintenance availability
Advantages
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Less Waste: Environmental impact REDUCING HAZARDOUS WASTE EXAMPLE 1: Typical waste of a 2000 kVA UPS after 20 years Static UPS Dynamic UPS 3 x 33,000 kg batteries < 100 kg of steel (15 minutes autonomy time) (bearing material)
A much GREENER Alternative!
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Less Waste: Environmental impact REDUCING HAZARDOUS WASTE EXAMPLE 2: Typical waste of a 8 MVA UPS after 20 years Static UPS Dynamic UPS 3 x 100 tonnes batteries < 400 kg of steel
(bearing material) A much GREENER Alternative!
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1 2 3 4 5 6
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2 3 4 5 6
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finishing varnish 1 layer finishing varnish 1 layer 2-component varnish 2 layers
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KINETIC ENERGY STORAGE MODULE (KIN) for UPS-Systems with a frequency variation of
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In case of mains failure, the kinetic energy stored in the KIN provides the UPS load until the supply via the diesel engine can be assured. Maximum frequency deviation : +/- 1% Maximum voltage deviation : +/- 10 %
6 5 4 2 1 3 7
1) AC / DC exciter machine 2) Stator winding of the exciter machine 3) Outer rotor mass 4) Squirrel cage 5) Inner rotor with AC / DC winding 6) Inner KIN bearing 7) Outer KIN bearing
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In case of mains failure, the inner rotor‘s magnetic field brakes the outer rotor and keeps the synchronous alternator‘s rotating speed constant. Advantages:
KIN-Modul Outer Rotor (squirrel cage) rotating speed: 2700 rpm Diesel engine 2700 rpm 1500 rpm KIN-module Synchronous alternator Inner Rotor rotating speed: 1500 rpm
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Electrical Operation and Energy Flow
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14 15 16 17 e 9 5 6 8 7 1 2 3 4 a b c d f 14 15 16 17 e 9 5 6 8 7 1 2 3 4 14 15 16 17 e 9 5 6 8 7 1 2 3 4 a b c d f
1. Diesel engine 2. Electromagnetic clutch 3. Synchronous alternator 4. Kinetic module 5. Choke 6. Mains CB 7. Consumer CB 8. Alternator protection 9. By-Pass CB By-Pass operation Stand-by operation Diesel operation a. Harmonic distortion b. Voltage peaks c. Voltage drops d. Power loss e. Mains supply f. Load output of UPS
Consumer – Pure Sine Wave
Mains supply
Frequency deviation: < 1%
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In a UPS system, the coupling choke connects the incoming grid with the UPS output supply, that has to meet highest quality requirements. The choke„s and the alternator„s special design guarantees a high degree of decoupling between the grid and the UPS output. The choke…
collecting bar
Uin Uout Ualternator X Iin Iout
Iin = line current Iout = consumer current Uin = line voltage Uout = consumer voltage Ualternator = alternator voltage
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This configuration„s output voltage is completely independent from the input side. The fundamentals (50Hz or 60Hz) are only determined by the alternator. Either the choke (since the reactance of the choke depends on the frequency) or the alternator blocks possible upper harmonics and transients. The connection between the terms Uchoke = I . Xchoke and Xchoke = 2 . π . f . L shows, that the choke is a determining component for higher frequencies while the alternator with its special configuration
(e.g. 3rd, 5th, 7th,…harmonics) Short circuits: In case of a short circuit on the input (equals a total mains failure in which the load is transferred from the input to the alternator via the choke), the choke limits the fault current until the cutoff of the input. The voltage drop on the choke‟s short circuit is added to the alternator‟s voltage via the choke‟s circuit. Therefore, the UPS‟s voltage equals approximately the alternator‟s voltage: ΔU = -10% to
Inverse operation of the input„s current transducer: As the inverse operation of the input„s current transducer depends on the temporary short circuit between two phases during the commutation period, the choke can avoid the influences on the not- affected power unit (UPS-mains), following the same principle.
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Hochfahren
Netz- betrieb Netz- ausfall
Abschalten
Netz- rückkehr
Start up Mains
Mains power failure Shut down Mains return
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synchronous machine in motor operation
voltage and reactive power to the consumers
Hochfahren
Netz- betrieb Netz- ausfall
Abschalten
Netz- rückkehr
Start up Mains
Mains power failure Shut down Mains return
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module Hochfahren
Netz- betrieb Netz- ausfall
Abschalten
Netz- rückkehr
Start up Mains
Mains power failure Shut down Mains return
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Hochfahren
Netz- betrieb Netz- ausfall
Abschalten
Netz- rückkehr
Start up Mains
Mains power failure Shut down Mains return
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losses)
consumption fast run down Hochfahren
Netz- betrieb Netz- ausfall
Abschalten
Netz- rückkehr
Start up Mains
Mains power failure Shut down Mains return
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2700 1500 0 1 2 3 4 5 6 7 ~800 Speed Kinetic Energy Storage t [sec]
Alternator speed Standard Starting Procedure:
starter
~800rpm
module Redundant Starting Procedure:
module to nominal speed
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consumer
Diesel
engine
fuel
Mains input
Control panel Coolant preheater Prelubrication Battery charger Active power kW Reactive power kVAR
Auxiliary power supply
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to nominal speed
module
consumer
Diesel
engine
fuel
Mains input
Control panel Coolant preheater Prelubrication Battery charger Active power kW Reactive power kVAR
Auxiliary power supply
Active power kW
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to the mains
consumer
Diesel
engine
fuel
Mains input
Control panel Coolant preheater Prelubrication Battery charger Reactive power kVAR
Auxiliary power supply
Active power kW Active power kW Reactive power kVAR Friction losses
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consumer
Diesel
engine
fuel
Mains input
Control panel Coolant preheater prelubrication Battery charger Reactive power kVAR
Auxiliary power supply
Active power kW Friction losses
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diesel engine has reached the nominal speed and can deliver full load
consumer
Diesel
engine
fuel
Mains input
Control panel Coolant preheater prelubrication Battery charger Reactive power kVAR
Auxiliary power supply
Active power kW Active power kW Quick start
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compensate the losses)
consumer
Diesel
engine
fuel
Mains input
Control panel Coolant preheater prelubrication Battery charger Reactive power kVAR
Auxiliary power supply
Active power kW Friction losses
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consumer
Diesel
engine
fuel
Mains input
Control panel Coolant preheater prelubrication Battery charger Reactive power kVAR
Auxiliary power supply
Active power kW Reactive power kVAR Friction losses
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100 200 ms
Software - Simulations Test Cabine - Measurements
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100 200 ms
Mains Failure Simulation Mains Failure Measurement
Tolerances NBDK: Frequency: ± 1% Voltage: ± 10%
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Control and Monitoring
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Office RS232/485 Converter EPS ROOM
+S1
SYSTEM 1 SYSTEM 2
power monitoring
MONITORING & OPERATION
with POWERCON Controller
Dieseloperation; U1=380V; U2=380V
TO CONSUMER
System 2 Alternator Mains
K06203V01BL01MAIN SWITCHBOARD UPS1 System 1 Consumer System 2 Mains Display Powercon 2
Mains input EPS ROOM
+S1
POWERCON [EPS]
SYSTEM 1 SYSTEM 2
& OPERATION MONITORING & OPERATION
UPS SYSTEM POWERCON Controller Alternator output
Diesel operation; U1=380V; U2=380V
TO CONSUMER
System 2 Alternator Mains
K06203V01BL01MAIN SWITCHBOARD UPS1 System 1 Consumer System 2 Mains Display Powercon 2
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System Configurations
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TIER Requirements Summary
Active Capacity Components to Support IT Load N N+1 N+1 N after any failure Distribution Paths 1 1 1 active and 1 alternative 2 simultaneously active Concurrently Maintainable No No Yes Yes Fault Tolerance (single event) No No No Yes Compartmentalization No NO No Yes Continuous Cooling Load density dependent Load density dependent Load density dependent Yes (class A)
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Single source No redundancy Single source After „N+1“ Double source 2 x „N“ „A-B“-supply Path A Path B Double source Each N+1 Path A Path B Enduser availability 99,67 % Enduser availability 99,75 % Enduser availability 99,98 % Enduser availability 99,99 % Enduser downtime 28,8 h Enduser downtime 22,0 h Enduser downtime 1,6 h Enduser downtime 0,8 h First introduced 1960-1970 First introduced 1960-1990 First introduced since 1990 First introduced Since 1994
TIER Requirements Summary
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Two single units paralleled , one Bypass- CB
Parallel
(N+I) 2 + 0
(P) 1
N… number of UPS needed to supply the load I… number of redundant units P .. number of paths
Critical load 1
G D A1 KIN G D A2 KIN
Utility
Example: Parallel Configuration
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Critical load 1 Utility
G D A1 KIN G D A2 KIN
G D A3 KIN
To achieve a higher level of output availability in N or N+1 configuration N: System components ; paths 3 ; 1 ; (Tier1) (unit A1+A2+A3 needed to supply the load)
Low voltage- limited due short-circuit power (8MWconfiguration) Middle voltage- nearby unlimited
Further configurations are simplified without manual Bypass-CB`s or additional switching devices
Parallel Configuration, N
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Critical load 1
G D A1 KIN G D A2 KIN
G D C1 KIN
+1
Utility
Parallel Configuration, N+I
To achieve a higher level of output availability in N or N+1 configuration N+I: System components ; paths 2+1 ; 1 ; (Tier2) A1+A2 >= load, A1+C1 >= load, A2+C1 >= load,
common bus bar affects the consumers/load
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Isolated Configuration
Critical load 1, Path B
G D A1 KIN G D B1 KIN
Critical load 1, Path A
Critical load 1
+1
Utility A B
There is a higher level of output availability possible, due independent/individual load supply N+I: System components ; paths 1+1 ; 2 ; (Tier3) A1 >= load, A2 >= load,
eliminates the single point of failure
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Isolated Parallel Redundant Configuration
Highest level of possible output availability (N+I)+(N+I): System components ; paths | (1+1)+(1+1) ; 2 ; (Tier4) Shown in this special configuration - each unit (A1,C1,B1,C2) able to supply the load.
Redundant Configuration
Critical load 1, Path A
G D A1 KIN G D C1 KIN
+1
Critical load 1, Path B
G D B1 KIN G D C2 KIN
+1
Critical load 1 Utility Utility A B
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Critical load 1, Path A
G D A1 KIN G D A2 KIN
Critical load 1, Path B Critical load 1
Utility B – High Availability +1
Utility Utility
Isolated Parallel Configuration
N+I: System components ; paths 1+1 ; 2 ; (Tier3) A1 >= load, A2 >= load,
availability of a second Utility
eliminates the single point of failure
available it is a really Operating costs optimized solution
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Isolated Parallel Configuration
All units are connected to a common bus (IP-Bus) by isolation chokes In case of short-circuit on the bus or unit failure, this chokes minimize fault currents to an acceptable level N+I: System components ; paths 1+1 ; 1 ; (Tier2) power outage of two units >= total load,
efficiency possible, this depends
configuration.
system configuration, small influences in case of bus bar failure
Critical load 1
G D A1 KIN
Critical load 2
G D A2 KIN
Critical load 3
G D A3 KIN
Utility
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G D A1 KIN
G D B1 KIN
G D C1 KIN
+1
Critical load 1, Path A Critical load 1, Path B Critical load 1 Spare Utility
Isolated Parallel Configuration
All units are connected to a common bus (IP-Bus) by isolation chokes In case of short-circuit on the bus or unit failure, this chokes minimize fault currents to an acceptable level N+I: System components ; paths 1+1 ; 2 ; (Tier3) power outage of two units >= total load,
efficiency possible, this depends
configuration.
system configuration, small influences in case of bus bar failure
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Parallel Configuration, 3units, STS
Additional unit is operating parallel to the 2 load bus bars, they are connected due Static Load Transfer Switches. In case of unit failure the static transfer switches to the remaining available supply. N+I: System components ; paths 1+1 ; 1 ; (Tier2) A1 or B1 or C1 >= load1 or load2,
each load without influencing to the other consumers.
range
Critical load 1
G D A1 KIN G D C1 KIN
G D B1 KIN
Critical load 2
Utility A B
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Parallel Configuration, STS
EPS
EPS
Non-critical load A
Critical load 1, Path A1 Critical load 1, Path A2
G D A1 KIN
Critical load 1
EPS
EPS
Non-critical load B
Critical load 2, Path B1 Critical load 2, Path B2
G D B1 KIN
Critical load 2
EPS
EPS
Non-critical load C
Critical load 3, Path C1 Critical load 3, Path C2
G D C1 KIN
Critical load 3 Utility A B C A B C
Configuration
High level of possible output availability The Availability depends from load conditions
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A
A
Critical load 1, Path A
G D A1 KIN G D A2 KIN
A
B
B
B
A B
A-B
A
A
Critical load 1, Path B
G D B1 KIN G D B2 KIN
A
B
B
B
A B
B-A
Critical load 1 Utility A Utility B
+1 +1
Parallel Configuration
Configuration
Highest level of possible output availability (N+I)+(N+I): System components ; paths | (1+1)+(1+1) ; 2 ; (Tier4)
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Hitzinger & on site service / maintenance / repair
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representatives
countries with no visa requirements)
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Organisation
Total work experience: > 300 years!
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More Reliability: Less maintenance Choose a solution which facilitates maintenance
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Qualification: Level M1 … trained personal (customer operator) Level M2 … qualified personal (Hitzinger service and maintenance partner) Level M3 … specialist of DDUPS manufacturer and service and maintenance partner Operation mode: A … automatic M … maintenance T … test
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Unit to be maintained Tasks
Qualifi- cation Operation Mode Daily 1 Monthly 4 Months 1 Year
Special period
Visual inspections
M1 A Bearing re-grease
M1 A automatic
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Unit to be maintained Tasks
Qualifi- cation Operation Mode Daily 1 Monthly 4 Months 1 Year
Special period
Functional tests, visual inspection and cleaning
M2 T Electromagnetic Clutch Check and re-adjust gap clearance M2 M
Readjustment after 100 HSS
Replace friction linings M2 M 10
Theoretical figure
Kinetic Energy Storage Unit Change lubrication oil of inside bearings M2 M
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Unit to be maintained Tasks
Qualifi- cation Operation Mode Daily 1 Monthly 4 Months 1 Year
Special period
Kinetic Energy Storage Unit Replace KIN-module inner bearings M3 M
5 Theoretical figure
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in Turkey
20KVA
electronic equipments support
engineers from Powerelektronik in Linz / Austria
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Stock items at Powerelektronik
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in Turkey
Power Elektronik SAN.VE TIC.LTD.STI Armağanevler Mh. Samanyolu Cd. İpekçi Sk. No : 12 Ümraniye ISTANBUL Power Elektronik SAN.VE TIC.LTD.STI ANKARA BÖLGE MÜDÜRLÜGÜ
Asagi Övecler, Cankaya ANKARA
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Summary and references
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Lower Total Cost of Ownership
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DYNAMIC ELECTRICAL PERFORMANCE Achieved by Hitzingers own tailored range of synchronous alternators
Energy Storage Achieved by Htizingers range of KIN modules
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Memc - Meran: 2 x 340 kW 2 x 150 kW Mechanical UPS – uninterrupted drive of rotating machines (e.g. pumps). STMicroelectronics Catania: 4 x 1750kVA
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International Airport Athens: 4 x 450kVA
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Governmental Data Centers 2 x 2000 kVA (dual output) 2 x 2000 kVA (dual output) 2 x 475 kVA (dual output)
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Data Centre – Global Switch London (22MVA in parallel Operation) 11 x 2000 kVA (11kV)
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General Hospital Linz 1 x 150 kVA 1 x 450 kVA 1 x 630 KVA 1 x 800 kVA Hospital Braunau 1 x 350kVA More than 10 MVA UPS power installed all over Austria.
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Austrian Parliament Vienna: 1 x 1225 kVA
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Prodor Piaget SA Geneva 1 x 850 kVA Data Centre Bern 3 x 2000 kVA
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International Airport Lefkosa 1 x 325 kVA International Airport Ljubljana 1 x 500 kVA
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International Airport Cairo: 2 x 600 kVA 2 x 800 kVA Reserve Bank Malawi - Blantyre 1 x 1000 kVA (dual output)
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International Airport Lagos 2 x 250 kVA International Airports Harare and Bulawayo 2 x 200 kVA 1 x 50 kVA
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Green Point Stadium – Cape Town 1 x 1000 kVA + Genset 1000kVA as Backup Nelson Mandela Bay Stadium - Port Elizabeth 4 x 550 kVA (dual output)
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Telkom SA – Projects: 1 x 550 kVA 1 x 1000 kVA 2 x 800 kVA 2 x 1000 kVA 2 x 1500 kVA (dual output) 2 x 1500 kVA (dual output) 1 x 660 kVA (dual output) 1 x 1000 kVA 1 x 1000 kVA (dual output) 1 x 1000 kVA 1 x 750 kVA (dual output)
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Bank of Tanzania 4 x 2000 kVA
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International Airport Cancun 1 x 290 kVA (60Hz)
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Venefoil C.A Caracas 1 x 1000 kVA (60Hz; dual output)
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International Airports Uch Kuduk & Baku 2 x 300 kVA
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ITT – LDK Solar: 9 x 55 kW 9 x 90 kW 9 x 225 kW 9 x 500 kW
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PVD Plast Mould Industries Ltd. **Fiberweb (INDIA) Ltd: 1 x 500 kVA 1 x 1000 kVA
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Various Hospitals: 1 x 100 kVA 1 x 250 kVA 3 x 250 kVA 6 x 1000 kVA
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Avgol Ltd. Barkan 1 x 975 kVA 2 x 1000 kVA 3 x 1500 kVA (dual output) 4 x 1300 kVA (dual output)
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X-FAB - Kuching (previous 1St Silicon Waferfab Plant) 4 x 1500 kVA
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Securities Commission Building, Kuala Lumpur 2 x 150 kVA USV Infineon Power Fab Kulim 6 x 2000 kVA USV (6,6kV) 2 x 2250 kVA ESV (6,6kV) Prime Minister Office Putrajaya 1 x 1500 kVA (dual output)
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International Airport Lahore: 1 x 200 kVA 1 x 250 kVA Adamjee Group: 1 x 500 kVA
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Moscow Interbank Currency Exchange: 1 x 500 kVA Unicom Bank Moscow: 1 x 250 kVA Moscow Government Central District: 1 x 150 kVA
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Siltronic Samsung PTE Ltd 1 x 2000 kVA (dual output) STMicroelectronics: 2 x 2000 kVA (dual output) 1 x 625 kVA (dual output) 2 x 1500 kVA 1 x 330 kVA (H-Vcon)
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Veterans Hospital Taipei 2 x 400 kVA 60 Hz 2 x 600 kVA 60 Hz
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Royal Thai Air Force: 1 x 120 kVA VVIP Terminal – Suvarnabhumi Airport Bangkok: 1 x 550 kVA