Electrifying innovation changing the future of mobility - BENNING

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Customer Magazine                                 informative · up-to-date · pioneering

       Electrifying innovation
changing the future of mobility
Photo: © Scharfsinn/Shutterstock.com

Rapid-charging modules for E-mobility 14
                                      28 – 17
                                           31

Secure offshore power supplies         123– –16
                                              5

Greater efficiency for the NY metro    17 – 31
                                       30   19

                                                                 www.benning.de
Electrifying innovation changing the future of mobility - BENNING
POWER news 10/2018                                                                                                                                                                  Safe power supplies for
                                     Editorial                                                                                                                                                                           offshore wind farms
                                                                                 Dear reader,
                                                               The UK is planning to build the world's largest battery power supply                                                                                      BENNING greatly contributes to energy transition:
                                                               network, consisting of 45 battery storage systems with a total
                                                               capacity of more than two gigawatts, helping balance any fluctuations
                                                                                                                                                                                                                         It supports offshore wind farm projects throughout Europe with
                                                               in electricity production and demand, so that a constant and stable                                                                                       secure power supply systems and customised services.
                                                               power supply is maintained – an important step towards better man-
                                                               agement of the transition to renewable energy. In parallel with the
                                                               installation of the battery power supply network, one of the largest
                                                               networks of rapid-charging stations for electric vehicles will be
                                     created. The UK power network will experience additional strain due to the electrification of
                                     road vehicles, these storage systems will help by reacting flexibly and compensating for any
                                     fluctuations.
                                     BENNING is also committed to making sure that the use of electric cars, trucks and buses
                                     becomes central to a smart, resource-conserving urban lifestyle. For this purpose, we have                                                                                          Energy transition is an issue that affects
                                     developed the HPC rapid-charging BELATRON modular range whose advantages we will                                                                                                    us all. At the UN Climate Change Con-
                                     be highlighting in this issue of POWER news.                                                                                                                                        ference in Paris in 2015, the Assembly
                                     You can also read about how BENNING uses highly efficient modular power systems to                                                                                                  adopted a climate agreement that pro-
                                     contribute to CO2 savings and greater efficiency in other areas, e.g. the modernisation of a                                                                                        vides for global warming to be limited
                                     power station in the UK, and the expansion of the Ukrainian mobile network or the moderni-                                                                                          to at least two degrees and ideally to
                                     sation of the New York metro.                                                                                                                                                       1.5 degrees Celsius. At the same time,
                                     I hope you enjoy reading this issue and look forward to your feedback.                                                                                                              CO2 emissions are to be significantly
                                                                                                                                                                                                                         reduced.
                                     Yours, Stephan Ratermann
                                     e-mail: s.ratermann@benning.de                                                                                                                                                      To achieve this goal, we want to implement
                                     telephone: +49 2871 93 0                                                                                                                                                            a gradual transition from conventional energy
                                                                                                                                                                                                                         sources to fully renewable ones. This article
                                                                                                                                                                                                                         describes the way the offshore wind industry
                                                  Contents                                                                                                                                                               is contributing to the latest trends and devel-
                                                                                                                                                                                                                         opments and the role of BENNING in this
                                     3–5          Safe power supplies for offshore wind                                          22            Energy Technology List Certification for
                                                  farms                                                                                        the ENERTRONIC modular SE                                                 regard.
                                                  Contributing to the energy revolution:                                                       BENNING’s modular UPS systems have
                                                  Europe-wide support for offshore wind                                                        received an award for their particularly high
                                                  farm projects                                                                                energy efficiency.
                                                                                                                                                                                                                         Promotion of wind energy
                                     6–9          Modular power protection in industrial                                         23 – 25 IABG certification for earthquake safety
                                                  applications                                                                           in the maximum danger zone                                                                                                                     19” modular rectifier plug-in unit with
                                                  Technical and economic advantages of                                                         Evidence of superb design: The UC-HE                                      In addition to the study of sustainable tech-                  4 modules TEBECHOP 3000 HDI
                                                  modular technology in the design and                                                         cabinet system, especially developed for use                              nologies, the promotion of wind energy is of                   and remote monitoring unit
                                                  operation of UPS systems                                                                     in earthquake zones, has been certified by
                                                                                                                                               Industrieanlagen-Betriebsgesellschaft mbH
                                                                                                                                                                                                                         particular importance when it comes to the                     MCU 2500
                                     10 – 13 Power supply systems and services for
                                                                                                                                               (IABG).                                                                   sustainable implementation of the energy
                                             the Ukrainian telephone network
                                                  For more than 20 years, BENNING Ukraine                                        26 – 29 New Drive Motors for historical                                                 transition.
                                                  has provided highly efficient power supplies                                           Kaiserwagen                                                                     As the construction of larger wind farms           however, high-voltage direct current (HVDC)
                                                  for reliable, energy-efficient operation                                                     Retrofit: BENNING has carried out a rotor-
                                                                                                                                                                                                                         turns out to be fairly complex in rural areas,     transmission is used, as this allows a lower
                                                                                                                                               stator configuration for the historic Wup-
                                     14 – 17 Highly efficient, fast-charging module                                                                                                                                      the focus is placed on the development of          loss of energy and thus more efficient energy
                                                                                                                                               pertal Suspension Railway Kaiserwagen.
                                             for electric vehicles
                                                  BELATRON modular – the new high-performance                                    30 – 31 Increased safety for one of the world's                                         Offshore Wind Farms (OWF), which are con-          transmission.
                                                  charging module for constructing high availability,                                    largest underground networks                                                    structed in coastal areas (e. g. in the North
                                                  economical electric vehicle charging stations                                                Individual product solutions and engineering                              and Baltic Seas, the Irish Sea or the Iberian      Increase in capacity
                                                                                                                                               services make New York's rail transport
                                     18 – 21 Built to last for a power plant’s lifetime                                                                                                                                  Atlantic coast) and supply energy to the
                                                                                                                                               safer and more efficient.
                                                  BENNING contracted to supply UPS systems to
                                                  one of the UK's largest and most energy-efficient                              32            Fairs, events and exhibitions                                             coast via submarine cables to feed into the        While the first OWF received substantial sub-
                                                  fired coal power stations                                                                    2018                                                                      general power grid.                                sidies from the government, the first projects
                                     Publication details
                                                                                                                                                                                                                                                                            are currently being implemented without
                                     BENNING Elektrotechnik und Elektronik       Liability and Copyright                        Picture credits                                                                          For transmission distances of less than 30         state funding. This is a clear sign that the off-
                                     GmbH & Co. KG’s client magazine             All texts are protected by copyright. The      © BENNING Elektrotechnik und Elektronik      industrieblick, Jakub Jirsák, Kadmy,
                                                                                 publication, adoption or use of texts, pic-       GmbH & Co. KG /                           Manuel Adorf, mariana_designer,             kilometres, the principle of alternating current   shore wind industry has established itself in
                                     Publisher: BENNING Elektrotechnik und       tures or other information is subject to the   © Anatoliy Sribny                            Max Topchii, Natalia Bratslavsky, newb1,
                                                                                                                                                                                                                         transmission is generally used. For longer         recent years as a new and strong industrial
                                                                                                                                                                                                                                                                            sector in Europe. 
                                     Elektronik GmbH & Co. KG,                   written agreement from BENNING GmbH.           © IABG                                       Nick Moulds, Petrovich12, Pixel Embargo,
                                     Münsterstrasse 135-137, 46397 Bocholt       No liability is accepted for any guidance,     © Oleksandr Ananyev                          rabbit75_fot, royyimzy, scharfsinn86,
                                                                                 references, recommendations or evalua-         © Uniper                                     Sergey Novikov, sirikornt, sk_design,       distances and high wind farm performance,
                                     Design und Production: Advertising Agency   tions. In spite of making every effort to      © WSW Wuppertaler Stadtwerke GmbH            Tobias Arhelger, Torbz, Varunyu,
                                     Paus Design & Medien GmbH & Co. KG,         carry out a correct presentation and           © arsdigital, beermedia, brianwhittaker,     Vera Kuttelvaserova / Fotolia.com
                                     Brinkstegge 13, 46395 Bocholt               checking of the subject matter, errors or         Christian Delbert, cphotos100,          © buffaloboy, Scharfsinn / Shutterstock.com
2 | BENNING | POWER news | 10/2018                                               mistakes in interpretation remain possible.       DamienGeso, envfx, Gorodenkoff,                                                                                                                                                                BENNING | POWER news | 10/2018 | 3
Electrifying innovation changing the future of mobility - BENNING
Especially in Germany, the offshore sector is      Not only the number of wind turbines, but         Secure power systems                               in the offshore wind energy sector in terms of
in the ascendancy. At the end of 2017, a total     also their average power has significantly in-                                                       safety and efficiency. BENNING is continually
of 1,196 offshore wind turbines were con-          creased to 10 MW. At the same time, the           For almost 15 years now, BENNING has               seeking to optimise service performance
nected to the grid in 20 OWFs with a total         voltage level and thus the use of DC connec-      proven to be a reliable designer and manu-         from planning through to maintenance in a
capacity of around 5,387 MW. But that is not       tions has increased – as a result of the larger   facturer of flexible and, above all, safe power    targeted fashion.
all: According to the plan, this figure is to be   amounts of energy, some of which are trans-       supply systems in the offshore sector. It sup-
increased to 10,700 MW by 2025 – and               ported over very long distances.                  plies both rectifier systems and UPS systems       BENNING’s extensive service package also
other European countries also wish to follow                                                         with batteries, which are primarily used on        includes the Hotline support service for its
suit. The Netherlands, for example, plans to       Artificial energy islands                         offshore platforms where permanent avail-          customers. On request, BENNING also pro-
expand its offshore capacity from 1,120 MW                                                           ability of critical loads (e. g. switchgear for    vides employees who specialise in offshore
currently to 7,000 MW by 2030.                     Several European energy companies are cur-        high voltage, communication and safety sys-        operations for on-site deployment. This en-
                                                   rently working on a major project which is        tems) must be ensured by means of uninter-         sures continuous operational safety of the
Over the past five to ten years, a large num-      significantly contributing to the implementa-     ruptible power supplies.                           wind turbine.
ber of OWFs have already been built and put        tion of the goals of the UN Climate Change        BENNING also offers tailor-made solutions          A small but important contribution on the way
into operation – especially in European coun-      Agreement. It consists of several man-made        for the wind turbines themselves, especially       to the energy transition. 
tries such as Great Britain, France, Germany       North Sea islands, on which various wind          in transition pieces. The systems used here
or the Netherlands. Most of these wind farms       farms are connected to generate electricity       must meet the highest requirements in terms        contact: Bram Slaager
have a total capacity ranging between              for the surrounding countries.                    of EMC, vibration and climatic influences.         telephone: +31 30 63 46 010
300 and 700 MW.                                    By the year 2027, they should be able to                                                             e-mail: slaager@benning.nl
                                                   produce sufficient energy to supply approx.       Customised service
A single wind turbine has an average power         80 million households. There are also central
output of 10 MW and is connected to a central      facilities such as accommodation for techni-      BENNING provides its customers with an ex-                         Scan the QR code for
platform (called hub) where all the energy is      cal and operational personnel as well as an       perienced team of competent experts whose                          further information
accumulated and routed to the mainland.            airport and water port close to these hubs.       aim is to maximise the use of power supplied

                                                      A                                                      B    The high wind farm capacities of
                                                                                                                  the artificially constructed energy
                                                                                                                  islands require high-voltage direct
                                                                                                                  current (HVDC) transmission.
                                                                                                                  This ensures a highly efficient and
                                                                                                                  low-loss energy transport over
                                                                                                                  long distances.

                                                      C                                                      D

                                                                                                                                                                                                         Redundant and modular power supply system
                                                                                                                                                                                                         with rectifier, inverter and DC/DC converter

4 | BENNING | POWER news | 10/2018                                                                                                                                                                                       BENNING | POWER news | 10/2018 | 5
Electrifying innovation changing the future of mobility - BENNING
Modular power protection
in industrial applications
The principle of modularity provides significant
technical and economic benefits in the design
and operation of UPS systems.

Modular power protection and conversion technology, partic-
ularly in the form of UPSs, has long been used in commercial
applications, but take-up in industrial applications has, to
date, been relatively slow.
                                                                                                  ENERTRONIC modular SE,                                                                                     BENNING’s UPS system is scalable and can
                                                                                                  40 kW modules                                                                                              increase in size in line with load requirements

                                         This relatively slow uptake is due, in part, to         Determination of functional                        Such a system could, for example, be in-           power. Because of its experimental nature,              a new drug. This decision now fundamentally
                                         a limited understanding of the “ilities” (“Avail-       characteristics                                    creased or decreased in size (see “scalability”    the directors of our fictitious company restrict        changes the design brief of the power pro-
                                         ability”, “Reliability”, “Scalability”, “Flexibility”                                                      article) to optimise TCO or additional mod-        the project’s budget and because it does not            tection system because if a power problem
                                         and “Maintainability”) commonly associated              At the initial design stage of a power protec-     ules could be added to it to introduce parallel    have a production line, the UPS system is not           causes the production line to be stopped
                                         with modular technology and how the vari-               tion system, the designer will prioritise the      redundancy (i.e. N+n) if maximised system          “business critical”, making TCO a greater               mid-batch, the entire batch must be
                                         ous “ilities” complement each other.                    most important aspects of the required             availability became a requirement.                 consideration than system availability. To              scrapped, costing the pharmaceutical com-
                                                                                                 system and will most likely compromise on          Finally, it would allow for power capacity to      meet this design brief a modular UPS sys-               pany tens of thousands of pounds.
                                         The fourth of five articles within our 'ility' se-      other design aspects. For example, if the          be relocated from system to system if the          tem, “rightsized” to the initial critical load by
                                         ries focuses on flexibility. We will define this        load is considered to be business critical the     needs of the critical load(s) across numerous      using two 40 kW modules, is installed (see              The design brief is now to maximise system
                                         in the context of the increasingly important            designer will prioritise availability above TCO.   systems ever needed to change.                     phase 1).                                               availability and an additional 40 kW module
                                         and popular modular technology and discuss                                                                 With the above “ideal world” we can define                                                                 is added to the modular UPS (see phase 3)
                                         how truly flexible systems allow system de-             Such prioritisation is not a problem if the        “flexibility” as a system’s ability to adapt to    Assuming that the company’s experimental                to add parallel redundancy and thereby meet
                                         signers to design power protection systems              needs of the site and/or critical load are guar-   the ever-changing needs of the site/critical       production line is an initial success, directors        the new design brief of maximum availability.
                                         capable of adapting to the potentially chang-           anteed to never change over the working life       load. High levels of system flexibility help de-   want to see how easily production capacity
                                         ing needs of a site and/or its critical load.           of the system (typically 20-25 years), how-        signers to “future-proof” their design and         can be increased on the experimental line,              As a result of increasing sales, the pharma-
                                                                                                 ever, we live in an ever-changing world and        below we will consider a practical example to      adding 50% capacity to the production line.             ceutical company opens up a new production
                                         Flexibility                                             such guarantees can rarely be given. The           see how the inherent flexibility of rack-          This increases the production line power re-            facility in a town, which is a 30-minute drive
                                                                                                 danger, therefore, is that a system that was       mounted modular UPS helped to future-              quirement by 30 kW from 60 kW to 90 kW.                 away, and decides to move the new drug’s
                                         In previous articles within this series we have         initially designed to meet one set of site/crit-   proof a system and thereby provided numer-         This challenge is overcome by simply adding             production line to the new production facility.
                                         defined modularity and discussed how mod-               ical load needs may no longer be suitable if       ous financial and operational benefits to the      one additional 40 kW module to the modular              The drug production line’s modular UPS is
                                         ular UPS systems can be designed to either              the needs of the site/critical load ever           system operator.                                   UPS system (see phase 2) to accommodate                 only 3 years old and rather than investing in a
                                         maximise system availability or minimise total          change. If this situation ever occurs it may be                                                       the increased load and still meet the initial de-       completely new UPS system the directors de-
                                         cost of ownership (TCO). We must now con-               an expensive problem to correct.                   An example of a highly flexible system             sign brief of lowest TCO.                               cide to relocate it to the new facility. However,
                                         sider how we can design a single system that                                                               design                                                                                                     the downtime on the production line must be
                                         is flexible enough to have the highest avail-           In an ideal world, a system would be de-                                                              The directors – who are delighted with the              minimised and the time needed to decom-
                                         ability or lowest TCO with the ability to switch        signed with the capability to quickly and          Let us assume that a pharmaceutical com-           performance of the now larger experimental              mission, de-install, physically relocate, re-in-
                                         between the two depending upon the pre-                 easily adapt to the prevailing needs of the site   pany decides to start up an experimental           production line, decide to turn it into a real          stall and recommission the existing UPS is
                                         vailing needs of the site/critical load.                and/or critical load.                              production line that needs 60 kW of UPS            production line and begin serial production of          considered to be too great. 

6 | BENNING | POWER news | 10/2018                                                                                                                                                                                                                                  BENNING | POWER news | 10/2018 | 7
Electrifying innovation changing the future of mobility - BENNING
Modular power protection

                          Power
                          [kW]

                                                                                                                                                                                                                                                                              200 kW (n+1)
                                                    installed power
                    180
                                                    requested power                                                                                                           new           old
                                                                                                                                                                            location     location
                    160

                                                                                    160 kW (n+1)

                                                                                                                               160 kW (n+1)

                                                                                                                                                                                                             160 kW (n+1)
                    140
                                                                                                                                                                 Transfer
                    120

                                                                                                                                                                                                                                                                                         120 kW (n+1)
                                                           120 kW
                    100

                                                                                               90 kW (n+1)

                                                                                                                                          90 kW (n+1)

                                                                                                                                                                                                                        90 kW (n+1)
                                                                90 kW

                     80
                            80 kW

                     60
                                60 kW

                                                                                                                                                                                                                                               40 kW
                     40

                                                                                                                                                                                                                                                   30 kW
                     20

                                                                                                                                                                                                                                                                                                                 Time
                      0             Location A                      Location A                           Location A                                 Location A              Location B   Location A                               Location B           Location A                                   Location B
                                        Phase 1                         Phase 2                              Phase 3                                             Phase 4                              Phase 5                                                         Phase 6

                                                  The solution is to install and commission an                         The above example shows the flexibility of a                      Modular systems with modules that have the                        Conclusion
                                                  empty modular UPS cabinet at the new pro-                            true modular UPS. In this example, we have                        inbuilt intelligence to be parallel redundant
                                                  duction facility (see phase 4).                                      seen a simple, cost effective:                                    (e.g. N+1) when the size of the load means                        With industrial power protection systems
                                                                                                                                                                                         they can be; or parallel capacity (i.e. N+0)                      having a design life of >20 years, one of the
                                                  When the production line is switched off at                          • Increase in system capacity                                     when they need to be, enable automatic,                           greatest challenges faced by system design-
                                                  the old facility, the four UPS modules are                           • Conversion from a TCO priority to an avail-                     real-time flexibility and ensure that the critical                ers is how to future-proof their design by en-
                                                  then simply switched off, removed from the                             ability priority design                                         load is always supplied with the highest level                    abling it to adapt to the potentially changing
                                                  original modular UPS cabinet, driven by car                          • Relocation to new premises                                      of protection possible. This capability auto-                     needs of the site and/or critical load.
                                                  to the new production facility, fitted into the                      • Reduction in system capacity and conver-                        matically maximises system availability.                          Rack-mounted modular UPS systems can
                                                  new modular UPS cabinet and switched                                   sion back to a TCO priority design                                                                                                be quickly and easily reconfigured to allow
                                                  back on (see phase 5). Because the new                                                                                                 Reduction of power consumption                                    the power protection system to adapt to
                                                  production facility was only a 30-minute drive                       Inbuilt intelligence for true flexibility                                                                                           site/critical load changes and can prioritise
                                                  away, the whole process took less than                                                                                                 Similarly, modular systems with modules that                      either highest availability or lowest TCO
                                                  90 minutes in total.                                                 The example above needed the pharmaceu-                           have the inbuilt intelligence to use only the                     depending upon the prevailing needs of the
                                                  The pharmaceutical company now decides                               tical company to make decisions and take                          required number of UPS modules necessary                          site/critical load.
                                                  to start up another experimental production                          physical actions to adapt the system to the                       to supply power to the critical load by putting                   Rack-mounted UPS modules with user con-
                                                  line on the original site and this line now                          changing needs of the site/critical load.                         “excess” modules into a “sleep mode” en-                          figurable inbuilt intelligence will automatically
                                                  needs 30 kW of UPS power.                                            In most cases this is perfectly acceptable,                       able the system to automatically operate as                       further enhance system flexibility without
                                                  Again, because of its experimental nature,                           however, there may be occasions when it                           efficiently as it can whilst ensuring that the                    removing ultimate control from the system                    contact: Alexander Proemel
                                                  the directors restrict the project’s budget and                      would be beneficial if the system itself were                     critical load continues to receive the required                   operator.                                                    telephone: +49 2871 93 238
                                                  because it not a real production line, and                           intelligent enough to make decisions and                          level of protection.                                              The next, and final, article in the “ilities” series         e-mail: a.proemel@benning.de
                                                  therefore not “business critical”, TCO is a                          take automated actions to maximise system                                                                                           will discuss “maintainability” and how select-
                                                  greater consideration than system availability.                      availability or minimise TCO.                                     If the critical load increases, a “sleeping”                      ing the right UPS topology will reduce servic-
                                                                                                                       Of course, such decision-making capability                        module will automatically be returned to full                     ing costs, minimise “local” spare parts hold-
                                                  To meet this design brief a single 40 kW mod-                        must be user configurable to ensure that the                      service and if the critical load decreases fur-                   ings and enable rapid “first line” fault                                      Scan the QR code for
                                                  ule is fitted into the original modular UPS sys-                     system operator retains ultimate system con-                      ther then another module will automatically                       rectification, all of which will ultimately max-                              further information
                                                  tem cabinet and the whole “experimental pro-                         trol, but such inbuilt intelligence will further                  be sent to “sleep”. This capability automati-                     imise system availability and minimise total
                                                  duction line” cycle starts again (see phase 6).                      enhance system flexibility.                                       cally optimises system TCO.                                       cost of ownership. 

8 | BENNING | POWER news | 10/2018                                                                                                                                                                                                                                                                                          BENNING | POWER news | 10/2018 | 9
Electrifying innovation changing the future of mobility - BENNING
Photo: © Oleksandr Ananyev

                                                                                                                                                                                                                                                                                                                                       Photo: © Anatoliy Sribny
                                                                   Power supply systems and services
                                                                   for the Ukrainian telephone network
                                                                                                                                                                                                                                     The rear cabinet series has a 48 V / 216 kW telecommunications system with TEBECHOP 13500
                                                                   BENNING Ukraine has been supplying the Ukrainian telecom-                                                                                                         modules consisting of module cabinets, mains supply fields as well as battery and load output fields,
                                                                                                                                                                                                                                     including a monitoring system. The front contains the battery system, along with battery connection
                                                                   munications market with high-efficiency power supplies
                                                                                                                                                                                                                                     boxes.
                                                                   for energy-saving, reliable operation for over twenty years.
                                      Photo: © Oleksandr Ananyev

                                                                   At the beginning of the new millennium,    Ukrainian telecommunication operators      Over 500 DC systems for Vodafone                                           between the two companies. Since 2005,              Virtually all the regions of the Ukrainian
                                                                   there was a surge in development in the    chose products and services from                                                                                      Vodafone Ukraine has received more than 500         Vodafone network are now equipped with
                                                                   telecommunications market in Ukraine,      BENNING. At that stage, the company        Vodafone, one of the largest telecommunica-                                DC systems with associated distribution sys-        BENNING telecommunications power sup-
                                                                   attributable to the economic progress of   had already accrued ten years’ experi-     tions network providers in Ukraine, also uses                              tems. These conform to the relevant interna-        plies – and Vodafone Ukraine is currently
                                                                   the country. This was also reflected in    ence in the Ukrainian market and nur-      know-how from BENNING for power supplies                                   tional and regional standards and are perfectly     using BENNING solutions for new mobile cell
                                                                   high demand for uninterruptible power      tured trust from a large number of cus-    for 3G and 4G telecommunications systems.                                  tailored to the strict individual requirements of   sites that are to be erected. The power sup-
                                                                   supplies for setting up network infra-     tomers with its bespoke product            The positive experiences since the start of the                            the Ukrainian telecommunications system,            plies delivered are based on SLIMLINE,
                                                                   structures. Despite the high competition   solutions, high standards of quality and   collaboration have served to underpin the                                  which repeatedly experiences network out-           TEBECHOP 12000 and TEBECHOP 13500 SE
                                                                   in that market sector, many high-profile   reliable support.                          good relationship that continues to exist                                  ages, especially outside major cities.              series rectifiers. 

10 | BENNING | POWER news | 10/2018                                                                                                                                                                                                                                                          BENNING | POWER news | 10/2018 | 11
Electrifying innovation changing the future of mobility - BENNING
... Turnkey Service

                                                                                                                                                                                                                                                          High-efficiency power supplies

                                                                                                                                                        BENNING power supply system                                                                       BENNING has delivered battery-powered
                                                                                                                                                        for telecommunication applications                                                                AC and DC power supplies to many mobile
                                                                                                                                                                                                                                                          phone and landline operators around the
                                                                                                                                                                                                                                                          world for decades. In recent years, it has
                                                                                                                                                                                                                                                          made particular investments in the develop-
                                                                                                                                                                                                                                                          ment of high-efficiency power supplies for
                                                                                                                                                                                                                                                          energy-saving, reliable operation. The latest
                                                                                                                                                                                                                                                          circuit topologies and state-of-the-art electrical
                                                                                                                                                                                                                                                          components support a very compact and
                                                                                                                                                                                                                                                          reliable design of system.

 Proactive Service – Technical On-Site Service

                       Rectifier series                                                                                                                                                                                                                    INVERTRONIC compact,
                       TEBECHOP 13500 SE,                                                                                                                                                                                                                  modular, single phase inverters –
                       48 V - 250 A (300 A)                                                                                                                                                                                                                19” Sub-rack with 5 inverters

Power capacities up to several hundred kilo-       Largest system in the Ukraine                      on-board control system and extensive mon-       maintenance work, as well as training for         developed the state-of-the-art ENERTRONIC
watts are covered, depending on customer re-                                                          itoring and diagnostic functions (remote         Vodafone Ukraine service technicians. As          Modular SE UPS system, the cooperation will
quirements and purpose. The modular tech-          The telecommunications system in Kharkiv,          monitoring) for preventative early detection.    BENNING has highly qualified personnel and        be intensified even further. The new high-tech
nology of the power supply systems also            a large city in the east of Ukraine, is not only                                                    technical resources, it is in a position to re-   product was unveiled in Ukraine at Elcom
provides customers with a quick and easy op-       the biggest one in the country with a capacity     Individual turnkey services                      spond quickly at any time to requests from        Ukraine 2017, an international trade fair for
tion for capacity scalability (pay as you grow).   of 48 V and 14,000 A, it is also one of the                                                         customers from a wide range of sectors and        power engineering, electrical engineering, en-
                                                   biggest in the whole of Europe. It consists of     However, central to the service portfolio pro-   to offer bespoke solutions.                       ergy efficiency and automation. 
Furthermore, each of the systems has an indi-      TEBECHOP 13500 rectifier modules,                  vided for Vodafone Ukraine are not only prod-
vidually developed DC distribution unit, an on-    TEBEVERT DSP power inverter modules and            uct solutions, but also various individual       Vodafone Ukraine requires optimum technical       author/contact: Andrij Piatachenko
line monitoring system (TCP-IP and SNMP            four distribution cabinets. These are respon-      turnkey services. In addition to the develop-    solutions and services, and not only for 48 V     telephone: 0038 044 501 40 45                                      Scan the QR code for
protocol), as well as a temperature compen-        sible for the power supply to the entire           ment, manufacture, installation and start-up     DC power supplies. As BENNING Elek-               e-mail: a.piatachenko@benning.ua                                   further information
sation system for gentler charging of batteries.   3G and 4G network and include both an              of the systems, this also includes service and   trotechnik und Elektronik GmbH & Co. KG has

12 | BENNING | POWER news | 10/2018                                                                                                                                                                                                                          BENNING | POWER news | 10/2018 | 13
Electrifying innovation changing the future of mobility - BENNING
Photo: © buffaloboy/Shutterstock.com
                                       Highly efficient, fast-charging module
                                       for electric vehicles

                                       With the BELATRON modular series, BENNING provides
                                       equipment suppliers and operators of EV charging stations with
                                       high-performance charging modules and systems which
                                       combine the highest level of system availability with maximum
                                       cost-efficiency.
Photo: © Scharfsinn/Shutterstock.com

                                                                             The German automotive industry is                                      19” module (87.5 kW)
                                                                             going to invest around 40 billion euros in
                                                                             e-mobility by 2020. This should make the
                                                                             use of electric vehicles a key feature of
                                                                             a smart, resource-friendly urban lifestyle.

                                                                             There is a clear need for optimisation, espe-
                                                                             cially with regard to the charging infrastruc-     Input per module:                     Output per module:
                                                                                                                                3 x 400 V / 50 Hz                         200 V to 950 V
                                                                             ture. According to a recent study, about           3 x 150 A (max.)                             max. 100 A
                                                                             25 percent of all potential car buyers are con-
                                                                             cerned about not finding an e-charging sta-        Block diagram: combination of rectifier and
                                                                             tion in the vicinity if needed.                    DC/DC converter in the 19” module (87.5 kW)
                                                                                                                                of the BELATRON modular                                                                 19” module (87.5 kW)
                                                                             In particular, the idea of experiencing this on
                                                                             the way to work or on holiday, was unwel-
                                                                             come. Consequently, the installation of fast-     PN: Mr. Erfen, could you briefly explain what               PN: Before going into more detail, can you            PN: With this equipment range, BENNING is
                                                                             charging systems will be the high-priority        makes the new BELATRON modular fast                         please explain to our readers what are the            entering a completely new market segment.
                                                                             task in the near future.                          charging module stand out?                                  most important benefits of this new range of          That’s a major risk for the company and its
                                                                                                                                                                                           devices?                                              potential customers, isn’t it?
                                                                             The challenge is to design the interfaces be-     Erfen: With pleasure. BELATRON modular is
                                                                             tween electric vehicles, charging devices and     a highly efficient modular system for effective             Erfen: Each 87.5 kW module has freely con-            Erfen: We do not see it that way. For more
                                                                             power grids as open systems. This would           installation of DC charging stations.                       figurable interfaces and is therefore an ideal        than 80 years, BENNING products have im-
                                                                             enable a wide variety of companies to collab-                                                                 building block for the installation of charging       proved safety and efficiency and contributed
                                                                             orate and jointly develop product modules for     The three-phase fast charging modules can                   systems at fuel stations and motorway ser-            to better utilisation of energy resources. Ever
                                                                             a common platform.                                be flexibly combined and are suitable for                   vice areas, for example. The modules are              since it began, the company has been pro-
                                                                                                                               charging a wide variety of vehicle types such               therefore aimed, in particular, at companies          ducing smart solutions for the conversion of
                                                                             A key component in this context is the newly      as cars, trucks and buses.                                  that plan and install the charging infrastruc-        electricity into multi-purpose or storable en-
                                                                             developed BENNING HPC rapid charging                                                                          tures. By opting for charging modules of the          ergy. Today, BENNING is known worldwide
                                                                             module the BELATRON modular. POWER                With the different configurable power ratings               BELATRON modular series, they will provide fu-        as a ‘quality leader’ for reliable smart-effi-
                                                                             news took the opportunity to discuss this         (e. g. 150 kW or 350 kW), vehicles with both                ture e-filling station operators with tailored con-   ciency AC and DC power supplies for the
                                                                             with Reinhard Erfen, Key Account Manager          400 V and 800 V batteries can be charged                    figurations that combine maximum system               telecommunications, power plant technol-           BELATRON modular system cabinet
                                                                             of the E-Mobility Division at BENNING.            efficiently.                                                availability with extremely efficient operation.      ogy, medical and IT industries.                   350 kW / 875 VDC

                                       14 | BENNING | POWER news | 10/2018                                                                                                                                                                                                                         BENNING | POWER news | 10/2018 | 15
Electrifying innovation changing the future of mobility - BENNING
2 x 175 kW / 875 VDC

                                                                                                                                                                                                                                                                              Transformer

                                                                                                                                                                                                                                                                                                                         Module 1

                                                                                                                                                                                                                                                            (10 kV . 20 kV)

                                                                                                                                                                                                                                                                                                    Sec.1: 3 x 400 V
                 And it’s not really a new market segment for                                                                                                                                                                                                                                                                                                                 175 kW

                                                                                                                                                                                                                                                                                Pri.10 kV / 20 kV
                 us. BENNING has been supplying chargers                                                                                                                                                                                                                                                                 Module 2                                                @
                 for forklift trucks for almost 50 years now.                                                                                                                                                                                                                                                                                                                 875 VDC

                                                                                                                                                                                                                                                                                                    Sec. 2: 3 x 400 V
                                                                                                                                                                                                                                                            Public mains
                 The name BELATRON is synonymous with
                 high-quality, robust and highly efficient charg-
                 ing systems for lead and lithium batteries.                                                                                                                                                                                                                                                             Module 3

                 PN: At whom is the newly developed product
                 aimed?                                                                                                                                                                                                                                                                                                                                                       175 kW
                                                                                                                                                                                                                                                                                                                          Module 4
                                                                                                                                                                                                                                                                                                                         UC system cabinet with distribution and                 @
                 Erfen: With the BELATRON modular series,                                                                                                                                                                                                                                                                overvoltage protection
                                                                                                                                                                                                                                                                                                                                                                              875 VDC
                                                                                                                                                                                                                                                                                                                         W 600 mm x D 800 mm x H 1800 mm
                 BENNING is providing equipment suppliers
                 and operators of EV charging stations with
                 high-performance charging modules and sys-                                                                                                                                                                                                                                                               350 kW / 875 VDC
                 tems that are specifically tailored to the ex-
                 tremely high requirements of fast-charging op-
                                                                                                                                                                                                                                                                              Transformer
                 eration. In addition to the cost-efficiency, these
                 also offer maximum operational safety, relia-                   Plug & play technology ensures quick and easy                                                                                                                                                                                           Module 1

                                                                                                                                                                                                                                                            (10 kV . 20 kV)
                 bility, energy efficiency as well as easily con-                exchange of modules
                 figurable User Space at the installation site.

                                                                                                                                                                                                                                                                                Pri.10 kV / 20 kV

                                                                                                                                                                                                                                                                                                    Sec.: 3 x 400 V
                                                                                                                                                                                                                                                                                                                         Module 2
                 PN: You have mentioned cost-efficiency as a                    The power module components consist of a

                                                                                                                                   Photo: © Scharfsinn/Shutterstock.com
                 key feature. This becomes evident when you                     redundant control unit, a three-phase rectifier

                                                                                                                                                                                                                                                            Public mains
                 consider the system total operating costs.                     and a DC/DC converter. Rectifiers and con-
                 These include, among other things, the in-                     verters are implemented in a 3-level IGBT
                                                                                                                                                                                                                                                                                                                                                                              350 kW
                                                                                                                                                                                                                                                                                                                         Module 3
                 vestment costs, the energy costs as well as                    technology, ensuring low power input distor-                                                                                                                                                                                                                                                     @
                 maintenance and service costs. How does                        tion and active power factor correction at all                                                                                                                                                                                                                                                875 VDC
                 the BELATRON modular meet these require-                       times. While the harmonic content of the
                 ments exactly?                                                 mains power consumption (THDi) is 3%, the                                                                                                                                                                                                 Module 4
                                                                                                                                                                                                                                                                                                                         UC system cabinet with distribution and
                                                                                input current is sinusoidal with cos ϕ of                                                                                                                                                                                                overvoltage protection
                 Erfen: Each 19” power module is stand-                         nearly 1.                                                                                                                                                                                                                                W 600 mm x D 800 mm x H 1800 mm

                 alone and highly efficient. Due to the highest
                 module efficiency of 97% the ongoing oper-                     PN: The module is offered not only as a
                 ating costs are minimised without compro-                      stand-alone unit, but also as an integrated
                 mising the voltage quality.                                    system in a cabinet housing. To what extent                                                                                                                              The block diagrams demonstrate how to use the 87.5 kW modules
                                                                                does the system design you develop affect                                                                                                                                as a basis to configure different DC charging systems
                                                                                the costs of rented areas or new buildings
                                                                                where the relevant equipment is installed?
                                                                                                                                   fuels. It is the top-priority task of the operator   PN: You mention short repair times. Could          Erfen: BENNING has always invested a                                                           potential downtime and ensure long-term
                   Charging power characteristics                               Erfen: The charging system has an output of        of an EV filling station to ensure that all EV       you briefly explain how these are achieved?        great deal of effort in maintaining the highest                                                cost-efficiency. Thus, our customers are well
                                                                                approx. 729 kW/m². Since the air flow is dis-      charging stations are available for operation                                                           service standards for its customers. Our cus-                                                  prepared for the challenges of today and the
[kW]                                                                            charged through the system roof, its installa-     on a permanent basis. How do you meet this           Erfen: The modular component concept is            tomers value the reliable, globally oriented                                                   opportunities of tomorrow.
                                                                                tion is extremely space-saving. The systems        requirement for maximum product availability?        the basis for a significant reduction in instal-   service structure that provides the best pos-
                                                                  400 A
                                                            ent                 can be easily placed ‘back to back’ on a wall                                                           lation and assembly times as well as for more      sible support for their respective require-                                                    PN: Mr. Erfen, thank you for the detailed and
                                                                                                                                                                                                                                                                                                                                          very interesting conversation. 
                                                     curr
Charging power

                                               ing                              or in a corner.                                    Erfen: In the new BELATRON modular se-               user-friendly and efficient maintenance activ-     ments.
                                         Charg
                                                              A                                                                    ries, BENNING combines the advantages of             ities in subsequent operation. All settings and
                                                       nt 200
                                                g curre                         Optionally, a rear ventilation system can be       maximum reliability and shortest repair times        service work can be configured and under-          In anticipation of future requirements, the ser-
                                         Chargin
                                                      ent 100 A
                                         Charging curr                          integrated. These possibilities ensure a high      (MTTR) in a product that meets the highest           taken from the front.                              vice department has been greatly expanded                                                      contact: Reinhard Erfen
                                                                                degree of flexibility and save a lot of space,     requirements regarding the availability and          The ‘hot swap’ capability allows each mod-         over the past few years. We are talking about                                                  telephone: +49 2163 500 994
                                                                                which in turn leads to a reduction in costs in     quality of a safe and reliable power supply of       ule to be replaced in less than ten minutes        Service 4.0 which is offered as a proactive                                                    e-mail: r.erfen@benning.de
                               Battery charge voltage                     [V]   terms of rented areas or building invest-          EV charging systems.                                 which equates to a maximum availability            360° service.
                                                                                ments, for example.                                By using high-quality components and their           of 99.9999%.
                                                                                                                                   generous performance rating in the critical                                                             BENNING 360° services encompass reliable
                  The characteristics show the linear change of                 PN: The goal is to achieve a fast charging         path, the design of the BELATRON modular             PN: You mention quick replacement on site.         maintenance and spare parts management,
                  the charging power in relation to the battery                 time of approx. 20 minutes for electric vehi-      system is optimally adapted to the harsh             Is the technical support provided for a large      with individual service contracts, which help                                                                           Scan the QR code for
                  charging voltage at different charging currents               cles, which is still relatively long as compared   conditions of rapid charging with high cur-          number of scattered locations not a critical       safeguard the business and production pro-                                                                              further information
                  of 100 A, 200 A and 400 A.                                    to the refuelling process with conventional        rents and voltages.                                  factor?                                            cesses of our customers, as well as prevent

                 16 | BENNING | POWER news | 10/2018                                                                                                                                                                                                                                                                                            BENNING | POWER news | 10/2018 | 17
Electrifying innovation changing the future of mobility - BENNING
Built to last for a
                                                  power plant’s lifetime
                                                  BENNING contracted to supply UPS systems to one of the UK's
                                                  largest and most energy-efficient fired coal power stations.

Uniper's power station in Ratcliffe-on-Soar is a 2,000MW coal-fired power station,                  For both large projects, BENNING proposed
which can meet the electricity needs of approximately two million homes. Commis-                    new redundant systems, incorporating effi-
sioned in 1970, the power station has four coal-fired boilers made by Babcock &                     cient and digitally controlled solutions, which
Wilcox, each of which drives a 500-megawatt (MW) Parsons generator set.                             provide a high level of availability, whilst min-
In addition to the plant's enormous capacity, it is also the first power station in the             imising risk and cost in maintaining the
UK to be fitted with Selective Catalytic Reduction technology (SCR), which reduces                  equipment.
the emissions of nitrogen oxides through the injection of ammonia directly into the
flue gas.                                                                                           Project one - 'critical supplies' upgrade

In April 2016, Ratcliffe Power Station's lead     Ratcliffe Power Station appointed BENNING         It is crucial for power plants to have back up
electrical engineer contacted BENNING to          for two contracts and some additional sys-        power systems in place that can start and
enquire about a small inverter system. When       tems:                                             control their operation if the mains supply is
visiting the site, it became clear that the                                                         interrupted.
plant's UPS systems for ‘Critical Supplies’ re-   • The first contract was to replace the old       To achieve this most effectively, BENNING
quired an upgrade.                                  station and coal battery charger systems /      designed two rectifier/charger systems for
                                                    rectifiers which support critical power plant   the site’s critical supplies. Accordingly, two
BENNING was identified as the right partner         systems. The new systems were to include        1000A, 240VDC station charger systems
for this project because of its specialisation      additional capacity and be relocated within     (A+B) were supplied and installed in the
in providing robust, industrial-scale modular       the building.                                   power station and one 400A, 240VDC
power solutions.                                                                                    charger system is installed in the coal plant.
                                                  • The second contract was to replace the ex-      The coal plant charger/rectifier, which feeds
In contrast to power solutions for the com-         isting site instrument, computer, measur-       batteries within the coal plant area of the
mercial sector, BENNING's industrial grade          ing, recording and regulating device UPS /      power station, has a future capability of 400A
solutions achieve a prolonged lifetime and          inverter/converter systems with a set of        at 240VAC, which was de-rated at delivery
higher availability by over-specifying compo-       modular UPS systems.                            to 200A to match the incoming AC supply.
nents and developing hardware that is de-                                                           All three systems were designed to use an
signed to withstand the harsh conditions          • In addition, BENNING won orders to re-          identical voltage so that they can be coupled
faced in the environment of industrial-scale        place multiple smaller emergency lighting       if needed during maintenance or in emer-
applications such as dust, temperature chan-        systems with modular UPS system de-             gency situations, increasing the power
ges or water ingress.                               signs.                                          plant's high availability level. 

                                                                                                                                                        UPS subsystem for instrumentation

18 | BENNING | POWER news | 10/2018                                                                                                                             BENNING | POWER news | 10/2018 | 19
... advantages
    thanks to
    modularity

                          Easy module swap due
                          to hot plug technology
                          and automatic module
                          configuration

The two 1000A, 240VDC station chargers
provide the power station with a fully redun-
dant N+N system (A+B), which ensures a
high level of availability. The systems, which
needed to be positioned in a new location
within the building, were not only designed
but also manufactured, installed and com-
missioned by BENNING. One challenge was
to correctly position the systems over the
cable tunnels, however, the team took all
client specifics into consideration, ensuring
that the systems were perfectly levelled,
aligned and positioned over the cable tunnels
in their new location.
                                                                                                                                                       Hier steht jetzt noch Blindtext als
Project two - UPS & inverter systems                                                                                                                   Beispiel für die Bildunterschrift
                                                                                                                                                                                                                                              ENERTRONIC modular SE
Following the success of the first "critical sup-                                                                                                                                                                                             40 kW module, developed for
plies" upgrade program contract, BENNING                                                                                                                                                                                                      the most demanding requirements
was asked to take part in the bidding pro-
cess for replacing 13 separate UPS/inverter
systems across the entire Ratcliffe-on-Soar
site. Most systems were at the end of their
life and an appropriate, future-proof replace-      modules, which can simply be added or re-       • Modules interchangeable with other sys-         this project." According to the loads these    is a modular, transformerless three-phase            reduce running costs and environmental im-
ment needed to be found. During survey vis-         moved from the larger UPS chassis unit,           tems: Modules can be swapped between            supported, these systems were:                 output UPS system based on IGBT/MOSFET               pact, while modular design allows for rapid
its with Uniper's team, BENNING were able           which has no single point of failure.             systems and spare parts can be kept to a        • 1 x Station Instrument UPS 30kVA N+N         semiconductor and DSP processor technol-             repair and pay as you grow system scalability
to assess the exact requirements of the site                                                          minimum due to their interchangeability           system with N+1 on each side and dual        ogy. It has been designed to provide the             through the installation of additional parallel
and gain an appreciation of the level of criti-     Key benefits of BENNING's suggested                                                                 battery strings                              highest level of protected power availability        connected modules.
cality involved. Closely working with the lead      modular system are:                             • Expandability and flexibility: The UPS sys-     • 1 x Coal Plant UPS 20kVA N+1 using sta-      for critical loads within the utilities, oil, gas,
engineer throughout, BENNING recommen-                                                                tem can grow with power requirements, as          tion battery set                             transport and other high-demand industries.          BENNING completed the positioning, instal-
ded a modular approach for the new sys-             • Increased availability: Units can be easily     modules can simply be added to achieve a        • 1 x FDG UPS 7.5kVA n+1 using dual bat-       As previously introduced, the truly modular          lation and SAT/commissioning of all of the re-
tems. This modular approach is well-estab-            added or replaced, as none represent a          higher capacity, giving operators a great         tery strings                                 design means that each ENERTRONIC mod-               maining UPS systems within the completion
lished in the commercial sector, when looking         single point of failure                         deal of flexibility                             • 1 x Communications UPS 7.5kVA N+1            ule contains its own rectifier, inverter, con-       target of November 2017. 
at smaller scale data centre UPS systems, for                                                                                                           using three battery strings                  troller and static bypass switch, ensuring that
example. However, its advantages have not           • Reduced MTTR: It only takes a few min-        • UPS black start function allows station to      • 1 x IT infrastructure UPS 25kVA N+1 using    there is no single point of failure within the       author/contact: Dirk Meyer
found their way into industrial environments          utes to remove or swap modules, all of          initiate a recovery procedure following an        single battery strings                       UPS system. This, coupled with a modular,            telephone: +49 2871 93 261
yet, as these environments require longer             which can be done whilst the overall sys-       extensive loss of supply                        • 4 x Instrumentation UPS 20kVA using sta-     hot-swappable design ensures a high system           e-mail: d.meyer@benning.de
UPS lifetimes, greater installed system com-          tem is online and running                                                                         tion battery sets                            MTBF and low MTTR. A manual bypass
plexity, and rugged system hardware.                                                                According to Uniper’s Lead Engineer Christo-      • 4 x Computer UPS 20kVA using battery         switch is provided for maintenance pur-
BENNING is the only manufacturer to meet            • Simple spare holding: Due to their small      pher Howe, “BENNING were the only indus-            sets                                         poses. The provided system also included
these unique industrial requirements whilst           size, UPS modules can be easily lifted and    trial supplier of such modular technology,                                                        2 x100% rated 12-15 Year design life VRLA
providing a highly functional modular system          carried by one person, while spare mod-       and this coupled with the flexibility of a mod-   The fully installed and commissioned station   batteries.                                                            Scan the QR code for
architecture. Rather than a monobloc sys-             ules can be stored to facilitate quick re-    ular system, led to the decision to employ        UPS system comprises a dual redundant          Low input harmonic distortion and high effi-                          further information
tem, the UPS is built out of smaller units, or        placements                                    BENNING as the partner of choice to deliver       ENERTRONIC modular SE UPS range, which         ciency, even at partial load, significantly

20 | BENNING | POWER news | 10/2018                                                                                                                                                                                                                          BENNING | POWER news | 10/2018 | 21
“We are proud
                                                                                                                             to be included
                                                                                                                             in the ETL. This
                        Energy Technology List                                                                               is evidence that
                                                                                                                             we offer our
                        Certification for the                                                          customers highly efficient product
                                                                                                       solutions that contribute to a reduc-
                        ENERTRONIC modular SE                                                          tion of ongoing operating costs and           IABG certification
                                                                                                       lower CO2 emissions.”
                                                                                                                                                     for earthquake safety
The modular UPS systems in the ENERTRONIC modular SE                                                   David Whitlow, Managing Director
range developed by BENNING have received a commendation                                                BENNING UK                                    in the maximum danger zone
for their particularly high energy efficiency.                                                                                                       The UC-HE cabinet system specifically developed
                                                                                                                                                     for use in seismic areas has been certified
For more than 80 years, BENNING prod-                                                                                                                by Industrieanlagen-Betriebsgesellschaft mbH.
ucts have stood for maximum security,
                                                                                                                                                     This is testament to the excellent design work
efficiency and optimised resource utili-
sation.                                                                                                                                              created on PC-based simulation technology.

The company has now received a special
commendation for its efforts – the inclu-
sion of the ENERTRONIC modular SE
UPS systems in the Energy Technology
                                                                    y

                                                                     n   c
List (ETL) for Enhanced Capital Al-                     y   Effi
                                                                 cie
                                                  Energ
lowances (ECA). This is official confir-         Natur
                                                       al R              CO2
mation of the particularly high energy                     e   so
                                                                 ur
                                                                   c
                                                                                                                                                                                       The need to consider earthquake risks            Highest safety standards
                                                                    es

efficiency of this BENNING UPS range.                                                                ENERTRONIC modular SE,40 kW Module IT Series                                      is almost everywhere. Currently, more
                                                                                                                                                                                       than 2.7 billion people live in an earth-        The highest safety standards must be met,
                                                                                                                                                                                       quake-prone area. If you take a look at          although a classification into different priority
The ETL certificate has been awarded by         there is a load increase. Therefore, the sys-       If maximum profitability and energy efficiency                                     the earthquake zone map, you will see            levels is also necessary. The failure of the
Carbon Trust, an organisation founded           tem has the capability to automatically main-       are of greater importance than the voltage                                         that many densely populated cities such          telecommunications system, for example,
by the British government for the reduction     tain the highest system availability, while en-     and frequency quality, it is possible to oper-                                     as Los Angeles, Shanghai, Tokyo, Lima            poses a much lower risk than a blackout of
of greenhouse gases.                            suring the lowest operating costs.                  ate in “Super Efficiency Mode”. This allows                                        or Istanbul are located in seismogenic           the pump system that supplies the cooling
                                                                                                    the supply of the load to be achieved via the                                      zones. In this case, we are talking about        circuits.
The ECA system supports companies in in-        Combined with the repair and maintenance            static bypass, as long as the voltage and/or                                       Category 4 hazard zones, based on US
vesting in energy-efficient equipment and       benefits of true “hot swap” modularity,             frequency of the supplying network lie within                                      UBC standard classification. If a major          In order to meet the variety of high demands,
machinery which allows them to receive          through which a whole UPS module can be             the preset tolerance ranges.                                                       earthquake occurs in one of these re-            BENNING has developed an individually con-
financial benefits. Tax exemptions enable       replaced in just a few minutes, this results in                                                                                        gions, it can cause severe damage to             figurable cabinet system that can be perfectly
the total cost of the new asset or machine      a UPS system with 99.9999% availability.            As soon as one of these values leaves its                                          buildings, infrastructure or technical           adapted to the different earthquake cate-
to be offset against the taxable profit for                                                         range, automatic and uninterrupted switch-                                         plant - affecting, among other things,           gories and safety requirements. It is available
the full financial year in which the purchase   Minimising Operating Costs                          ing into double conversion operation takes                                         transport, industry, healthcare system or        in the following versions: UC (Standard),
was made.                                                                                           place. At the same time, the load receives                                         energy supply.                                   UC-LE (Light Earthquake Resistant), UC-ME
                                                Thanks to the “pay as you grow” scalability         complete protection against harmful network                                                                                         (Middle Earthquake Resistant) and UC-HE
Maximum Energy Efficiency                       and very high operating efficiency, even at         influences.                                                                       On average, large earthquakes with a mag-        (Heavy Earthquake Resistant).
                                                partial load, the actual operating costs of the                                                                                        nitude of 6.0 and higher occur about three
The energy optimisation mode, selectable        ENERTRONIC modular series are kept to a             contact: Dirk Meyer                                                                times a week - nearly 100 earthquakes a year     In comparison to conventional designs that
and configurable by the user, automatically     minimum, without compromising on network            telephone: +49 2871 93 261                                                         cause structural damage, according to re-        seek to achieve the necessary earthquake
minimises the total cost of ownership (TCO)     quality. Every UPS module therefore repre-          e-mail: d.meyer@benning.de                                                         cent statistics from the National Earthquake     resistance of housing through high rigidity,
while maximising system availability.           sents a highly efficient, serial online UPS                                                                                            Information Centre (NEIC). This unpredictabil-   the new UC cabinet variants are charac-
                                                (VFI-SS-111).                                                                                                                          ity makes it necessary to protect electrical     terised by a cutting-edge approach. This ap-
An intelligent algorithm determines the         The supply of the critical load via the rectifier                                                                                      equipment by using UPS systems for bridg-        proach and the use of high strength steel
number of modules required for safe oper-       and inverter of the ENERTRONIC modular SE                                                                                              ing any power outages and network failures,      allow a structure to perform well-defined
ation and switches all other modules to hi-     also eliminates all voltage and frequency                                                                                              for example.                                     movements without weakening the cabinet
bernation mode. System efficiency is max-       fluctuations of the national grid and thus                          Scan the QR code for                                                                                                system. A construction method that has also
imised by making the latter available only      secures the operation of loads sensitive to                         further information              An individual configurable        But how are the UPS and power plants pro-        found its way into the automotive sector, for
when they are really needed, e.g. when          interference.                                                                                        UC-HE cabinet system by BENNING   tected against the impact of an earthquake?      example. 

22 | BENNING | POWER news | 10/2018                                                                                                                                                                                                        BENNING | POWER news | 10/2018 | 23
... certified by IABG

Specific simulation options

The cabinet system development process
has also changed. The method used in the
past was to first produce drawn construc-

                                                                                                                       Photo: © IABG
tions as test objects and then to expose
them to extensive tests. If the expected as-
sumptions were not confirmed, the engineers                                                                                            Seismic verification,
would repeat the process chain (Design >                                                                                               vibration test and
Construction > Tests) until the target was                                                                                             certification by IABG
achieved.

An integral part of the state-of-the-art con-
struction processes at BENNING, however,
is computer-aided development with specific
simulation options, which are carried out be-
fore the actual hardware tests. This makes                                      acceleration-frequency-diagram
the development process significantly shorter                     [m/s2]
                                                                               response spectrum – 5 % damping
and more efficient.
                                                                                                                                                   TRS_x
                                                                                                                                                   TRS_y
BENNING has also developed a simulation                                                                                                            TRS_z
tool which can determine the cabinet require-                                                                                                      RRS_xy
ments prior to the construction stage in order                                                                                                     RRS_z
to select a suitable cabinet.

Finite element method

Computer-aided simulations are used to
check the load limits using structural and dy-
namic calculations based on the finite ele-
ment method (FEM). This results in a stan-
dard-compliant analysis and calculation of
the deformations or stresses of a cabinet                                                                                                          [Hz]
frame during the construction. In addition,
physical properties of the cabinet system can                      TRS = transmissed response spectrum (x-axis, y-axis, z-axis)
be visualised, and potential weaknesses can                        RRS = required response spectrum (xy-axis, z-axis)                                           Example construction earthquake cabinet UC-HE                  UPS-System ENERTRONIC I in seismic design UC-HE
be precisely located for targeted optimisation                                                                                                                  H 2200 x W 800 x D 800 mm                                      H 2200 x W 800 x D 800 mm
measures.

Stringent requirements fulfilled

The construction of a test housing and the       struction exceeds all normative requirements      rectifier system, which supplies the pumps of               ferent is the system casing, i.e. the enclosure.   a welded structure and the other has a          ment increases without resonance. The
verification of the calculations in the com-     in terms of earthquake resistance, even in the    the internal cooling circuit, ensures maximum               Due to this technical and functional analogy,      bolted structure. During an earthquake, the     higher the attenuation factor of the device,
pany's own environmental laboratory do not       worst-case scenario.                              safety and therefore chooses an housing cer-                a technician can find his/her way around a         structural elements in the bolted housing       the lower its response curves. 
take place until the simulation process has                                                        tified to the highest earthquake categories for             servicing task faster. This provides the highest   move relative to each other, causing friction
been successfully completed. Here, so-           Maximum cost-efficiency                           this area. In this way, both power supply sys-              level of safety with maximum cost-efficiency.      and noise, such that the seismic energy         author/contact: Stefan Kleefeld
called vibrating tables are used, which mimic                                                      tems used are provided with the optimal pro-                                                                   dissipates much faster than in the welded       telephone: +49 2871 93 358
the vibrations and shock loads caused by an      Another decisive advantage arises from the        tection that complies with the cost-efficiency              Seismic switchgear terminology                     housing. The bolted cabinet will thus dampen    e-mail: s.kleefeld@benning.de
earthquake.                                      fact that all four cabinet system versions de-    and safety requirements. On the other hand,                                                                    the energy faster than the welded one, thus
In addition to its own test results, BENNING     veloped by BENNING are based on the same          this provides for easy and quick maintenance                The damping characteristic of a switching          reducing the time required to build up seis-
has had the current UC-HE cabinet design         design principle. Suppose, for example, that      because the base frame of the cabinet con-                  device limits the overall gain that it experi-     mic response. The damping properties of a
certified by a recognised testing laboratory,    in earthquake zone 2, a rectifier system in       struction as well as the arrangement of the                 ences during resonance. Suppose, for exam-         system are indicative of the system's ability                     Scan the QR code for
the IABG (Industrieanlagen- Betriebsgesell-      UC-ME design is used to secure the telecom-       power and functional elements are identical                 ple, that two cabinets are identical in design,    to dissipate earthquake energy. Without at-                       further information
schaft mbH), with the result that this con-      munications system. At the same time, the         in both systems. The only thing which is dif-               assembly, and weight, but one cabinet has          tenuation, the resonance gain of the equip-

24 | BENNING | POWER news | 10/2018                                                                                                                                                                                                                                  BENNING | POWER news | 10/2018 | 25
Reduction of headway

                                                                                                                                               Photo: © WSW Wuppertaler Stadtwerke GmbH.
                                                                                                                                                                                                                                                                                              WSW Mobil GmbH aims to replace all 27 old
                                                                                                                                                                                                                                                                                              vehicles with 31 new vehicles by spring 2019.
                                                                                                                                                                                                                                                                                              These should achieve a higher average
                                                                                                                                                                                                                                                                                              speed thereby reducing the rush hour head-
                                                                                                                                                                                                                                                                                              way from three to two minutes.

                                                                                                                                                                                                                                                                                              As in the case with the power increase, the
                                                                                                                                                                                                                                                                                              requirements for the mains voltage have
                                                                                                                                                                                                                                                                                              also changed: All new vehicles and the his-
                                                                                                                                                                                            Historical wheel set of the Kaiserwagen                                                           toric Kaiserwagen are no longer designed
                                                                                                                                                                                                                                                                                              for a mains voltage of 600 V, but, rather, for
                                                                                                                                                                                            Original design: Rotor and field coil                                                             750 V DC.
                                                                                                                                                                                            from 1900

                                         New Drive Motors
                                         for historical Kaiserwagen
                                         BENNING carried out a rotor-stator re-build on the historic
                                         Kaiserwagen of the Wuppertal suspension railway to ensure
                                         that it can continue to be used for round trips and festivities                                                                                                                                      Data capture in BEM test bay

                                         in the future.

                                         The Wuppertal suspension railway is con-         To date, the Kaiserwagen has been pre-                                                           Historically, the Kaiserwagen has been            configuration needed to be implemented. As      and implemented the appropriate solution
                                         sidered one of the longest engineering           served for posterity, surviving the two world                                                    powered by four 25 kW series motors using         part of the modernisation, this represents a    strategies using its technical know-how and
                                         landmarks in the world. On the route of a        wars as well as several generations of older                                                     600 V DC, whilst the new 'Generation 15' ve-      particularly complex and costly process,        extensive experience in the repair, construc-
                                         13.3-kilometre long railway system, it trans-    cars. In addition to the regular transportation                                                  hicle series will only use 750 V DC mains volt-   which can only be professionally fulfilled by   tion and reconstruction of electric motors.
                                         ports around 70,000 passengers a day             services, it is not only used for round trips,                                                   age for the three-phase asynchronous motors,      very few companies.                             The customer was WSW Mobil GmbH as the
                                         through the capital of Bergisches Land.          but also as a venue for birthdays, anniver-                                                      to allow a headway of only two minutes (see       How and where does one start if no technical    operator of the Wuppertal suspension rail-
                                         A special highlight is a ride in the nostalgic   saries or weddings, for example.                                                                 info box at top right).                           documents are available, only an outdated,      way.
                                         ambience of the historic Kaiserwagen.            To ensure that 'the good parlour of Wuppertal',                                                                                                    albeit functional, sample frame, which was
                                         Kaiser Wilhelm II and his wife Auguste Vik-      as the historic car is commonly called, is also                                                  Adaptation to the new operating system            used back in 1900 to support the suspen-        Rotor-stator configuration
                                         toria made the inaugural trip through the        available for rides and festivities in the future,                                                                                                 sion railway?
                                         Wupper Valley in 1900 - about two and a          it must be adapted to meet the increased                                                         To ensure that the engines of the Kaiserwagen                                                     As part of the rotor-stator configuration, fol-
                                         half years after the start of construction of    mains voltage requirement of the new gener-                                                      can be adapted to the voltage requirements of     A challenge facing the BENNING electrical       lowing successful assembly of the sample
                                         the suspension railway.                          ation of cars.                                                                                   the new operating system, a new rotor-stator      machines (BeM) department, who developed        rack on BENNING's own test station, 
 Historical running gear, disassembled
 for data capture

26 | BENNING | POWER news | 10/2018                                                                                                                                                                                                                                                             BENNING | POWER news | 10/2018 | 27
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