The Peak Power 200 flywheel enabled a diesel generator powering an industrial chiller be downsized, resulting in fuel, cost and emissions savings.
Clients:
Carrier and WBPS
Industries:
Applications:
By downsizing the required diesel generator, the Peak Power 200 saved the operator £13,400 as well as reducing their CO₂ emissions by 34.4 tonnes over a 20-week rental.
Large industrial chillers have myriad uses across multiple industries. These systems are often deployed in remote or temporary locations where mains power is not available, requiring the use of temporary diesel power. In this case study, Carrier partnered with power provider WBPS and energy storage and management specialists Dumarey Green Power to demonstrate significant cuts to power rental costs and CO₂ emissions using the Peak Power 200 flywheel system.
The Model 522 CAR is a large industrial chiller from Carrier Rental Systems. It has a nominal capacity of 579kW, and is typically powered by a 320kVA diesel generator where mains power is not available. Given the typical applications, it’s normal for the generator to be run 24 hours per day. The model 522 has 8 hermetic scroll compressors controlled by a microprocessor. The startup of these compressors results in a brief spike in current, and the generator needs to be sized to cope with these spikes.
The Peak Power 200 flywheel system stores energy from the diesel generator during periods of low load, and can rapidly supply both real and reactive power when needed. This allows operators to reduce the size of the diesel generator required. The customer then makes three savings: firstly, saving on the rental cost of a smaller generator. Secondly, the lower fuel costs associated with a smaller generator and finally they save CO₂ emissions due to lower fuel usage. The combination of these factors makes the Peak Power 200 environmentally friendly and economically attractive.
For this application, a 330kVA diesel generator (SDMO R330C5) and a Peak Power 200 flywheel system were provided by WB Power Services. The test setup involved heating a large tank of water to 60°C using an industrial boiler. When the tank reached the set temperature, the chiller was turned on with a set point of 7°C. The test was ended when the water reached 15°C. Data was recorded from both the flywheel and the generator for later analysis.
The results of the application were very promising. Analysis of the data showed a maximum continuous current of 260A. The flywheel successfully reacted to each motor start with a rapid injection of power to support the generator and minimise frequency and voltage drops. Although compressor starts were never simultaneous, the flywheel would be able to manage 5 of the compressors starting at the same time.
The result is that on this application, the generator can be downsized from a 320kVA to a 200kVA. Savings for this are considerable, and are multiplied by the long running hours. We estimate that this downsizing would save around 650 litres of fuel per week. The customer would also see savings on generator rental, AdBlue usage and fuel deliveries. These more than offset the rental cost of the flywheel. On a typical 20-week rental, a user should see a net financial benefit, including flywheel rental costs, of approximately £13,400 as well as reducing their CO₂ emissions by 34.4 tonnes.
Dumarey Green Power would like to thank the technical and commercial teams from Carrier Rental Systems UK and WP Power Services. Both provided equipment, logistics, and expertise to make this application a success.
Flywheel Energy Storage System, capable of 186A of peak power
Smaller generators use less fuel, cutting costs and emissions
The smaller power system saved on space, critical in offshore operations
£ saved in a 20-week rental
tonnes of CO₂ emissions prevented
amps of continual current
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