details at a glance - world class power solutions - benning€¦ · benning | power news | 8/2017 |...

www.benning.de

Details at a glance – progress starts with understanding

8/2017

UPS systems safeguard bioreactors 22– 23

Power station relies on modular systems 6– 9

10– 13Outstanding BELATRON charging unit

Photo: ©

Axpo Pow

er AG

Photo: ©

Biogen GmbH

Customer Magazine informative · up-to-date · pioneering

BENNING | POWER news | 8/2017 | 3

POWER news 8/2017 Editorial

Publication detailsBENNING Elektrotechnik und ElektronikGmbH & Co. KG’s client magazine

Publisher: BENNING Elektrotechnik undElektronik GmbH & Co. KG,Münsterstrasse 135-137, 46397 Bocholt

Design und Production: Advertising AgencyPaus Design & Medien GmbH & Co. KG,Brinkstegge 13, 46395 Bocholt

Liability and CopyrightAll texts are protected by copyright. The publication, adoption or use of texts,pictures or other information is subject to the written agreement from BENNINGGmbH. No liability is accepted for anyguidance, references, recommendations or evaluations. In spite of making every effort to carry out a correct presentationand checking of the subject matter,

errors or mistakes in interpretation re-main pos sible.

Picture credits© BENNING Elektrotechnik und Elektronik GmbH & Co. KG / © Apple Inc. / © Axpo Power AG / © Biogen GmbH / © Cisco / © Google Inc.© MEV Verlag GmbH / www.mev.de

© alephcomo1, artstudio_pro, christian42,chungking, dikson, Ezume Images, Gina Sanders, hansenn, industrieblick, intararit, kras99, kwanchaift, markhall70,Nataliya Hora, newb1, pico, pingingz,pixelkorn, Rainer, Sashkin, Scanrail, Sergey Nivens, starlineart, tum2282,yewkeo, Zffoto / Fotolia.com

Dear Readers,

It is over 150 years since the birth of one of the 20th century’s leadingfemale scientists: Franco-Polish physicist and chemist, Marie Curie.She is the only woman to have won two Nobel prizes: for physics in1903 and for chemistry eight years later, for her research into radioac-tivity and the co-discovery of elements polonium and radium. Her workis one of the main foundations for ongoing research in these fields andhas enabled the use of nuclear power for energy production.

Today, there are 438 nuclear reactors in 31 countries. To make these as safe and reliable aspossible, various checks and measurements are employed to reduce potential risks to anabsolute minimum. And BENNING is making a major contribution here, as you can read inthe article about fitting highly reliable modular power supply systems in Switzerland’s Beznaunuclear power station.

In this edition, you will also find out how BENNING makes bioreactors in the pharmaceuticalsindustry even more failure-proof, and how their efficient teamwork reduced the productionshutdown time at a petrochemical company by several months.

Happy reading, and I look forward to hearing your feedback.

Best wishes,

Yours, Stephan Ratermann

e-mail: [email protected]

telephone: +49 2871 93 0

Contents3– 5 Recording, saving and sharing readings

preciselyTRUE RMS digital multimetre with logging function and Bluetooth®

connection to BENNING app for smartphones and tablets.

6– 9 Extra safety for the Beznau Nuclear Power Station BENNING’s modular power supply systems help ensure the Beznau Nuclear Power Plant continues to supply around three million people with reliable electricity..

10– 13 Celectric receives an award for BELATRON High efficiency charging systemsBENNING’s BELATRON charging systems are among the select numberof products to have been awarded thecoveted KEMA-KEUR quality seal in the Netherlands.

14– 18 Modular power protection in Industrialapplications – understanding the “ilities”Availability and reliability in modular technology

19– 21 Repairing motors for companies in thepetrochemical industryBy working successfully as a team,BENNING reduced production down-time by several months.

22– 23 Safeguarding one of the world's mostadvanced pharmaceutical productionsystemsUS biotech group, Biogen, uses BENNING's modular UPS systems for the permanent safeguarding of its new state-of-the-art biopharma-ceutical production system.

24 Fairs, events and appointments 2017

2 | BENNING | POWER news | 8/2017

Recording, saving and sharing readings preciselyTRUE RMS digital multimetre with logging function and Bluetooth® connection

to BENNING app for smartphones and tablets (iOS / AndroidTM).

BENNING’s powerful MM 12 logging multimetre is ideal for service and maintenanceengineers who work with complex, problematic industrial applications in electricalsystems (CAT IV 600 V/CAT III 1000 V), power distribution systems and in automationand electrical engineering, handling demanding measuring tasks in developmentand laboratories, and also industry and electrical specialisms, using the smartphoneapp to forward measured data to the team so that they can examine and analysethe data.

BENNING MM 12 connected directly to a PC

to record up to 100,000 measured values

POWER news (Pn) spoke to Mr. Tobias Enckof BENNING’s testing and measurementequipment department about the multimetre’smain functions and benefits.

Pn: Mr. Enck, what makes BENNING’s newMM12 digital multimetre so interesting tousers?

Enck: As measuring tasks become increas-ingly complex, the demands on measuringsystems also rise. Precise readings, regard-less of the environment, are important for di-agnosing and solving problems. By recordingmeasured values and displaying them asgraphs on your PC monitor, smartphone ortablet, you can see anomalies, solve prob-lems and minimise downtimes more quickly.I’d also like to mention how easy they are touse. You can change settings easily via thecentral navigation key, which you can alsouse to quickly select menu functions andsub-functions. The BENNING MM 12 has in-dividual setting facilities for LCD lighting, au-tomatic shutdown and setting threshold val-ues when conducting continuity tests. Youcan also activate and deactivate the signaltones and saving readings automatically, andset the LCD readout display in two sensitivityranges with higher and lower digits.

Pn: There’s no doubt the BENNING MM 12is a first-class measuring device. Its specifi-cations and description reflect its many func-tions, and the certificate of calibration thatcomes with it is a testament to its top quality.But what makes this measuring device differ-ent from those of other manufacturers incomparable performance segments?

Enck: I'm glad you mention the specific per-formance features. There are comparablemeasuring devices, of course, but they’regenerally much more expensive. A good price-performance ratio – and thisapplies to all our testing and measurementsystems – is something you’ll find with allBENNING products. Meanwhile, people

BENNING | POWER news | 8/2017 | 54 | BENNING | POWER news | 8/2017

sured value and peak memory, relative mea-surement, displaying maximum, minimum andaverage values and level measurement.

Pn: Many thanks for sharing all of this, Mr. Enck

author/contact: Tobias Enck

telephone: +49 2871 93 111


Legal attribution:

Apple and the Apple logo are trademarks of Apple Inc., regis-

tered in the U.S. and other countries. App Store is a service

mark of Apple Inc., registered in the U.S. and other countries.

IOS is a trademark or registered trademark of Cisco in the U.S.

and other countries and is used under license.

Google Play and the Google Play logo are trademarks of Google Inc.

sured; but it shows the protective earth isconnected correctly. One major extra feature that the BENNINGMM 12 has is a low-pass filter (HFR) for tak-ing precise voltage and frequency readingson drives and other electrical equipmentwhere the basic frequency is overlaid by har-monics. This has proved itself to be particu-larly important for industrial use.

Pn: Both the measurement categories, whichdefine the application areas for measuring de-vices, and measuring procedures in complexsystems are major selection criteria. How doesthe BENNING MM 12 perform here?

Enck: It meets the requirements of the highest-rated measurement category, CAT lV 600 V /CAT III 1000 V. As voltage is always stated rel-ative to earth, the phase-to-phase voltage canbe 1.732 (√3) times higher, so the measuredvoltage can be > 1000 V. As you would expectfrom measuring devices in this performance

suffice, you can use a clamp adapter like theBENNING CC 3 to extend the measuringrange up to 300 A AC/DC. The input sock-ets have a 1000 V overload protection fea-ture in all functions; and if you connect themA and A range sockets the wrong wayaround, the BENNING MM 12 emits anaudio alarm and the display reads ‘ProbE’ asa warning.

Pn: Are there any other special featureswhich could be of interest to users?

Enck: Switching to a lower input impedance(LoZ < 3 kΩ) when measuring voltages canbe used to suppress reactance voltages; andyou can also trip an FI/RCD residual currentdevice in this mode if phase and protectiveearthing conductor are in contact. The result-ing leak current is around 75 mA. This testdoes not meet the guidelines for testing fixedelectrical systems, as the leak current is notprecisely defined and no trip time is mea-

class, we use the TRUE RMS (root meansquare) measuring method to measure ACvoltage and current, enabling you to measureasymmetric voltages and currents, which varyfrom the basic sinus shape precisely. Asym-metric voltages occur mostly in the case ofpower controllers like dimmers, speed con-trols, cycle-timed switch controls, pulsed-loading devices and electronic speed controlsin modelling, etc. With such special measuringtasks, conventional average measuring de-vices sometimes produce extreme deviationsin measurement.

Pn: Finally, could you please give us a few de-tails about the BENNING MM 12's memoryand logging capabilities?

Enck: You can record up to 100,000 mea-sured values via the software when connectedto a PC. Our internal data logger (LOG) cansave 40,000 and the memory function (MEM)1,000 measured values. We also have a mea-

resistance readings when making the finalchecks on their product. The unit saves mea-sured values as soon as they stabilise, sothat this is possible. Other applications are inproblematic electrical installations, controlsand systems. Viewing them via smartphoneor tablet means you can stay a safe distancefrom an object if it is in a risk area. Measuringdevices which meet development and labo-ratory requirements must work reliably andtake readings precisely. The BENNING MM 12can monitor and record systems and pro-cesses for many hours at a time.

Pn: Can you tell us something about themeasurement functions, Mr. Enck?

Enck: The measurement functions cover everything you’d expect from a measuringdevice, including current, voltage, resis-tance, frequency, capacity and temperature,as well as continuity and diode testing. And,if measuring currents up to 10A does not

Connect up to five BENNING MM 12s by Bluetooth® to our free app BENNING MM-CM-Link

Implemented images: app display and delivery contents

are aware that our measuring devices alwayscome with software (with no licence fees),protective bags and extensive accessories atno extra charge, unlike those of most othermanufacturers.

Pn: Let’s remain a little longer on the subjectof costs. How expensive is recalibration?

Enck: The BENNING MM 12 comes with a cer-tificate of calibration. Recalibrating it at the fac-tory costs € 81.20, whilst a DAkkS recalibrationis € 103.75. We plan to keep operating costsstable in the long term, so users will be able tobudget for these.

Pn: What are the BENNING MM-CM-Linkapp’s strengths, and how does the applica-tion work in practice?

Enck: Installing the app and setting up thelink is child’s play. Once you’ve activated theBluetooth® functions, just select the measur-ing device in the app. Now you can recorddata in real time, send it wirelessly and dis-play it continuously as a graph, or specify atarget file and start recording a series of read-ings, precisely setting the cycle time betweentwo readings in advance. You can link up tofive BENNING MM 12s at any time and dividethe screen up as you want, so you can seeall the graphics together. And once you’vecompleted and saved recordings, you canemail them for analysis.

Pn: Can you say which applications highlightBENNING MM 12’s benefits?

Enck: Not long ago now, one of our clientssaid they wanted to take and record multiple

"As measuring tasks become increas-ingly complex, the demands on mea-suring systems also rise. Precise read-ings, regardless of the environment,are important for diagnosing and solv-ing problems."

Tobias Enck,

Sales

Scan the QR code for

further information

Extra safety for the Beznau Nuclear Power Station BENNING’s modular power supply systems help ensure

the Beznau Nuclear Power Plant continues to supply around

three million people with reliable electricity.


Located in Switzerland, in the LowerAare valley near the parish of Döttingen,Beznau Nuclear Power Station (KKB)consists of two largely identical blocksequipped with pressurized water reac-tors with a capacity of 385 MW each.

KKB is owned and operated by AxpoPower AG (formerly Nordostschweiz-erische Kraftwerke AG). It has generatedaround 250 m MWh of electrical energysince it was commissioned in 1969 and1971.

The installed UPS systems, rectifiers andinverters form a network of connectedpower supply systems, with correspondingbatteries that power key nuclear powerplant loads, both when the grid is workingand if it fails.

These include:

• The power station control systems • Signalling, control and protection

electronics • Remote measurement and control

systems • Telecommunications equipment • Motors • Solenoid valves • Pumps

When the grid is live, the UPS systemssupply loads at the existing mains voltageand supply batteries with charging andmaintenance current. This ensures batter-ies are always available at full capacity inthe event of a power failure, ensuring loadscontinue to be supplied with clean powerduring the switchover period.

Retrofitting the power supply

For retrofitting the secure power supply, AxpoPower AG also relies on BENNING’s powerdevices and systems. Thanks to their modu-lar technology, which has been used suc-cessfully in various applications for manyyears, the availability of the secured powersupply can be easily maximized.

Close to the customer

The partnership between Axpo Power AGand BENNING started in 2012. After theSwiss energy group made the initial contact,various meetings and conferences followed- both at KKB and at BENNING Switzer-land’s offices, located just 50 kilometresaway, and at the BENNING Bocholt com-pany’s headquarters.


Modular plug-in rectifier

TEBECHOP HDI,

Output: 110 V / 100 A or

Output: 24 V / 350 A

ADC rectifier

(Module type),

Output: 14 V / 20 A

UPS module

ENERTRONIC modular,

Power: 20 kVA

Inverter module

INVERTRONIC modular,

Output: 400 V / 15 kVA

Photo: © Axpo Power AG


or n + 2 redundancy system with maximumavailability and reduced MTTR (Mean Time toRepair). The system performance can be in-creased or decreased at any time by addingor removing plug-in modules, without inter-rupting the supply – a principle that meetsthe highest demands on availability and easeof maintenance. As well as increasing redun-dancy, the multi-strand design of the powersupply units was maintained, according tothe motto: Twice as safe is stronger.

Training, Maintenance & Service

Thanks to the intensive and successful cooperation with Axpo Power AG, severalfollow-up projects were made possible. BENNING provided reliable power supplies(255 kVA UPS) for the PRW project and sup-plied several 1E-rated ventilation motors withthe support of its Electrical Machines division.There were also several training sessions atBENNING’s training centre in Bocholt atwhich KKB employees were shown how thenew modular power supply systems work.

There are also plans for BENNING Switzer-land to provide local support in the mainte-nance and service sector for KKB in the fu-ture. It deals with defined response andaccess times for the maintenance required tokeep a high availability. This is another majorcontribution to ensuring safety at KKB in thefuture.

author/contact: Paul-Gerd Demming

telephone: +49 2871 93 410


Being close to their provider meant the cus-tomer could easily discuss its demandingsafety requirements collaboratively when de-veloping customised, bespoke solutions.

The 1E-rated power supplies were first sup-plied in January 2015, not long after all the re-quired tests such as earthquake, EMC, typeand climatic conditions were successfullypassed. For each of the two power stationblocks, BENNING provided 15 modularpower supply units.

These included UPS systems from the ENERTRONIC modular range (60 - 80 kVA),INVERTRONIC modular inverters (30 - 60 kVA)and rectifier systems (24 V / 140 - 1120 A,110 V / 220 - 300 A), all installed in earth-quake-proof system cabinets. Additionalproduct deliveries are planned depending onthe next scheduled overhaul times.

Hot-plug-in systems

Before adopting the BENNING products,KKB used a multi-strand system with se-cured power supplies made of monoblocsystems. Compared with the new modularpower supply systems, monobloc systemsare relatively heavy, bulky and not easily scal-able. If one of the monobloc systems fails,the whole supply line can fail - a scenario thatis prevented by the modular technology nowused.

BENNING modular systems consist of paral-lel power supply modules, using hot plug-intechnology. Switching in parallel gives an n + 1



further information

The power station control room is where it all comes together.

BENNING's modular power supply systems ensure the various

systems are always available.

This inverter system provides emergency lighting.

The supply is redundant and is taken from the

120 V rail. Each inverter cabinet contains three

INVERTRONIC modular modules.

The installed power supplies

are designed to be earthquake-

proof to class 1 E. In the adja-

cent picture, this can be seen,

for example, in the cross struts

of the walls and ceilings.

This system contains up to

20 rectifier modules from the

TEBECHOP 3000 HDI series

(26 V / 1400 A).

Each nuclear power station block

has four of the UPS systems shown

on the left with the appropriate

battery cabinets. They supply the

plant information system of the

control room and are based on the

ENERTRONIC modular series.

The power supply shown on the left is part of the so-called VITAL system.

Each power station block has four of these systems, supplying the

control room instrumentation, the emergency oil pump and the 118 V rail.

The system cabinets contain, from left to right:

• The input field with network priority switching and AC distribution

• The rectifier field with up to 15 TEBECHOP 3000 HDI modules

and up to four rectifier modules of the ADC series

• The inverter field with up to four INVERTRONIC modular modules

• And the output field with the AC and DC distribution

The 120 V DC network (e.g.: the emergency oil pump and control voltage

for switchgear) is supplied via the rectifier. The inverters supply the fire

detection system, TXS and the measurement and reporting systems.

Photo: ©

Axpo Pow

er AG

Photo: ©

Axpo Pow

er AG

BELATRON charging systems have the

class 1 energy efficiency label in the

Netherlands, This allows the investor to

apply for state subsidies.

Tabor: If we assume that a conventional 48 V to 500 Ah drive battery is charged 240days a year with a BELATRON High Effi-ciency Charger, then the electrical energysaved compared with a conventional chargeris about 1900 kWh. When generating theelectrical energy required to charge a battery,approximately one-half kilogram of CO2 is re-leased per kilowatt hour. Every kilowatt hoursaved reduces CO2 emissions and is there-fore a contribution to climate protection. The energy saved reduces CO2 emissions by980 kg and is comparable to the CO2 emis-sions from a diesel vehicle, which coversmore than 7000 kilometres.

Pn: This is indeed an impressive amount. Letus briefly remain on the topic of environmen-tal protection. When we think of batteries, wethink mainly about their chemistry, lead andacid, but less about how environmentallyfriendly they are. How do you deal with that?

device from BENNING, which meets EMClimits for all areas.

An important and special feature of the BELATRON charging system is that it uses acontrolled charging curve which prevents anyshort charging or overloading caused by fluc-tuating mains voltages. Compared with con-ventional chargers, this reduces power con-sumption during the charging process by25% - resulting in a significant reduction inenergy costs and significantly lower CO2emissions. Energy-efficient products such as the BELA-TRON are subsidised in the Netherlands bythe Energy Investerings Aftrek (in English: En-ergy investment allowance), to add yet an-other advantage.

Pn: How does the CO2 reduction associatedwith the BELATRON translate into kilowatthours?

Tabor: That may be true, but I can assureyou that the products we offer are highly environmentally-friendly. We are convincedelectrical energy is a green alternative to nat-ural resources. So we offer these with a veryclear objective: We aim to be the best sup-plier of innovative and future-oriented energystorage solutions such as lithium-ion systemsor fuel cells. To achieve this and offer maximum qualityand emission-reducing products, we worktogether companies like BENNING, whichcomplies with the specified ISO standards.Pn: How do you assess the use of lithium-ion systems in ecological and economicterms?

Tabor: The use of lithium-ion systems isproving to be rational and profitable. In manycases, we already rely on these systemswhen planning new installations. They reducethe energy costs required by another 30% or

so - the same also applies to CO2 emissions.And being able to charge batteries midwaythrough their lives compared with lead-acidbatteries offers considerably more flexibility inpractice.

Pn: Let's go back once again to the chargersyou offer. How far does their quality affect theaging of lead-acid batteries?

Tabor:With highly-efficient chargers such asthe BELATRON already mentioned, specialemphasis is placed on optimizing the charg-ing factor in the characteristics provided forwet batteries. In addition, the acid mixing re-quired in these batteries in the rechargephase is carried out by a very effective pulsecharge. As a result, the gassing phase canbe shortened so that the water consumptionand the temperature rise in the battery is re-duced. Reducing the re-charging time re-duces maintenance costs, leads to a


The KEMA test centre (Keuring van Elektrotechnische Materialen at Arnhem or‘electrical inspection establishment at Arnhem’ in English) is well-known in theNetherlands. It has advised and assisted government organizations, manufacturers,suppliers and consumers in the electrical industry since as far back as 1927. The KEMA KEUR label, issued by KEMA, lets the consumer know that the producthas been tested and is safe - just like the standard seal of approval issued by theVDE Testing and Certification Institute. As one of the first providers of storage solutions in the Netherlands, Celetric received a KEMA-KEUR certification for theBELATRON high-efficiency charging system developed by BENNING.

POWER News (Pn)discussed the highenergy efficiency interms of CO2 emis-sions and the otherquality characteristicsof the Celectric prod-ucts with Mr. BasTabor, Celectric's sales

manager. View an extract from that interviewbelow:

Pn:Mr. Tabor, the BENNING company is oneof your powerful long-standing partners. Towhat extent does the BELATRON tractioncharging system, for which you have receivedthe KEMA-KEUR certification, differ from con-ventional chargers?

Tabor: We offer our products and services in awide range of market segments. For this rea-son, we need a BELATRON series char ging

The complete product line was subjected to a comprehensive test by KEMA at theBENNING plant in Bocholt, which resulted inits being rated energy efficiency class I.This makes the BELATRON one of the fewcharging systems in the Netherlands whichscores the best of the six energy classes ofthe BMWT efficiency labels. BMWT is a spe-cialist Dutch association for manufacturersand importers of construction machinery,storage facilities, road construction and trafficengineering.One of several prerequisites for the certifica-tion was the detection of a sinusoidal currentconsumption with a power factor of almost1, which generates no reactive power con-sumption and means peak current valuescan be considerably reduced. Likewise, theBELATRON EMC values for industrial areasalso meet the significantly lower limits for res-idential and commercial areas and has a verylow total input distortion (THDi).

Celectric receives an award for BELATRON High efficiency charging systems

BENNING’s BELATRON charging systems are among the

select number of products to have been awarded the coveted

KEMA-KEUR quality seal in the Netherlands.


About CELECTRIC

Celectric is an internationally-oriented energy storage group based in the Netherlands. Specializing inmodern and innovative storage solutions, especially in the field of intralogistics, the company supplies itscustomers with a wide range of batteries, chargers, corresponding accessories and services: productsand services that enable motors, machines and other applications to deliver the highest standards ofperformance. To achieve this, a team of approximately 75 people is on hand, keen to develop high-qualityproducts with maximum reliability, while at the same time, meeting and maximum economic and eco-logical requirements as far as possible.

With Celectric, quality is also a very important factor in its choice of business and cooperation partners.A claim which was particularly honoured with the assignment of the KEMA-KEUR award. The companyis also certified to DIN EN ISO 9001 and 14001 as well as VCA ** (Veiligkeit Check Aannehmers, con-tractor safety check).


further information

the state of the battery fleet. The LEDs alsohelp engineers on site to assess the batteryelectrolyte status immediately and whether itneeds to be topped up. This saves us a lotof time in on-site service.

Pn: What other benefits and opportunitiesdoes using a BATCOM battery controller pro-vide?

Tabor: Large forklift fleet operators receive avariety of operational data on their forklifts,but not on their battery fleet. But the batteryis an important aspect of the truck. Using theBATCOM battery controller you now seewhat the battery status is as well as a greatdeal of other relevant battery data. The BATCOM measures, records and dis-plays relevant application data via a stackerand traction battery. Data can then be re-trieved e.g. by means of notebook or PC.Lithium batteries could be another interestingaspect in the coming years - also in this casewe are in close contact with the develop-ments in the BENNING enterprise.

Pn: Mr Tabor, thank you for this very informa-tive interview.

author/contact: Manfred Wies

telephone: +49 2871 93 233



...excellent energy efficiency

3

1

2

The Celectric battery charging room charges

pre-assembled batteries and services and re-

pairs used ones.

For this, on the one hand, BELATRON high-effi-

ciency chargers are used as stand-alone/wall-

mounted housings (see 1) and on the other

hand the space-saving BELATRON UC indus-

trial design (see 2). This system can accommo-

date up to 12 BELATRON chargers.

At the same time, the BFS 2000 battery forma-

tion and testing systems (see 3), which are also

manufactured by BENNING, control and moni-

tor the formation and test procedures required

in the manufacture of batteries. Designed for

user-friendly series testing, these charge-dis-

charge converters save time and energy com-

pared with other processes.

reduced electrical energy consumption andboosts the working life of the drive battery. The charging electronics also optimize thecharging factor when recharging partially-dis-charged batteries and ensure full charging,generating little heat and reducing water con-sumption.

Pn: Your company is not only responsible forthe sale or leasing of high-quality and future-oriented products from the field of energysupply, but also as an innovative serviceprovider. What exactly is your service philos-ophy?

Tabor: More than 70% of our employeeswork in customer-oriented roles. In otherwords, they deal directly with our customers,advise them in choosing the right energy sys-tem, or operation, installation and mainte-nance directly on site. Transparency is abso-lutely vital here. Our customers alwaysreceive a complete overview of costs andservices.They also benefit from a high level of flexibil-ity. We always carry out repairs and mainte-nance work quickly and reliably and guaran-tee a flexible contract design, which isperfectly tailored to individual customer re-quirements. Our contract services are basedon the special requirements profiles of ourcustomers at the time the contract is signed- and if customer requirements change dur-ing the contract period, we can adjust thecontract retrospectively.

Pn: You said when we started that you aredeveloping your services to be progressivelymore customer-oriented. Can you give an ex-ample?

Tabor: With pleasure. Because of ourmany years of experience with the servic-ing and maintenance of traction batteriesand charging rectification, we have devel-oped the Celectric Secure program - acomplete service package that offers anall-inclusive fault rectification with up to1500 charging cycles. During this time, thecustomer is provided with a completeoverview of the costs and services re-quired for the maintenance of his energysupply, e.g. for the electric truck. Thismakes Celectric Secure a major contribu-tion to maximizing deployment, combinedwith efficient cost management for all elec-

trical vehicles used in the company. Thisway, the customer saves money and canalways see what is happening.

Pn: You also need to factor your own costsinto servicing effectively, of course. How canyou reconcile this with evaluating each bat-tery within the fleet?

Tabor: We use BENNING traction monitor-ing. For smaller installations, we can simplyaccess the protocols stored in the chargersvia a laptop and a USB port and evaluatethem for each battery. This is an option thatcan even be implemented online at largercharging stations – so batteries can be main-tained preventively, i.e. before they fail or shutdown.

Pn: Assuming you plan and install a com-plete charging station, to what extent doesspace efficiency play a role?

Tabor: Many of our customers would natu-rally rather not provide space for this - butthis is only possible with decentralized charg-ing as with the LIONIC systems, so it cannotyet be used everywhere in practice. BENNING also offers an optimal solution withthe BELATRON UC. This is modularly expand-able and can accommodate twelve chargingmodules in a footprint of only 80 x 80 cm withup to 24 V and 80 A or 48 V and 60 A - orthree charger modules with up to 80 V and240 A.

Pn: You work with a fixed price. Isn’t that arisk to some extent?

Tabor: No, I don’t think so. Celectric Securetariffs are based on a purchase or perfor-mance-dependent lease of the batteries orrectifiers. So, we rely exclusively on qualityproducts - and in conjunction with the mon-itoring solutions already mentioned, errorscan be detected early on, even before aproblem, e.g. the damage to a battery, oc-curs.

Pn: Is this not particularly important in theleasing business?

Tabor: You’re absolutely right, we guaranteelong working lives. That’s why we use BAT-COM Plus battery controllers to monitor bat-teries. They detect and analyse the load and


MTBF = 1/λ

68

1/0,1467 = = 681

Availability

MTBF/(MTBF + MTTR)

F = 1/λ F = 1/

2013 actuarial “actual life tables” stated thata 30 year old male (i.e. system) had a0.1467% probability of dying (i.e. failing)within 1 year. Applying this “failure rate” (λ) of0.1467% to the above MTBF equation givesus:-

MTBF = 1/ λ = 1/0.1467 = 681 years

The fact that no 30 year old male currentlyalive can expect to live (i.e. not fail) for 681years shows how reliability statistics can bemisleading when used in isolation.

Availability

If availability is the probability that a systemis operating when required we must alsoconsider how long it takes to return the

ence between the two that creates most ofthe confusion surrounding their usage.Although counter-intuitive, reliability is not themost important factor in power protectionsystem design. Power protection systemsmust be available every second of every dayand therefore maximising system availabilityis the overriding objective for any power pro-tection system design and what technologyis used in what configuration will dramaticallyaffect system availability.

Reliability

Every mechanical or electrical system ever in-vented will, if operated long enough, proba-bly fail at some time. This probability is knownas the system’s failure rate and in reliabilityengineering is shown as λ (Lambda).

The second of five articles within our 'ility' se-ries focuses on availability and reliability. Wewill review the technical and mathematic back-grounds and explain how both terms relate tothe increasingly popular modular technology.

Availability v Reliability

Before we can discuss the similarities and dif-ferences between availability and reliability wewill define them as follows:-• Reliability is the probability that a systemwill not fail.

• Availability is the probability that a systemis operating when required.

These two definitions appear to be very sim-ilar, and there is a relationship between thetwo but they are different and it is the differ-

If λ is the probability that a system will fail, theprobability that a system will not fail is 1/ λand because every system will probably failat some time, λ can never be 0% and a sys-tem’s reliability can never be 100%.

As percentage probabilities are more difficult(for most of us) to comprehend than time, itis more common to consider a system’s reli-ability as the average number of hours ittakes to fail. This measure of reliability is re-ferred to as Mean Time Between Failure(MTBF), therefore:-

MTBF = 1/ λ.

But using purely MTBF figures to estimatehow long a system is likely to operate withoutfailure can be misleading. For example, the

Modular power protection and conver-sion technology, particularly in the formof UPSs, has long been used in commer-cial applications, but take-up in indus-trial applications has, to date, been rel-atively slow. This relatively slow uptake is due, in part,to a limited understanding of the “ilities”(“Availability”, “Reliability”, “Scalability”,“Flexibility” and “Maintainability”) com-monly associated with modular technol-ogy and how the various “ilities” comple-ment each other.

Modular power protection in Industrialapplications – understanding the “ilities” Availability and reliability in modular technology

Modular plug-in UPS system with

mutually independent standalone

UPS modules

Replace modules easily

using hot-plug technology

ENERTRONIC modular SE

40 kW module


the MTTR of this topology is the highest ofthe 3 topologies and, for the purposes of thisexample, we will assume it is 8 hours. There-fore:-

System Availability= MTBF/(MTBF + MTTR)= 800,000/(800,000 + 8)= 800,000/(800,008)= 99.999% (often referred to as “five

nines” availability)

Modular-block architecture

As with the traditional mono-block topology,this parallel redundant system configurationcomprises two separate UPS cabinets feed-ing the critical load (i.e. N+1 = 1+1) and thesystem component count is double that of asingle UPS solution and we will assume thesystem MTBF is the same 800,000 hours. However, because the system components(PCBs, IGBTs etc.) in a modular-block sys-tem are grouped into sub-assemblies that

Traditional mono-block

In this topology, the parallel redundant sys-tem comprises two separate UPS cabinetsfeeding the critical load (i.e. N+1 = 1+1) andthe system component count is thereforedouble that of a single UPS solution. It fol-lows that the greater the number of systemcomponents, the greater the probability of acomponent failure, however, because thesystem is parallel redundant, a componentfailure in one of the UPS cabinets will not ex-pose the critical load to raw mains and will,therefore, not result in a system failure. Wetherefore have a highly reliable “system” and,for the purposes of this example, we will as-sume its MTBF is 800,000 hours.

However, because the system components(PCBs, IGBTs etc.) in this topology are sepa-rately housed in the UPS cabinets and mustbe separately removed from and/or added tothe UPS system all components must be in-dividually replaced on site. This means that

system to full operation after it has failed i.e.how long it takes to fully repair the system.This “repair time” is typically referred to as theMean Time To Repair (MTTR) and gives usthe following availability equation:-

Availability = MTBF/(MTBF + MTTR)

From this equation we can see that if a sys-tem’s MTTR is 0 hours the system’s availabil-ity will be 100% regardless of the system’sMTBF. It is clear, therefore, that in order tomaximise a system’s availability it is neces-sary to minimise a system’s MTTR. This is not to say that it is OK completely dis-regard a system’s MTBF (reliability) as clearlya system with a high MTBF will be more avail-able than a system with a low MTBF if thesystems’ MTTRs are the same. What it doessay, however, is that low MTTR increases theavailability of reliable systems.Some Availability v Reliability examples:- You will (hopefully!) recall the 3 off modularUPS topologies discussed in the first article

in the “ilities” series, namely Modularity. In theModularity article the three system topologiesdiscussed were “traditional mono-block”,“modular block” and “rack-mounted modu-lar”. We will now consider the respectiveMTBFs and MTTRs of these topologies tosee what, if any, impact the various topolo-gies have on system reliability and, more im-portantly, system availability.

In order to help maximise the level of criticalload protection let us assume the following:-

1. all of the UPS “modules” are of a highquality, industrial design;

2. the systems are properly maintained in linewith manufacturer recommendations;

3. in all 3 examples that the critical load is120kVA;

4. all 3 systems are parallel redundant (N+1)UPS.

modular power protection

BENNING’s UPS system is scalable and can

increase in size in line with load requirements

UPS system design as DPA (Decentralised

Parallel Architecture) – 100% redundancy

means no single point of failure

Decentralised-Parallel-Architecture

Mains 1 Mains 2

The US Uptime Institute has introduced a tier-classifica-tion system as the global standard for rating computercentre availability: this is part of TIA-942 (Telecommuni-cations Infrastructure Standard for Data Centres) and canbe applied both to individual systems, like air-conditioningor UPS, and to computer centres as a whole. Tier I pro-vides 99.67% availability with 28.8 hours of downtime ayear, Tier II 99.75% availability with 22 hours' downtime,Tier III 99.982% availability with 1.6 hours' downtime, andTier IV 99.995% availability with just 0.8 hours' downtimea year. While Tier I and II are sufficient for conventional PC work-stations and office servers, Tier III availability is almost in-dispensable for process-critical applications in industry,using n+1 redundancy as a prerequisite. And any com-pany that provides services around the clock 365 days ayear, such as computer centres in the financial sector,would rely on the top Tier IV. Here, all components andpathways are 2n+1 redundant, avoiding single points offailure completely.BF/(MTBF + MTT

= 99.9995 %

= 1/λ

reliability

0.000/(800.000 + 8)

availability

99.99996 %

681

MTBF/(MTBF + MTTR

MTBF = 1/λ =

six nines availability



availability


further information

Highly reliable modules are important com-ponent parts of a highly available power pro-tection system but how the modules are con-figured and their topology are moreimportant. Parallel redundant module config-uration will increase the reliability and avail-ability of power to the critical load so should be used wherever possible. Rack-mountedmodular topology maximises system avail-ability.

The next article in the “ilities” series will dis-cuss “scalability” and how modular topologycan minimise the capex and opex of a powerprotection system.

contact: Alexander Proemel

telephone: +49 2871 93 238


than that of the mono-block and modular-block systems at, say, 500,000 hours. However, because each UPS module in thistopology is a fully functioning and completeUPS that can be “hot swapped” (see Modu-larity article) in less than 10 minutes theMTTR is a very impressive 0.17 hours. There-fore:-

System Availability = MTBF/(MTBF + MTTR)= 500,000/(500,000 + 0.17)= 500,000/(500,000.17)= 99.99996% (often referred to

as “six nines” availability)

This shows that a very significant improve-ment is system availability is achieved whenthe MTTR is minimised, regardless of a re-duction in system MTBF.

Conclusion

The most important design consideration forany power protection system is its availability.

can be replaced as sub-assemblies ratherthan as individual components in a mono-block system the MTTR is lower. Let us as-sume it is 4 hours.

System Availability= MTBF/(MTBF + MTTR)= 800,000/(800,000 + 4)= 800,000/(800,004)= 99.9995%

This demonstrates that a significant improve-ment is system availability is achieved whenthe MTTR is reduced.

Rack-mounted Modular

In this topology, for reasons that will be ex-plained in the “Scalability”, “Flexibility” and“Maintainability” articles in this series, wehave chosen to use four parallel redundantmodules to feed the critical load (i.e. N+1 =3+1). As the system component count isnow quadruple that of a single UPS solutionwe must assume the system MTBF is lower

To rate computer centre availability, theGerman Federal Office for Information Se-curity (abbreviated as BSI) has divided itinto six availability classes or ACs. From AC 4 upwards, maximum availabilityis 99.999%, as calculated using the tradi-tional monobloc system equation. Thesehave only minor outages, which are barelynoticeable due to the parallel-redundantsystems, as found in many process-criticalapplications in industry. They are especiallyrecommended for financial groups whosecomputer centres must function perfectly24/7, 365 days a year.

modular power protection

ENERTRONIC modular SE

40 kW module (IT series)

IT series UPS supply with

ENERTRONIC modular SE modules99.99996 % 1/λ

Stator post-pyrolysis

D.-HV motor as supplied

Every year, German companies invest 2–4% of their original capital costs in maintainingtheir production plant. This investment pays for itself, as any downtime can have seriousconsequences for an industrial plant. Even short stoppages cost a company time andmoney, can damage their reputation, and also cause customers to feel dissatisfied andlose confidence in them. One worst-case scenario occurred at a petrochemical company in the Ruhr region inearly 2016, when a faulty winding in an ageing motor shut a high-pressure reciprocatingcompressor down and resulted in the whole production plant completely closing down.

x height) was made by AEG for use in petro-chemicals in 1972. Its combination of rela-tively low speed and very high torque, whichis atypical of motors today, was uncommonand its like had not been made for manyyears.

Additionally, the motor’s explosion-proof de-sign meant that its windings were subject tospecial limits, which were officially certified atthe manufacturing plant. Designed for maxi-mum safety and efficiency, there are very fewcompanies capable of successfully produc-ing a motor to this specification.

Aiming to keep financial losses as low as pos-sible, the company decided against rebuild-ing, which could have taken around a yeardue to the unique design of the defectivemotor. Instead, they hoped to find a companyto repair it quickly; but looking for the rightpartner proved to be anything but simple, asthe motor’s age and specific characteristicsrequired special expert knowledge.

Low speed, high torque

This highly robust 12-tonne motor, measur-ing 3500 x 3000 x 2200 mm (length x width

Repairing motors for companies in the petrochemical industryBy working successfully as a team, BENNING reduced

production downtime by several months.

Preventive servicing

BENNING’s years of experience in me-chanical diagnostics and measuring sys-tems mean that BENNING can offer itsclients a tailor-made maintenance service,customised perfectly to their requirements,including status-driven systems monitoring,working proactively to minimise disruptionsin advance or even eliminate them alto-gether. Firstly, BENNING checks statusconditions in depth, then offers its clients arange of solutions to ensure safe opera-tions. This means that BENNING doesn'tjust supply measured data but actually pro-vides recommended action informationtoo.



motor reached BENNING’s works in Bocholt,the protective switchgear cover, pipes andsteel supports were removed carefully toavoid damaging them.

Over 1000 working hours

The repairs turned out to involve consider-ably more working hours than if repairing astandard motor. BENNING worked non-stopover six weekends and spent over 1000hours on the job, working continuously in two– sometimes three – shifts making coils,winding and assembly. Day in, day out, usingtoday's materials and without compromisingon quality, BENNING had to recreate the oldsolutions and elements that the motor used.Flat copper wire was made specially, for ex-ample, as it’s no longer readily available inthis form. The repair work was made even more diffi-cult as there was no motor documentation.

AEG, the original manufacturer, ceased pro-duction in 1996 but a company based in thesame chemical park reported that it hadbeen working successfully with BENNING forover ten years.

Time factor decisive

As soon as BENNING was contacted, it wasclear that time was key. After extensive ne-gotiations in which special bonuses werepromised for getting the motor up and run-ning quickly, BENNING agreed to deliver inthree months: a time span that was very tightfor a project like this, but which BENNINGachieved by deploying several of its electricalmachinery employees.

Transferring the motor undamaged from thepetrochemical company to BENNING was achallenge as the carrier truck required a spe-cial device to secure the load. Once the

Making one-piece HV coils

for stator windings

Analysing stator plate package thermographically

before fitting new winding

Stator before

being repaired

Stator windings finished and

ready to be impregnated

Stator as

repaired

This is normally produced when making amotor and is used to record relevant detailsof how it works and what it can do, so thatany future work can be done more quicklyand easily. Instead, BENNING had to pro-duce new, detailed documentation through

reverse engineering, as it took the motorapart and recorded a range of electrical andmechanical measurements and recalculatedall the winding data. The documentation alsoincluded precisely reviewing the air-gap mon-itoring winding: this is a device that monitors

the air gap between stator and rotor. If thegap is irregular, which could damage thebearings if it changes its alignment, for ex-ample, then an alarm would be raised. Again, BENNING had to remake this windingfrom scratch and check the data involved byway of calculation to ensure it was feasiblefirst.

Successful teamwork

BENNING`s client sent a quality acceptanceengineer to the work of BENNING at regularpoints to see how the repairs were progress-ing and record them on-site, so he was al-ways able to verify that BENNING was onschedule at all times. The repairs and installingthe motor went smoothly, so not only didBENNING keep to the dates agreed on com-missioning, it also managed to bring forwardthe full implementation to the start of July –originally planned for mid-July 2016.

Proof of the client’s satisfaction was apparentas this project led to a follow-up order. UsingBENNING’s preventive service, BENNINGnow ensures downtimes of any kind can bedetected and avoided in good time: a majorcontributor to ensuring that the operating pro-cesses run continuously in future – signifi-cantly minimising downtimes and risks.

author/contact: Matthias Loerwink

telephone: +49 2871 93 318



further information


systems in February – April 2017. The con-tract included ten 200 kW UPS systems ofvarying basic configurations (80, 120 and160 kW) and two 400 kW UPS with a basicconfiguration of 160 kW each including bat-teries, battery chassis and all accessories.For even more reliability in preventing down-time, the UPS systems power critical-oper-ating loads via an A/B rail in each case, andpower loads for which only one powersource is allowed via a static transfer switch,which can switch between the two UPS sys-tems seamlessly, providing an additional levelof redundancy.

99.9999% availability

Each ENERTRONIC modular SE UPS mod-ule in itself provides a highly efficient onlineUPS, combining maximum system availabilityand power quality with minimum repair times(MTTR) and total operating costs (total costof ownership), thus meeting the demandingrequirements of process-critical applicationsin the industry in the most effective way. True

200,000 m² site. An administration buildingwill make up the major part of the productionplant, and a supply building, a sprinkler con-trol centre and emergency power systemhave also been proposed.

Maximum quality and reliability

As with many other sectors, in the pharma-ceutical industry, production downtime is ex-pensive, so maximum quality and reliabilityare key criteria when it comes to selectingthe right power supply system to safeguardIT and production systems. With this in mind,BENNING quickly proved itself to be the idealbusiness partner: firstly, because BENNINGhad already provided a high level of satisfac-tion to Biogen Denmark’s customised pro-duction solutions in the past and, secondly,because BENNING was also able to guaran-tee an effective locally-available service via itsSwiss subsidiary.

BENNING Switzerland started technical plan-ning in March 2016, and delivered the UPS

hot-swap capability means modules can bereplaced in minutes, providing 99.9999%availability.

When procuring/installing a UPS, it isn’t al-ways foreseeable just how much power willbe needed. A well designed modular UPSsystem is scalable to perfectly match the sizeof the critical load and therefore optimisecapital costs (capex) over the UPS's workinglife.

The ENERTRONIC modular SE in use at Biogencan always be fitted with precisely the num-ber of modules needed to achieve the sys-tem performance and redundancy levels re-quired at any time. Modules can be simplyadded or removed as the critical load in-creases or decreases. A principle that offersclients maximum flexibility whilst minimisingboth capex and running costs.

author/contact: Mathias Schmaenk

telephone: +49 2871 93 316


Biogen, founded in Geneva in 1978, spe-cialises in neurological diseases and isa market leader in applications andtreatments for MS, using recombinantDNA to make human proteins and there-fore pharmaceuticals using microorgan-isms. In autumn 2015, faced with the ris-ing global demand for high-grade drugsto help combat MS and also other neu-rological diseases like Alzheimer's andParkinson's, Biogen decided to build itscutting-edge NGM (Next GenerationManufacturing) biopharmaceutical pro-duction plant in the Canton of Solothurn.As the world's most modern pharmaceu-tical production plant, it is due to open in2019 and will triple existing production:to be more precise, a 148,000 litre pro-duction capacity that can be expandedfurther still should the need arise.

Since February 2016, building experts, engi-neers and technicians have been working flatout to create a production plant with its as-sociated stores, labs and offices on the

Safeguarding one of the world's most advanced pharmaceutical production systemsUS biotech group, Biogen, uses BENNING's modular UPS systems for

the permanent safeguarding of its new state-of-the-art biopharmaceutical

production system.


Photo: ©

Biogen GmbH

High production costs

Biopharmaceuticals cannot be made over -night. Completing the processes requiredusually takes weeks, mainly because mam-mal cells are slow growing. Not until theseare available on the scale required can theproduct be made in the fermenters in anyquantity. Even interrupting this processchain for an instant can have far-reachingconsequences, as this means productiontakes longer or even needs to be restartedcompletely. Therefore, a power supplywhich is not 100% reliable is extremelyrisky.

Production plant with

bioreactors


further information

Photo: ©

Biogen GmbH

www.benning.de

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BENNING Elektrotechnik und Elektronik GmbH & Co. KG

Factory IMünsterstr. 135-137

Factory II Robert-Bosch-Str. 20

46397 BOCHOLTGERMANY

Tel.: +49 2871 93 0 Fax: +49 2871 93 297

E-Mail: [email protected]

All details provided without liability

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