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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 2 - AdD HyStor (Demonstration of dynamic grid stabilisation with an Adaptive-flywheel/battery Hybrid energy Storage system in Ireland and UK)

Teaser

Summary

The overall objective of AdD HyStor is to develop, integrate and demonstrate innovative adaptive flywheel battery hybrid energy storage systems which utilise a European manufactured and specified adaptive flywheel. Leveraging existing grid connected pilot scale battery systems in the UK and Ireland, the flywheel technology will be integrated to provide a novel hybrid solution, proving the unique energy storage system in an operational setting and laying the foundation for successful commercial exploitation by enabling maturity of the technology from TRL 6 through TRL 7 (system prototype demonstration in an operational environment) leading to achievement of TRL 8 (system complete and qualified) prior to commercialisation (TRL 9).

The containerised multi-source inverter was delivered on site in Month 8 of the project (October 2017) and then connected to the grid and the existing battery array. Partial field commissioning (battery-to-grid operation) was achieved in Month 09 of the project (November 2017). The flywheel is expected on site in mid 2018, after which the full system will be commissioned and tested to determine the suitability of the solution for a range of commercial applications to enable the transition to a decarbonised economy.

During the second year of the project one flywheel arrived to Rhode testside, the flywheel was susccesfully bolted to the concrete slab and connected to the grid and the automation systems.
After delivery and installation of the first flywheel the second phase of field commissioning of the multi-source converter took place. A number of functional tests and safety tests were performed and the communication with flywheel controller and central site controller was established. Finally grid connection could be established to start extensive testing of the flywheel system and hybrid operation of flywheel and battery system.
The plant has been tested and has gone live providing frequency regulation for the Irish grid, generating valuable data and very promising results. Testing of the flywheel showed a faster reaction than expected and an accurate behavior of the system following power commands from the energy management system.

Work performed

Adaptive Balancing Power designed and manufactured two adaptive flywheels.
Freqcon designed and manufactured a multi-source inverter
Schwungrad Energie designed and constructed a grid connected testing facility for live testing and performance validation of the two technologies (flywheels and inverter).
Freqcon designed and manufactured the 1.0 MW Multi-Source Converter. The design phase took 4 months with the involvement of electrical engineering, mechanical engineering and software engineering. Based on the CAD-drawings from mechanical engineering the manufacturing process started in Month 3 of the project (May 2017) with manufacturing of the customized container. Based on the electrical diagrams from electrical engineering the manufacturing of the actual multi-source converter started in Month 4 of the project (June 2017). The final system integration (installation of cabinets, cooling system and transformer inside the container) was done in Month 7 of the project (September 2017). Delivery of containerized system on site in October 2017, first commissioning phase in November 2017. The multi-source converter is connected to the grid on the AC-side and to the existing battery array on the DC-side. The basic functions of the converter (charging / discharging) have been successfully tested, further testing of more sophisticated functionalities will be done once the flywheels are connected to the system.
In Month 17 of the project (July 2018) the first flywheel was delivered and installed. In Month 18 (August 2018) testing and commissioning (Site Acceptance Test) of the Multi Source Converter (MSC) was performed to enable flywheel operation and further testing of the flywheel system. After energizing the converter (400 V grid connection and auxiliary supply) all the safety systems were tested. The E-Stop function was tested to make sure the main circuit breaker trips in case of activation. The smoke detectors were tested using test spray to make sure the safety chain is activated in case of smoke or fire. The temperature sensors inside the cabinets were tested as well.
After establishing and testing Modbus communication between the MSC-controller and the flywheel master controller as well as communication between the MSC-controller and the Valmet central site controller the inputs and outputs between the converter PLC and the periphery were tested, including emergency stop signal from flywheel master controller.
This was followed by extensive testing of the flywheel system and hybrid operation of the flywheel-battery system.
During the test period the parameterization of the multi-source converter was optimized and a number of smaller technical issues were rectified. One issue was the pressure loss of the water cooling system, which was caused by a safety pressure valve with too low pressure relief settings. This resulted in a pressure loss every time the cooling liquid warmed up and expanded. The problem was solved by exchanging the safety pressure valve to one with the correct pressure relief settings.
The UOS has been preparing for the arrival of the flywheels at their Willenhall site. This has included an extension to the land and private substation design to enable the hybridization of the existing battery facilities. Extensive modelling has been

Final results

The 1.0 MW multi-source converter contains a number of technical solutions beyond the state of the art. The concept of connecting several energy sources to the same DC-link via separate DC-DC-converters is a novel concept and increases the efficiency of hybrid energy projects significantly. At the same time it will reduce costs because only one DC-AC-converter and only one control system is needed. Another feature to increase efficiency are the newly developed liquid-cooled inductors which are deployed for the first time in this project. They will reduce overall thermal losses and also reduce electrical consumption of auxiliaries due to a more efficient cooling system. Another improvement from the original design is the positioning of the heat exchanger which is now placed in a separate room inside the container.
The test results of the operation of the multi source converter in this project so far have confirmed the feasibility of the novel multi source converter concept. It is already clear that this technical hybrid concept can be adapted to other project configurations (e.g. photovoltaic plus battery storage) to help increase renewable penetration and grid stability in Europe.
Adaptive Balancing Power has successfully designed and manufactured two Flywheels, one was shipped to the test-site and commissioned. The project impressively showed the possibilities of the Adaptive Flywheel technology and provides a valuable demonstrator for the technology. Especially in combination with the online database visualization tool, potential customers get a real-time experience of the technology, even without traveling to the test-site in Ireland. Adaptive Balancing Power has significantly increased its in house capability including resources and was able to close a venture capital financing round based on the results achieved in this project so far.