Overview

Alleviating power problems at NXP Semi-Conductors Stockport by

the introduction of a diesel rotary UPS System

Contents

• Background – The power related issues experienced at NXP Stockport

• The Solution - Installation of a diesel rotary UPS system

• The UK power security landscape – The National Grid

• How It Works - How a DRUPS operates

• Conclusions – Next steps

• Q and A

Background – The power related issues experienced at NXP

Stockport

2006/7

• The site is served by two incoming 11kV supplies from Electricity North West.

• Frequent power disturbances in the form of voltage and frequency excursions resulting in drop out of

process equipment, scrappage and delays in production.

• UPS system identified as the solution to ensure site maintains business continuity and is protected from

poor quality supply.

• Critical loads are not centralised but distributed around the site off various substations. Decision was taken

that the entire site would be protected by UPS.

• Project launched to evaluate the cost to the business of poor quality power compared with costs for a UPS

system. Concluded there was a business case.

Background

2008

• Evaluation of UPS technologies concluded a

rotary based system is the optimum solution.

• EURO-DIESEL selected to build a UPS power

house comprising 3 x 2000 kVA diesel rotary UPS.

With provision for a future 4th machine.

Background

2016

• UPS system has been in service since 2009 and has fulfilled its brief, eradicating historical power issues

on site and helping to make NXP Stockport one of the most successful plants for NXP globally.

• Noticeable improvement in equipment uptime. Power supply is constant and smooth, particularly

beneficial for Switch Mode Power Supplies.

• Latest project recently concluded, installing a fourth machine due to site load increase over time.

Today

Sweating the asset

The power available from the UPS system on site is contracted in to National Grid power reserve schemes.

NXP participate in revenue generating schemes that call upon the output from the embedded site

generation capacity, at times of peak electrical demand on the grid.

The Solution - Installation of a diesel rotary UPS system

EURO-DIESEL

• Established 1989

• HQ in Liege Belgium

• Manufacturing facilities in Belgium & Germany

• 75 million EUR Turnover

• Offices worldwide

EURO DIESEL UK & IRELAND

Cirencester

Sales, service, warranty and application

engineering.

Portfolio

• GENSETS: 500 - 3000 kVA

• DRUPS: 300 - 3000 kVA

Full Turnkey Solutions

Power House

Power House

The power security landscape - The National Grid

The National Grid – The job of providing electricity

Available power from generators

• Load is changing constantly

• Available power is changing constantly

• Impractical to store electricity

Consumer demand

National Grid

4th April (0730am to 0830am)

21st century challenges in keeping Grid stable

Renewable power sources are increasingly contributing

- Unpredictable, offering little or no system inertia

Less spinning reserve in the grid

- Driven by efficiency improvements

- Fossil fuel power stations taken off line

• Failure of hardware

• Accidental power interruptions

• Effects of down stream switching

Local DNO Distribution Issues

The potential consequences

1. Spikes

2. Frequency Deviations

3. Sags

4. Outages

5. Harmonics

6. Transients

Wednesday 28th May 2008

• Both Sizewell B and Longannet power stations fall

off line within minutes of each other

• Hundreds of thousands of homes and businesses

across London, Cheshire, Merseyside and East

Anglia lost power

• National Grid issue Demand Control Imminent

(DCI) warning

What if this scenario occurred today, how would we cope?

The future UK Power Landscape

National Grid are excellent at what they do, providing a relatively robust and

reliable power supply 365 days of the year.

However circumstances beyond their control; lack of government direction on

Nuclear power, closing down of fossil fuel power stations to meet emissions

commitments and the ever increasing amount of renewable energy adds up to an

uncertain future……be prepared!

How It Works - How a DRUPS operates

Power Conditioning from a UPS

DIRTY INTERRUPTIBLE POWER CLEAN UNINTERRUPTIBLE POWER

Most common approach diesel generator set back up

Site Load

• Typically 10 to 20 Seconds interruption to site loads.

• Only addressing one issue – Outages

Diesel Generator Set

Mains Supply

Introduce a UPS System

Site Load

• Without break in supply to the site load

• Incoming power source is “conditioned”

Diesel Generator Set

Mains Supply

UPS

Battery UPS systems

• Lead Acid Batteries require lots of space, not favoured from an environmental perspective, high operational cost due to plant replacement cycle and high cost of consumable energy in maintaining acceptable battery room temperatures.

• 500 kWe requires 7 Tons of batteries

A Rotary UPS system

Site Load

“NO-BREAK” Diesel Rotary UPS

Mains Supply

• Without break in supply to the site load, Incoming power source is conditioned

• No requirement for diesel generator set

• The UPS has the benefit of improving site power factor – reducing energy bills

• No Batteries!

Rotary NO-BREAK KS® System

Simple Layout

Building a NO-BREAK KS® System

NO-BREAK KS®

Used in dual mode

Assisted engine starting

System Configurations

Typical Scope

Multiple Machines

Ring Configuration

Outdoor Enclosure Options

Summary

• First evaluate the business case.

• Consider not only the direct benefit in business continuity but also the indirect

benefits such as power factor correction, improved equipment life as a result of a

cleaner power source, and revenue from National Grid schemes.

• Arrange for EURO-DIESEL to visit your facility and provide a free initial assessment .

Questions ?