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When disaster strikes

It was 6 PM on a sunny Thursday evening. Our service manager had just left the office when his cell phone rang. It was one our long-time customers on the line. Disaster had struck. They had a fierce fire, and they were struggling to keep their factory going. They needed our help immediately.

This customer has a large Hitec Diesel UPS installation that has provided uninterrupted power to their plant since 1998. Their production process is critical, and any interruption in power causes huge losses.

Their factory fire brigade is well prepared for calamities. Though the fire raged through one of the diesel UPS rooms, they were able to extinguish it quickly. The fire was short but violent and had damaged one unit; cables were burned and wires were shortened. The bad news was that the fire had not only damaged the daily fuel tank for that unit—the diesel supply to the other units was out of order, too. The operators had to switch off all units as a precaution. The factory was still operating, but on raw mains power without protection.

The first thing we did when we arrived on site was to secure the operation of the remaining units to protect the factory. Then, we investigated the damage to the burnt unit.

The fire started in the unit room, which is next to the daily fuel tank room. That room was used to store fuel tanks for four of the eight units. Therefore, before the customer could restart the remaining units, they had to repair and modify the fuel system to allow them to run off the unaffected diesel tanks.

The diesel UPS system was running in diesel operation when the fire started. A unit does not immediately stop turning when it receives a ‘stop’ command. Instead, the machines slowly run down, which takes about half an hour. Meanwhile, the machine’s internal fans were sucking in hot air, smoke and the foam and water used by the fire brigade to battle the blaze. Given this situation, we knew we would have to dismantle and overhaul these machines in our workshop.

The unit’s control panel appeared to be damaged, though the foam and water treatment made the internal parts look clean. Still, plastic parts of many components appeared brittle and fell apart when touched. The control panel was no longer reliable, if functional at all, and we knew we would have to rebuild it.

The diesel engine had taken the hardest punch. It did not seem feasible to repair the engine, so our client decided it must be replaced.

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Hitec Electric delivered the new diesel engine to the site, along with the overhauled electrical machines and control panels. We also supplied new daily fuel tanks. Hitec Electric’s engineers assembled the unit on site, testing it thoroughly before putting it back into operation.

Lessons learned

No one wants to experience a disaster like this, but when one happens, they offer invaluable lessons:

  1. Always be prepared.
    This customer has a fire detection system that worked well, and its fire brigade knew what to do. They prevented the spread of the fire to the rest of the system or, worse, to the factory.
  2. Redundancy is valuable.
    In a system with multiple units, it makes sense to have at least one redundant unit. That allows the system to keep running if one unit is out of operation for any reason. Rebuilding a unit, like in this case, takes time. The redundancy in their system ensured the continuity of the production.
  3. Design is important.
    When designing the room layout of a diesel UPS installation, it is important to take fire safety into consideration. The placement of components in separate rooms helps, but fire separation measures and the selection of fire-resistant materials for cabling and piping are also important.


Hitec Electric is a rotary UPS systems specialist. Building on years of experience, we can design and install your rotary UPS system to be robust and reliable. Should disaster ever strike, we’ll be around to help you maintain your business and recover as quickly as possible.

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UPS Fundamentals – About Flywheels

When you think of flywheels, what is the first thing that comes to your mind? You may think of magnificent steam engines with huge flywheels; the ones you find in museums nowadays. Beautiful machines that powered the industrial age. But do you know that flywheels still play a vital role in powering today’s modern data centers? And that they keep the factories going that produce chips for the Internet of Things (IoT)? Flywheels today may be less visible, but they are at the heart of our rotary UPS systems.

This post touches on flywheels for storing energy. It describes how flywheels store energy and explains why we prefer flywheels over batteries in our rotary UPS systems.

What Is a Flywheel?

A flywheel is “A heavy revolving wheel in a machine which is used to increase the machine’s momentum and thereby provide (…) a reserve of available power,” according to the Oxford Dictionary.

This definition contains some interesting elements. It mentions that the purpose of a flywheel is to store energy and make it available for later use. This power reserve is available in the form of momentum. This means that it takes power to start rotating the flywheel. The heavier it is, the more force is required to increase the speed. The opposite is also true. To stop the object from rotating, an opposite force must be applied. Otherwise, it keeps spinning forever, assuming there is no friction. This is how a flywheel stores kinetic energy.

The definition mentions that flywheels are heavy. That, of course, is relative. The flywheel of a diesel engine is heavy if you need to lift it by hand, but compared to the total weight of the engine, it is not that much. The mass of a flywheel is one of the factors that determines the amount of energy that it can hold. So, one way to store a lot of energy is to make the flywheel heavy. But that is not the only factor that counts.

The formula that describes the amount of kinetic energy in a flywheel is:

Flywheel parameters

E=\frac{1}{2}k m r^2 \omega^2

E is the kinetic energy in Joule.
k is a constant that depends on the shape of the flywheel. For example, k = 0.606 for a solid disk.
m is the mass in kilogram.
r is the radius in meter.
\omega is the angular velocity in radians per second (simply said, the rotation speed).

According to this formula, the radius and the speed have more influence on the energy than the mass. So, if you want to store a lot of energy in a flywheel, it is more effective to make it big and to spin it fast.

As always, constraints limit the possibilities. The tensile strength of the flywheel material determines the speed that it can run. And the bearings must be able to support the weight and the speed.

UPS Application

Uninterruptible power supplies need an energy reserve to be able to bridge interruptions in the mains supply. The amount of energy depends on the power rating of the UPS and the desired bridging time.

Rotary UPS systems use flywheels to convert electrical energy into kinetic energy and vice versa. This principle is well known, and there are good reasons for that:

  • Flywheels are simple devices. In essence, a flywheel is a round piece of steel that is sturdy and reliable.
  • There is no limit to the number of charges and discharges.
  • It is an efficient way to store and retrieve energy.
  • The stored energy is instantly available when it is needed.
  • A flywheel has a long lifetime. The recycling and reuse of the materials is well possible after the usable lifetime.

The bridging time that in practice can be achieved is measured in seconds. Many applications, though, need longer bridging times. In those cases, the UPS uses a second source of energy to get the desired autonomy time. This can be, for example, a diesel engine. In such a case, the main purpose of the flywheel is to bridge the startup time of the diesel engine.

Manufacturers of rotary UPS systems have produced various designs to meet the requirements of applications. In a later post, we will explore some popular designs.

Flywheels Versus Batteries

Most UPS systems today use batteries for energy storage. Most of these systems still use lead-acid batteries. The price of Li-Ion batteries has dropped over recent years with the rise of large-scale production facilities. Yet, lead-acid batteries are still cheaper. Li-Ion has advantages, such as higher power density. But in most UPS applications, this does not outweigh the higher cost.

UPS systems based on batteries are solid-state, all-electrical systems. The bridging time is measured in minutes and, sometimes, hours. For most UPS systems, those rated below 100 kVA, this is the technology of choice.

Batteries have some drawbacks compared to flywheels:

  • Batteries, in particular lead-acid batteries, are sensitive to temperature. The available capacity drops significantly at low temperatures. At high temperatures, battery performance is irreversibly degraded.
  • Batteries can perform a limited number of charge-discharge cycles. The capability of the battery degrades with every cycle. After 500 full cycles, the battery usually has reached the end of its useful lifetime.
  • The environmental impact of batteries is high. The lead compounds used in batteries are extremely toxic. The recycling of battery lead is possible in recycling plants. Unfortunately, many batteries still end up in landfills after their useful lifetime.

These may all be good reasons to favour flywheels. But the main reason UPS systems utilize flywheels is that they are very suited to high-power applications. Think of UPS installations with ratings of 1 MW and above used in, for example, large data centers or factories.

In these applications, another difference between flywheels and batteries is a decisive factor. Lead-acid batteries can deliver around 180 Watt per kilogram (the specific power). For flywheels, this figure is much higher. This is also true for the power density, the power per volume. If you store the same amount of energy in a flywheel and in a battery of equal weight or volume, you will be able to retrieve it faster from the flywheel. In other words, if you need a lot of energy for a short time, a flywheel is smaller and weighs less than a battery. This gives flywheels the edge in today’s high-power UPS applications.

This post is the first in the UPS Fundamentals series, which explores key concepts and technologies of uninterruptible power supplies (UPS). In the next post, I will investigate the technologies UPS manufacturers use to get the most out of the flywheel.

Editor’s note:

A Spanish translation of this article appeared on https://upsdinamico.com.
Courtesy to Angel Garcia Torreiro from IEM Power Systems.

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HITEC PowerKEM Explained

HITEC Power Protection recently introduced the PowerKEM. In this post, I will explain what PowerKEM is and how it fits into the HITEC product portfolio.

What is PowerKEM?

PowerKEM is a rotary UPS system. It stabilizes the mains voltage and continues to power the load when the mains fails, using a flywheel to store enough energy to bridge mains interruptions of around 10 seconds. PowerKEM is available in modules from 400 kVA up to 2000 kVA.
Now let’s have a look at what PowerKEM adds to the HITEC product range.

About HITEC PowerPRO

HITEC is well known for its PowerPRO diesel rotary UPS systems, which  feature an integrated diesel engine. The main purpose of the flywheel on the PowerPRO is to provide bridging time in which to start this diesel engine. This has two benefits:

  • The flywheel can be small.
  • The system can cope with any mains interruptions, from small dips to outages of many hours.

The PowerPRO thus offers high power density. The integrated system design makes it reliable and it is completely tested before it leaves the factory.

How Does PowerKEM Fit into This Portfolio?

PowerKEM fits well in the HITEC product range. It shares valuable characteristics with the PowerPRO portfolio:

  • It uses rotary technology for energy storage. This makes it rugged, reliable and suitable for demanding industrial applications.
  • It uses the same line-interactive design, making it highly efficient without compromising the security of the critical load.

PowerKEM has a larger flywheel that stores more energy to give it a longer autonomy time. It has no integrated diesel engine however. For long-term outage protection, it relies on an external source. This may be a genset, but more options are available – think of CHP or a separate transmission feed. This feature makes PowerKEM primarily a flexible component rather than a stand-alone solution.

This makes sense when you realize that long-term outages are rare in many power grids. Most disturbances such as spikes, surges and dips rarely exceed one second. PowerKEM’s flywheel can cover such interruptions with ease.

Smart Protection of Industrial Plants

In many applications, not all processes are critical. Consider, for example, a factory that produces PET bottles. The machine that produces the bottles is critical. An unscheduled power interruption will not only stop the production process but also mess up the machine. Re-starting the process is time consuming, so it surely pays to protect the power supply to this machine.

This is not the case for other parts of the production process. Packaging, factory lighting and raw-material supply, for example, are not as critical. The factory can manage interruptions to these processes without incurring major costs.

PowerKEM is a cost-effective solution for this kind of application. It protects the critical machinery against the most frequent mains disturbances, which ensures continuous production. The less critical parts of the plant can work on the utility supply and regular diesel generators may protect the plant against long-term outages if needed. A transfer to a second transmission line feed can work as well.

Renewable Energy Application

A second application area relates to renewable energy. Solar and wind are rapidly growing sources of energy. That is good news for our planet, but it does cause some headaches for utilities. Energy generated from local renewable sources may destabilize the grid. Wind- and sun-generated power are by nature variable, as they depend on the weather.

PowerKEM maintains a stable supply voltage for critical loads. The kinetic energy stored in the PowerKEM dampens load surges, helping to stabilize the grid. Also, PowerKEM transfers the load between the available power sources without interruption.

The Verdict

It is tempting to look at PowerKEM as a low-cost alternative to PowerPRO. That would be a mistake. PowerKEM is a flexible building block in an integrated power infrastructure. It has its own sweet spot of applications, different from those of PowerPRO. As such, it indeed ably complements the HITEC rotary UPS product range.

Do you see interesting applications for PowerKEM? Share your thoughts with us in a comment!

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Africa Improved Foods first anniversary

Africa Improved Foods (AIF) makes nutritious fortified foods in Africa for Africa. The plant in Rwanda officially opened one year ago on 31st May 2017 and celebrated its first anniversary. The impact of AIF during the first year of operation in addressing malnutrition and encouraging local production has been widely recognized.

At Hitec Electric we are proud that we can contribute to the success of AIF. We supplied and installed the rotary UPS systems that provide the plant with continuous and clean electrical power. We trained factory staff to operate the units. And we take care of maintenance to keep the system in mint condition.

Africa Improved Foods in Kigali is one of the largest nutrition factories on the continent. Its annual production capacity is 45,000 tons and it employs over 300 staff. AIF intends to buy at least 50% of its maize and soy locally to contribute to rural development. This has a large impact on the local farmers. AIF sourced over 4,500 metric tons of maize from Rwanda alone in 2017. 24,000 Rwandan farmers produced this maize and sold it to AIF.

AIF, in partnership with the Government of Rwanda, supports nutrition programs for the most impoverished communities. Also, it produces relief foods for the World Food Programme.

Royal DSM is part of the AIF Rwanda joint-venture. DSM published a press release about the one-year celebration that is worth reading. It describes the impact of AIF in Rwanda and beyond.

CNBC Africa also featured the AIF first anniversary. CNBC assesses the impact of AIF one year after the plant opened:

Hitec Electric congratulates AIF with this first successful year. We wish many more years will follow.

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Hitec Power Protection distributor meeting

One of the best events I joined in years. That is how I experienced the Hitec Power Protection distributor meeting last week. And it was not because of the excellent hotel in a beautiful and quiet rural area in The Netherlands. And also not because of the smell and taste of the fine roasted meat, accompanied by a good glass of wine. No, I will explain later on what I liked best, but first, let me give you some highlights.

Hitec Power Protection had a lot of news and information to share.
Garrett Forde, the CEO of Hitec Power Protection, explained the strategy that he and his team has been implementing. This strategy is crisp and clear.

Hitec Power Protection is committed to being the leading provider of rotary UPS systems. Hitec develops innovative and reliable solutions based upon proven technology. The recently introduced PowerPRO 2700 series is a proof of that. The feedback on the PowerPRO from participants with field experience is promising.

Not less important is that a major element of the current strategy is customer focus. This may sound obvious, if not obligatory. But for a technology-driven company acting accordingly is not straight-forward. Making it part of the core strategy does make a difference. The action plans that are being executed all contribute to enhancing customer experience. Organizational changes help to respond faster and more accurate to customer requests.

I am impressed how Hitec Power Protection is working on the quality of its products and services. Implementing standards and best practices from the German car industry demonstrates Hitec’s commitment to reliability and quality. Rotary UPS systems nowadays are complex products comprising many complicated components. Maintaining consistent quality is a difficult task. But essential to ensure the utmost reliability that our customers expect.

Hitec Power Protection introduced the latest member of the product family, the PowerKEM. This is a rotary UPS system with around 10 seconds backup time. It can work with regular gensets if longer back-up is needed. In a future blog post, I will explain more about the PowerKEM.

Hitec Power Protection is active globally ever since the early ages of the rotary UPS back in the 1950’s. Distributors, partners, and employees from all over the world joined the event. It was a welcome opportunity to meet colleagues and to exchange experiences and ideas. For partners new to the business it was an excellent opportunity to learn a lot.

Many of the participants have been working with Hitec Power Protection for decades. Some as a business partner, some as Hitec employee and some even as both. Their deep domain knowledge, derived from many years of hands-on experience, is impressive. Their enthusiasm and dedication contagious.

Hitec organized the event not only to deliver information. A large part of the event was to listen to its partners and try to understand their needs. Partners shared experiences, made suggestions, explained their needs and commented on the plans.

This is what I liked best about this distributor meeting. Hitec Power Protection recognizes the value of its partner network. And the fact that Hitec organized the event this way shows that they are serious about it. I am looking forward to the next meeting!

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Star of Bosphorus Data Center opening

NGN celebrated the opening of its Star of Bosphorus Data Center in Istanbul with a special launch on the 25th of April. A large group of guests joined NGN in the Four Seasons Istanbul at the Bosphorus for the celebration. It included speeches from prominent speakers and video’s presenting the facilities capabilities. The highlight of the evening was a marvelous music show by Sertap Erener.

The Star of Bosphorus Data Center is a unique facility for corporate customers. It offers a wide range of carrier independent services including cloud, disaster recovery, data warehousing and hosting. The unique design guarantees highest reliability and best continuity. The data center construction is resilient to earthquakes. This makes the facility Turkey’s most advanced data center. It holds Tier III certification from Uptime Institute.

Hitec Electric has supplied and commissioned 8 MW of Hitec Diesel Rotary UPS systems. These ensure a continuous supply of electrical power to the data center. All infrastructure is in place to add another 8 MW of uninterruptible power when needed.

We congratulate NGN and the Star of Bosphorus Data Center team with the opening of the data center. It is a major achievement. We are honored that we could contribute our part to this unique facility.