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EPRI Proprietary Licensed Material Safety As with any energy storage technology, hazardous conditions may exist around operating flywheels. Considerable effort has gone into making flywheels safe for use under a variety of conditions. The most prominent safety issue in flywheel design is catastrophic failure of the flywheel rotor. In large, massive rotors, such as those made of steel, failure typically results from the propagation of cracks through the rotor, causing large pieces of the flywheel to break off during rotation. Unless the wheel is properly contained, this type of failure can cause serious damage to surrounding equipment, and injury or death to people in the vicinity. Large steel containment systems are employed to prevent high-speed fragments from causing damage in the event of failure. Composite flywheels have other failure mechanisms, usually through gradual delaminating of the concentric layers of the rotor, or through vertical delaminating, or crack propagation parallel to the axis of rotation. In most cases, these failure mechanisms cause noticeable deviations from normal operational behavior long before catastrophic failure, and control mechanisms are often used to catch impending failure conditions. Nonetheless, the possibility of hazardous failure modes cannot be completely ruled out, and containment systems are also applied to composite flywheel systems, in part to enhance the perceived safety factor for such devices. Some systems are installed underground to further improve containment. As with any electrical equipment, care must be taken to avoid accidental electrical discharge. Standard electrical codes and procedures can be applied to flywheel construction to prevent these failure modes from occurring. Environmental In contrast to many other energy storage systems, flywheel systems have few adverse environmental effects, both in normal operation and in failure conditions. Neither lowspeed nor high-speed flywheel systems use hazardous materials, and the machines produce no emissions. The most important environmental constraint for flywheel systems is noise when in operation. Many large flywheel systems, especially low-speed systems, are quite loud, often reaching noise levels in excess of 70dB at 6 feet. On the other hand, high-speed systems with vacuum containment are considerably quieter, and those that are installed underground can be unnoticeable. Status There is an ever-growing selection of new flywheel products on the emerging on the coattails of advances in technology. Consequently there are also a number of applications that now propose using flywheels as the energy storage medium. These include inrush control, voltage regulation and stabilization in substations for light rail, trolley, microturbine and wind generation. Still the majority of products currently being marketed by national and international-based companies are targeted for power quality (PQ) applications. And the number one application in power quality is short-term bridging through power disturbances or from one power source to an alternate source. Flywheels Page 14
EPRI Proprietary Licensed Material Flywheels are being marketed as environmentally safe, reliable, modular, and high-cycle life alternatives to lead-acid batteries for uninterruptible power supplies (UPSs) and other power-conditioning equipment designed to improve the quality of power delivered to critical or protected loads. Major Manufacturers and Systems Although the majority of products being sold and marketed today fit into the PQ niche market, there are a number of key areas where electric utilities can directly benefit from the use of available flywheel systems. These include hybrid distributed energy resources (wind and flywheel, photovoltaic and flywheels, etc.), T&D grid stability (e.g., mass transit substation support), and potentially diurnal load leveling (peak shaving). This section focuses on existing and emerging flywheel products that may have applicability to utility T&D operations and will address product availability, performance characteristics, cycle life, and expandability/modularity. Table 3 lists the best-known manufacturers of flywheel systems for utility applications at present, along with the names and characteristics of their main products. The following sections describe these manufacturers and the special features of their products with respect to other flywheel systems. Active Power Active Power, located in Austin, Texas, manufactures low-speed power flywheel systems to provide a brief ride-through or bridge to a standby generator when voltage is low or power is not available. The company was founded in 1996 with private funding from various venture sources, and has since issued public stock, trading on the NASDAQ exchange under the ticker symbol ACPW. Active Power is rather unusual among flywheel manufacturers in having a steel wheel design that incorporates many of the features of higher speed composite wheels. The flywheel operates in a low and relatively wide speed range from 7700 to 2000 rpm, and is contained in a near vacuum environment. According to the company, the decision to go with steel rotors was made to avoid the technical difficulties and expense associated with composite rotors, magnetic bearings, complex controls, and containment systems required at high rotor speeds. Flywheels Page 15
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