UPS system prevents loss of several millions at Novo Nordisk

One production standstill at Novo Nordisk in Gentofte, Denmark can result in a loss in production of several millions in Danish kroner. Since August 2014, an UPS system from ABB has prevented 30 probable production breakdowns due to voltage dips in the power supply.

Jesper Agertoft Pihl, electrical engineer and plant owner, is responsible for the electrical installations at Novo Nordisk in Gentofte.

Novo Nordisk in Gentofte, produce medicine for the bleeding disorder hemophilia. During the manufacturing process, the ventilation systems contribute to keeping the environment sterile by generating pressure, which prevents impurities from penetrating from the outside. However, Novo Nordisk had problems with voltage drops in the power supply, where the sensitive ventilation system cut out resulting in large production losses.

“In case of missing pressure above the atmosphere, all medicine must be discarded and production premises as well as equipment shall undergo an extensive cleaning that takes three days”, says Jesper Agertoft Pihl, electrical engineer and plant owner at Novo Nordisk in Gentofte.

A standstill may cost several millions Danish kroner and in the worst case, the pharmaceutical manufacturer will not be able to supply the market. Novo Nordisk in Gentofte is in production 24 hours a day throughout the year, which means that it is not possible to make up for a production loss and this could affect the supply security of the consumers. That is why the factory chose to install two offline PSC100 UPS-I systems from ABB in 2014, which keeps the voltage stable and prevents shutdowns.“

An offline UPS system is connected in parallel with the supply. It monitors the network, and if it detects a fluctuation in voltage or a failure in the supply, it will take over the load”, explains Rasmus Theill, product marketing director of Power Protection & EV Infrastructure at ABB in Denmark.

Increase in voltage dips

Previously, the pharmaceutical company typically had four to six shutdowns a year, which had been increasing. From the installation of the UPS facility in August 2014 to mid-December 2016, they had registered 59 voltage dips. From this, 30 would probably have caused downtime because the voltage dips fell below 30 per cent where the ventilation systems cut out.

“Only three weeks after installation, it prevented a breakdown due to voltage dips it had then paid for itself”, says Jesper Agertoft Pihl.

The voltage dips occur at switching of the mains voltage between power plants (wind energy and solar energy). The number of these disconnections had been increasing during the last few years as more and more of the power supply comes from alternative energy sources. The voltage drops will not affect a normal production, but it is problematic in highly sensitive facilities.

Best security in the market

The function of the UPS system is not only to prevent breakdowns due to voltage fluctuations, but also to act as a general emergency supply and here every precaution is taken. The construction of the system is redundant with eight modules per plant, each having five battery strings. Even if one module drops out, the remaining modules ensure that there is supply. The plant has no less than ten minutes of battery backup.

The uniqueness of the UPS-I is that the transfer time the time it takes for the system to connect, is less than 1.4 milliseconds. Additionally, it does not have the same power loss as an online UPS solution, but achieves an efficiency better than 99 per cent, which is the highest in the market, emphasizes Rasmus Theill.

At the factory, they had previously problems with harmonic currents, which caused unintended tripping and affected the lifetime of the components. For each UPS system, they have consequently installed two 100 amp active filters from ABB that solve this problem.

The UPS-I facilities had a payback period of only three weeks.

The touch screen visualizes the status of the plant and supply conditions.

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Video: Maximum UPS efficiency in all loading conditions

When an uninterruptible power supply (UPS) is operating at significantly under capacity, its energy efficiency can be negatively impacted. Xtra VFI mode is a smart way to minimize losses and improve efficiency when running in double conversion mode by dynamically adjusting the number of active modules to match the load.

Modules that are not needed are switched to standby but remain in state of readiness if the load increases. The efficiency improvements achieved by this mode of operation are especially significant when the load is less than 25 percent of full UPS system capacity.

Watch the video below to find out more:

More about Xtra VFI operating mode»

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ABB opens comprehensive UPS test center

With a well-attended official opening on June 8, 2017, ABB opened its brand-new test facility for uninterruptible power supply (UPS) systems at the UPS factory in Switzerland. With this new facility, ABB has taken a significant step forward in strengthening its position in the global power protection market.

On June 8, 2017, Remo Lütolf, Managing Director of ABB Switzerland, welcomed international guests from the data center and critical power industry to ABB’s UPS factory in Quartino, Switzerland for the official opening of a state-of-the-art UPS test facility.

The inauguration of the new amenity opens up a new chapter in ABB’s power protection capabilities: Now, even the largest UPS configurations can be tested as one system so that when they are delivered to the customer, they can be quickly and smoothly integrated into the power infrastructure. The test center is designed with ample capacity to accommodate large UPS sizes and turn key critical power solutions. The test area is laid out such that testing with extended UPS systems – including, for example, energy storage, input and output switchgear, power distribution units (PDUs) and static transfer switches (STSs) – can be accommodated. This new capability will enhance ABB’s ability to address trends toward bigger, more power-hungry data centers and industrial plants that require ever-larger UPS systems.

As part of the opening event, guests were given a live demonstration of the test facility’s capabilities. The demonstration was viewed from the comfort of the attached conference room, which has large windows that overlook the test bays so that customers and engineers can monitor the entire test process. The proximity to the FAT (factory acceptance test) area, and teleconference and video sharing facilities, allows remote FATs to be performed.

The guests at the inauguration ceremony were also made aware of the environmental advantages of the test bays: The use of a power-loop principle implemented into the test infrastructure tremendously reduces the power consumption from the public electrical network and allows approximately 90 percent of the electrical energy to be re-used. Test stations are equipped with highly flexible infrastructures that allow customized testing with a nonlinear load or an external generator. In addition to accomodating needs for testing at 400 VAC, standard voltages for Europe and other IEC markets, the facility can be adapted to perform tests at 208 VAC and 480 V, typical for the North America area and other UL markets.

UPS system power specifications are increasing year-by-year as applications grow ever more power-hungry and complex. As one of the few major players in the UPS market, ABB has, with the opening of the new test facility, acquired a tool to reinforce the ability of the company to successfully design, build and test UPS systems for applications involving the highest power applications.

Find out more


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Use Case for PowerValue 11 RT: High architecture meets advanced technology

The new Mario Botta-designed building for the new restaurant and conference center on Monte Generoso, Ticino, Switzerland not only provides a striking example of the architect’s work. It is also a use case for ABB’s PowerValue 11 RT single-phase UPS, which was chosen to protect the conference center’s technical equipment:

To ensure business continuity, ABB’s PowerValue 11 RT UPS double conversion topology has been chosen to protect the load from all possible input mains disturbances.

The PowerValue 11 RT’s compact and flexible design allows for easy setup and maintenance, configuration in tower or rack-mount format and connection to parallel battery modules for extended run time.

Due to its high reliability, low cost of ownership, flexible design and efficient service concept, ABB’s PowerValue 11 RT is ideal for use in Monte Generoso.

Find out more about ABB’s UPS on Monte Generoso below:

Download (PDF, 188KB)

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Top three trends driving the global three phase UPS systems market 

Technavio’s latest report on the global three phase UPS systems market provides an analysis of the most important trends expected to impact the market outlook from 2017-2021

Thanikachalam Chandrasekaran, a lead analyst from Technavio, specializing in research on energy storage sector, says, “A three-phase UPS provides continuous power supply to electrical equipment in instances of unforeseen power disruption. It also protects the equipment from power surges, thereby effectively averting the loss of productivity, equipment breakdown, damage, and replacement.”

The top three emerging trends driving the global three phase UPS systems market according to Technavio energy research analysts are:

Advances in UPS technology: „End-users worldwide prefer smaller UPS systems because they require less space, leaving more space for core business activities“,  according to Thanikachalam.

Declining lithium-ion battery prices: The lithium-ion battery prices have been exhibiting a declining trend since 2007. The cost of battery packs has seen a decrease of 53% during 2007-2015. The price of lithium-ion batteries is expected to further decline by 50% during the forecast period.

Increasing market for green data centers: The major issues being faced by data center operators in developed countries is growth in power consumption and carbon emissions. This has created awareness among enterprises on the construction of green data center facilities. Advanced technologies and strategies are being implemented in data centers to improve their performance. Many global enterprises are involved in the operation of green data center facilities or are in the process of constructing them.

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Welcome to the new issue of „power“ magazine!

The new edition of „power“ details the new product launch activities of the PCS120 MV UPS and its unique ZISC based architecture, introduced to the market in London at Data Centre World, and in Houston, Texas at ABB Customer World.

Another highlight in this issue is an article on ABB’s success with biopharmaceutical giant, Novo Nordisk. It shows how this world leading company maintains continuous operations throughout their delicate manufacturing process.

Also in this issue: How High architecture meets advanced technology. See how the double conversion topology of the PowerValue 11 RT UPS ensures business continuity for a newly opened Mario Botta signature designed attraction situated in the picturesque mountains of Monte Generoso, Ticino, Switzerland.

You can read and download this issue of „power“ below:

Download (PDF, 10.63MB)

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