CRITICAL PROCESSINGpowerprofile

For its new Beijing plant, Heidenhain recognized the need for a 24/7continuous power system that would reliably condition power andprotect their critical manufacturing process.

CUSTOMER: Dr. Johannes Heidenhain(China) Co. Ltd.

LOCATION: Beijing, People’s Republicof China

Customer Requirement: Power conditioning and stand-by uninterruptible power for critical manufacturing operations

Scope of Supply: Equipment – • Cat® UPS 750 kVA• Cat 3412 520 kW Generator Set

(Standby configuration)• 1250A Automatic Transfer Switch Services – Design analysis, systemcommissioning, calculation, siteinstallation arrangements, start-upand budget management.

Cat Dealer: WesTrac China

POWER NEED

Dr. Johannes Heidenhain (China) Co. Ltd. required clean,

continuous power to protect their advanced manufacturing

equipment from power disturbances and support their critical

loads at the German-based company’s new plant in Beijing,

China. As a manufacturer and assembler of optical and

electronic components (including linear, angular and rotary

encoders, as well as several measuring and inspection devices)

for semiconductor and electronic equipment, maintaining a

consistent factory environment overall – including air quality,

temperature and power supply – is vital to Heidenhain’s core

business. This meant not only ensuring continuous power to

the manufacturing machinery, but also the ancillary temperature

control and room cleaning control equipment in the space where

the machinery is located.

For its new Beijing plant, Heidenhain recognized the need

for a 24/7 continuous power system that would reliably

condition power, while also providing additional protection

from power failures, micro and macro outages, voltage sags and

surges, and harmonic distortion – all of which could compromise

the manufacturing process and result in inaccurate or damaged

componentry. As such, the system would need to include an

Uninterruptible Power Supply (UPS) that would work

seamlessly and effectively with the generator set to deliver

continuous power despite any disturbances or outages.

Heidenhain Optics and Electronics, Ltd., in conjunction

with German engineering company ED Zublin AG, approached

Caterpillar® Hong Kong to provide a continuous power solution

that met pre-determined parameters originally specified to a

competing product line. A Cat® Electric Power consultant worked

closely with Heidenhain’s local Caterpillar Dealer, WesTrac

China, to formulate a proposal that both met Heidenhain’s unique

power needs and provided a clear advantage over other system

providers. The simplicity of product design, structure, operation

and maintenance requirements earned Heidenhain’s business as

the single-source provider of a continuous power system for the

new plant.

CRITICAL PROCESSING powerprofile

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SOLUTION

To deliver the established 500 kW of power support,

Heidenhain’s contractor, ED Zublin AG worked with WesTrac

to supply a Cat 3412 520 kW generator set and Cat UPS 750 kVA,

the latter of which would be the first Cat® UPS to be installed for

commercial use within the People’s Republic of China.

“With a continuous power system running 24 hours a day,

7 days a week, intermittent maintenance becomes an inevitable

factor,” said Zhu Jianming, senior sales engineer from WesTrac,

“The Cat UPS provided a significant advantage over the

competing product, a true rotary machine with a shaft between

the motor generator and the UPS that requires the complete

system to be taken offline for even routine maintenance.”

“The Caterpillar continuous power system is designed to

allow the generator set to bypass the UPS and provide power

directly to the low voltage distribution system in the event of

the UPS needing to go offline,” explained Jack Shu, Caterpillar

EP consultant in Beijing. “That way, something like a simple

bearing change in the UPS does not affect continuous operation

of the remainder of the system.”

The Cat UPS’ integrated flywheel energy storage design is

of critical importance in the plant’s operation. In addition, its

high power density and small footprint allowed for the unit and

a Cat 520kW generator set to be installed in a small 12-meter by

4-meter space inside the room in which the actual equipment is

located.

The Automatic Transfer Switch (ATS) connects the Cat

UPS and generator set. The ATS is additionally connected to

the utility power. In the event of power loss, energy is derived

from the flywheel of the UPS to provide uninterrupted power

to the critical load at nominal voltage. The ATS will

simultaneously send a signal to the generator set for automatic

start-up. When power from the generator set is available, the

UPS synchronizes the output and input voltages and transfers

the load to the generator set. During the whole process, power

supplied to the critical load is protected and clean continuous

power is the result.

RESULTS

Installation of the Caterpillar continuous power system was

completed at the site in April of 2005 and the whole plant was

handed over to Heidenhain. Since the installation was completed,

several tests have been conducted, including planned shutdowns

of the utility power.

“After much testing, the Cat UPS, generator set and ATS

equipment have all proven their mettle,” said Zhu Jianming. “These

tests have demonstrated that the Cat 3412 generator set starts up in

less than 8 seconds, with the Cat UPS providing successful ride-

through beforehand. In monitoring the sensitive machinery during

the continuous power system testing, there has also been no evidence

of a disturbance or failure upon shutdown of the utility. As such,

Heidenhain has expressed confidence that the system will perform,

as intended, when it goes online full time once construction is

finished and operations are running at the plant.”

With high power density and a small footprint, the Cat UPS was installedin a small 12-meter by 4-meter space, along with the Cat 520 kWgenerator set.