AP intro - Industrial June 2016_compressed 2

Best of Breed … Cost, Reliability, and Sustainability
Power Quality Solutions for
Industrial & Manufacturing

2Proprietary and Confidential | ©2016 Active Power Inc.
Our company saves nearly $200,000 per year in
operating expenses, by eliminating power disturbances
and keeping our semiconductor production lines running
using Active Power UPS’s.”
Active Power Solves Industrial &
Manufacturing Problems
In our highly sensitive manufacturing environment we
needed a reliable UPS that could handle power
disturbances and provide a bridge to generator during
an outage. Active Power’s product has never failed.”
With the flywheel UPS, we never have to worry about
losing power or productivity, and in a factory setting,
having that peace of mind is invaluable.”
Unreliable utility power caused production downtime and
economic losses at our bottling plant, until we installed
Active Power UPS’s on our factory floor.”
1,330+ Units Installed • 325+ Customers • 44 Countries
“
“
“
“

Global Competition Increasing levels of
automation
Never ending
quest …
• Process
• Machine Control
• Communications
• Material Flow
• Higher Productivity
• Improved Quality
• Lower Cost
• Efficiency
• Resiliency
Industrial Facilities Are Mission Critical

Harsh Environments Remote Locations Critical Processes
• Unstable Grid
• Dirty Power
• Continuous
Operations
• Expensive
Machines
• Expensive Raw
Material
• Temperature
• Air Quality
• Safety is a Priority
Industrial Environment is Unique

Active Power Provides Unique Advantages for
Industrial & Manufacturing Facilities
Eliminates the costs
associated with
downtime and
necessary clean up
Protects against
all power quality
issues
A great fit to
integrate into your
operations and
achieve your goals

Select Active Power Industrial & Manufacturing
Customers

Flywheel vs Battery:
The Advantages of Flywheel Technology are Clear
Flywheel Energy Storage
Advantages
 20 year operating life
 No degradation with use
 Limited maintenance required
 Operating temperature range up to 40C
 Compact, enclosed footprint
 If the flywheel is spinning,
power is available
Lead-Acid Battery
Challenges
Multiple replacements during UPS life
Frequent use degrades lifespan
Sensitive to temperature variations
Extensive maintenance and monitoring
Expensive safety and health systems
Most common reason for UPS outages

Why Active Power? Power Quality Protection
Bottling Company
“The lack of consistent and reliable power to
support our operations was an ever present
management headache before we installed
CleanSource UPS. Since installation, we are
very pleased with the improvement in our
day-to-day operations.”

Active Power Systems Provide
Complete Power Conditioning
Harmonic
Distortion
Line Noise
Transients
Spikes
Surge
Sag
Brownout
Outage
CleanSource UPS corrects all types of power
problems by use of TVSS, line inductance,
line capacitance, active filtering, power converters
and flywheel energy. The UPS provides isolation at
ALL TIMES (on utility, in discharge, and on generator).
Corrected
Sine wave
Frequency

Unmatched Reliability
Twelve times less likely to fail
Field proven to be the most reliable solution
Active Power
CleanSource UPS
Typical UPS
with battery backup
Mean Time Between Failures
(including energy storage)
2 million hours Not published **
Demand failures of the flywheel energy storage system are extremely
unlikely; if the flywheel is operational at the moment an outage
occurs, the flywheel will almost certainly function.”
– Steve Fairfax, Mtechnology
“
Typical UPS with battery backup
Annual probability of failure*
Active Power CleanSource UPS
6.4%
0.5%
* Active Power White Paper #115, “Mitigating Risk of UPS System Failure,” Jan. 2016
** UPS manufacturers only publish MTBF for UPS excluding energy storage (batteries)

Active Power’s Limited Maintenance is a Benefit for
Industrial & Manufacturing Customers
Limited maintenance requirements . . .
1 non-invasive preventive maintenance per year
Bearing change every 3-4 years
. . . Minimize disruption and risk to your facility
• Reduced downtime
• Less time you’re unprotected
• Fewer opportunities for human error
… … years

A Great Fit
Glass Manufacturer
Active Power systems
are small and durable,
so I can fit ours right
on our production
floor. That helps me in
my already too-
cramped facility.”
“

Smallest Footprint
Half the Space
• The most power dense UPS on the market today
• Perfect for retrofits & tight spaces
• Ambient operating range up to 40C
• More usable space for business purposes
Footprint comparison based on published specifications of equivalent 750 kVA units with four standard battery cabinets versus CleanSource 750HD UPS

40% Total Cost of Ownership Savings
Key assumptions: 1 MW UPS capacity at 75% load; CleanSource HD 97.8% efficient; 750 kVA battery UPS: 96.5% efficient; 6 minute VRLA
batteries w/ 5 year replacement cycle; $0.10/kWh energy cost
TCO ($ mil.)
Years
CleanSource
HD UPS
Over 15 years, total cost is
3-5X the initial purchase price
15
1.0
1.5
0.5
0.0
2.0
0 105
Additional
cost
$0.9M
$0.6M
$1.4M
$0.9M
$1.9M
$1.1M
Competitor
UPS
$800k
savings
over 15
years

Active Power’s Solution Helps
Customers Reach Their Sustainability Goals
• No hazardous materials introduced to
your facility
• No spill containment needed
• No added ventilation requirements
• Does not emit harmful gases in to your air
• Safety
• Completely enclosed – no open racks or
exposed power connections
• LEED certification points
• Energy efficiency
• No hazardous material
• No recycling / disposal responsibilities

Smart and Responsible
Energy efficiency and permanent energy storage combine to make Active Power
the smart and responsible choice
• 90% less carbon used in UPS manufacture
• Over 40% less carbon emitted over 15 years
For a 1 MW facility, 1,800 metric tons less carbon emissions over 15 years.
Equivalent to:
1,400 metric tons less coal mined
27,000 mcf less natural gas burned
4,700 fewer barrels of oil consumed
216 homes powered
400 fewer cars on the road

Are We a Fit For Your Operation?
Ideas to move forward:
• In-depth review of your requirements and specification
• Custom TCO and sustainability analysis
• Active Power customer case study examples
• Active Power technical deep-dive
Eliminates the costs
associated with
downtime and
necessary clean up
Protects against
all power quality
issues
A great fit to
integrate into your
operations and
achieve your goals

Appendix

Active Power Provides a Full Portfolio of
Power Technology & Services
UPS Systems Modular Solutions Services
Factory-built and tested
electrical systems and
modular data centers
designed for low cost,
rapid deployment, and
superior management
capability.
Preventative maintenance
and support programs to
ensure your critical power
infrastructure operates
with the utmost reliability.
Active Power's flywheel-
based UPS solutions
provide reliable,
economical backup power
for mission critical
operations.
• CleanSource HD UPS (750
kVA/675 kW) with a large
system building block
• Modular and expandable
CleanSource UPS (150
kVA to 1200 kVA)

CleanSource 300 UPS CleanSource HD UPS CleanSource DC
• 675 kW UPS
• Parallelable for larger
applications
• Largest, most cost
effective building block
• 250-500 kW DC energy
storage
• Replaces or augments
batteries in
conventional UPS
solution
• 150 kW – 1 MW single
UPS solution
• Parallelable for larger
applications
• N+1 energy storage
available
• Flexible, modular
design
CleanSource UPS Products

DataHouse modular
data center
PowerHouse modular
power system
All-in-One IT, power,
and cooling
• Containerized UPS and
switchboards
• IT, power, and cooling
in one system
• 5-10 racks
• White space for 10-20
IT racks
• Multiple cooling options
Modular Systems
Proven Capability • 200+ modules deployed globally
• Standard products, infinitely customizable
• Integrated design, manufacturing, services
• Proven scalability

Comprehensive Service Offerings
Assess
• Site survey
• Site validation
• System design
Implement
• Turnkey installation or installation
assistance
• Start up and commissioning
• Project Management
Support
• Maintenance and warranty
programs
• Training and technical support
• Remote monitoring and power
management

Active Power Knows Industrial & Manufacturing
Contact Lens
Manufacturer
"In our highly sensitive environment, we needed a reliable UPS that could
handle power disturbances and provide a bridge during an outage. Active
Power’s product has never failed.”
– Damien Wassell, Utility Engineer
Three CleanSource UPS selected to protect air handlers precisely
managing temperatures for vaccine production
“We run a 24-hour operation, meaning there’s never any downtime.
There’s a huge demand for our product, so any interruption would lead to
back orders. Choosing Active Power was a business continuity decision,
and the UPSs have never let us down.”
– Director of Facilities and Workplace Services
Four CleanSource UPS systems deployed to protect robotic
contact lens manufacturing equipment
“The lack of consistent and reliable power to support our operations
was an ever present management headache before we installed
CleanSource UPS. Since installation, we are very pleased with the
improvement in our day-to-day operations.”
– Mauro Caceres, General Superintendent, Operations
Over 20 MW of CleanSource UPS deployed at repumping stations
across Mexico

Superior Performance for Industrial Applications
• CleanSource UPS ability to handle power problems, especially inrush
from dynamic demand devices is far superior to traditional UPS
• Traditional double-conversion UPS have to be oversized
to handle industrial equipment life VFDs and pumps
• Oversizing leads to waste and cost
• Space
• Energy efficiency
• Increased infrastructure costs for
cabling, breakers and switchgear
• Active Power CleanSource UPS can support equipment
step loads without the need for oversizing and
maintaining voltage regulation during step load

At Merck’s Durham, North Carolina facility, engineers
develop and manufacture liquid vaccines to improve
patient care.
Challenge
Solution
Result
• Manufacturers of medicines and vaccines must adhere to strict
federal production guidelines to prevent contamination. If an
electrical interruption occurs, all product in process must be
discarded and operations can’t resume until affected equipment is
cleaned & revalidated.
• Merck chose to deploy three Active Power CleanSource® UPS
systems to protect the facility’s air handlers from voltage sags and
other short power disturbances. The flywheel-based UPS systems
require less frequent maintenance than battery-based competitors,
reducing the risk of production stoppage caused by human error.
Additionally, CleanSource UPS was selected due to its smaller
footprint and lower total cost of ownership.
• Since installation in December 2013, the equipment protected by
Active Power UPS systems has not experienced a power-related
interruption.
"In our highly sensitive environment, we
needed a reliable UPS that could handle
power disturbances and provide a bridge
during an outage. Active Power’s product
has never failed.”
– Damien Wassell
Utility Engineer
Merck – Durham, North Carolina

Vishay Intertechnology is one of the world’s largest
manufacturers of discrete semiconductors and passive electronic
components . It has production facilities in Israel, Asia, Europe,
and the Americas with more than 20,000 employees worldwide.
Challenge
Solution
Result
• One of Vishay’s production facilities near Turin, Italy, was experiencing
micro-outages due to interferences from industrial sites nearby and no
linear behavior on power distribution. These anomalies created
downtime periods with each outage costing an estimated $170,000 in
operating losses. Vishay required a rugged, critical backup power
solution insensitive to ambient temperature that could support a frequent
number of charge and discharge cycles.
• Vishay deployed its an Active Power CleanSource 250 kVA UPS in
2007 and because of the success, they deployed Active Power’s
CleanSource 625HD UPS in 2014 to expand coverage. The two
systems protect production tools such as furnaces, photomasking
equipment, and electronic components.
• Both flywheel UPS systems experience on average more than 15
discharges a day with no interruption to operations and saving the
manufacturer nearly $200,000 annually in operating expenses. These
savings are due to the systems’ high operating efficiencies, lower
cooling requirements, and less maintenance versus a conventional
battery UPS.
Vishay Intertechnology – Turin, Italy

The company’s Johns Creek, Ga. facility manufactures
contact lenses, houses a research and development unit
and serves as a global distribution center.
Challenge
Solution
Result
• The company’s contact lenses are manufactured by highly
sophisticated robotic equipment. Even the slightest electrical
interruption would shut down the assembly line, stalling operations
until all of the machinery can be restarted. The company required
a reliable critical backup power solution to ensure the factory
remains fully operational during an utility outage.
• Four Active Power CleanSource® UPS Systems were deployed to
protect the robotic equipment from occasional power disturbances.
They selected Active Power over competitors due to
CleanSource’s smaller footprint and lower total cost of ownership.
• Since installation, the assembly lines protected by Active Power
UPS systems have not experienced a power-related interruption,
even when other equipment within the facility has shut down
during utility outages.
•“We run a 24-hour operation, meaning
there’s never any downtime. There’s a huge
demand for our product, so any
interruption would lead to back orders.
Choosing Active Power was a business
continuity decision, and the UPSs have
never let us down.”
•– Director of Facilities & Workplace
Services
Contact Lens Manufacturer – Johns Creek, Georgia

Founded in 1962, Active Power’s customer is a leading
manufacturer of residential glass for windows and doors. The
company has more than 6,000 employees at 37 manufacturing
locations throughout the United States.
Challenge
Solution
Result
• The company required a reliable critical backup power solution to
protect their critical conveyors that handle and transport glass
within the facility and to ensure the plant remains operational
during utility outages frequently caused by severe weather in
Tornado Ally.
• The company chose to deploy a 900 kVA flywheel UPS. The UPS
is ideal for the industrial setting because it can withstand higher
ambient temperatures and has a smaller footprint than a
conventional battery UPS. This enabled the customer to deploy
the system right on the factory floor near the conveyors.
• The flywheel UPS is saving the end user money and valuable floor
space due to the fact the system requires less cooling and delivers
approximately twice the power in half the space of a battery UPS.
Facility managers indicate plans to expand the plant and intends
to again select flywheel UPS to provide backup power protection.
"With the flywheel UPS, we never have to
worry about losing power or productivity,
and in a factory setting, having that peace
of mind is invaluable.”
– Mechanical Engineer
Glass Manufacturer – Durant, OK

As the third largest brewer in the world, the customer
operates more than 190 breweries in more than 70
countries.
Challenge
Solution
Result
• One of the brewer’s production facilities is located on an island off
the coast of Africa where utility power is unreliable. Micro-outages
and other electrical disturbances can impact production causing
downtime and economic loss.
• The brewer chose to deploy an Active Power CleanSource 750
kVA UPS to protect its sensitive operations. The system was
deployed on the facility’s production floor without the need for
cooling equipment because of its rugged, electromechanical
design. A legacy battery UPS would have required additional
design and build cost to house batteries in conditioned space.
• Since installation, CleanSource UPS has experienced hundreds of
discharges with no interruption to the customer’s production lines.
Unlike a legacy UPS, the system doesn’t degrade over time
providing the same predictable level of service in year one as it
does at year 10. The brewer has since installed CleanSource UPS
systems at more than 10 additional production sites worldwide.
International Brewer – France

Pemex is the world's second largest non-publicly listed company.
The organization operates re-pumping stations that pump crude
oil, gasoline, and diesel to and from various cities across Mexico.
Challenge
Solution
Result
• The motors and turbines at Pemex Refinación re-pumping stations
contain sensitive controls making quality power critical for efficient
operations. With many of the stations in remote areas and located
at the end of utility lines, incoming power is poor and unreliable.
• Pemex Refinación has deployed more than 20 megawatts of
Active Power CleanSource UPS systems across 22 stations in
Mexico, protecting the stations’ automated systems and motor
loads from power interruptions. The systems effectively manage
in-rush currents typical of inductive loads. In addition, the battery
free UPS’ ability to operate in industrial environments, smaller
footprint, and overall lower maintenance costs makes it a better
solution for Pemex’s needs.
• The rugged and inherently reliable design of CleanSource UPS
made it an ideal solution to support these mission critical re-
pumping stations. The systems help ensure oil and gas continues
to flow and prevents potential revenue loss and equipment
damage.
“The lack of consistent and reliable power
to support our operations was an ever
present management headache before we
installed CleanSource UPS. Since
installation, we are very pleased with the
improvement in our day-to-day
operations.”
– Mauro Caceres
General Superintendent, Operations
Pemex Refinación – Mexico

AP intro - Industrial June 2016_compressed 2

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