Case Studies

Project Overview 

Orion is an electricity distribution business operating in the Canterbury and Central Otago regions of New Zealand’s South Island. As a provider of critical infrastructure Orion plays an important role in supporting the local community, keeping substations, overhead power lines and underground lines operational.  

Orion was looking for a custom-engineered energy storage solution that supported their 125vDC secondary protection assets at substations throughout the region. Engineers from Valen and Orion worked together to co-create a new solution that delivered significantly better performance and efficiency than the old system.  

The end result is a flexible, modular, easy-to-maintain system that is suitable for high seismic areas, and this jointly designed package is now being rolled out in all upgraded and new substations across NZ. 

The Challenge 

Orion needed a reliable energy storage solution to power 48VDC communication systems at their substations, with the project calling for a single, flexible solution that would be suitable for all sites. Our challenge was to provide a solution that was easy to install, test, and swap out batteries if necessary, while also being modular and scalable to accommodate different capacities and protection loads.  

Additionally, the solution needed to comply with IEEE693 High Seismic standards to ensure safety and stability in case of seismic events. 

The team at Orion had previously spent countless hours with engineers and consultants who had recommended very customised, niche – and hard to procure – battery systems. Because of this negative experience, the Orion engineering team specified that any new design must include easy-to-source, off-the-shelf part codes, which met AS2676 and AS3011 Electrical Standards.  

The Orion maintenance crew had also reported that their existing systems were difficult to access and maintain, so a design that provided safe, simple and straightforward access for technicians in the field was a must.   

Co-creating a Solution 

Valen’s engineers worked together with Orion to co-create a solution that surpassed the client’s expectations. Beginning with a thorough discovery process to understand how the systems would be installed, used and maintained, our engineering team then provided preliminary designs to Orion that met the project brief.  

The proposed system needed to tick many boxes in order to be a success in the field, and by designing the energy storage system in tandem with Orion’s engineers, we were able to jointly solve problems and deliver the best fit-for-purpose result.  

Critical specifications for the project included a design that had all battery terminals facing forwards for safety, ease of maintenance, and simple testing. All terminals needed to be insulated, and mechanical battery hold-downs were specified rather than the existing straps.  

Battery racks that were stackable and easy to assemble meant less time for techs in the field, and a modular system was determined to be the best option as it allowed Orion to use the same rack for both 100Ah and 155Ah installations. This meant that if a capacity upgrade was required, they could reuse the existing racks. A modular approach would also permit the replacement of a single underperforming battery rather than the whole rack, further reducing costs. 

The final two-tier design is compact, creating a very small footprint at sites with limited space – something that installation crews have appreciated. The terminals on all systems are forward facing with insulation and terminal covers, providing safety for technicians and easy access for battery testing.  

Outcome 

The front terminal battery packages are providing a highly reliable power supply to the communication system, reducing downtime, improving efficiency and improving Orion’s SAIDI index. The racks were also designed to comply with all three seismic categories, providing a highly stable and secure solution in case of seismic events. 

Orion has begun rolling out these custom-made energy storage units in all upgraded and new substations, with the project team reporting that the process has been incredibly easy so far. The modular system allows for easy expansion and maintenance, further improving reliability.  

Critically, every system can be kitted quickly from in-stock components, heavily reducing the time to engineer and ship each new package to site.  

Orion provides essential power services that support the local community and facilitate economic growth, and the business now has a highly flexible and scalable energy storage design that can adapt to their changing needs.  

Contact Us to find out more or to discuss your next project.

The Watzmann has been fascinating mountaineers from all over the world for more than 200 years. However, the Berchtesgaden monument not only occupies a firm position in alpine sports: the mountain also has the potential to play a very special role in safeguarding the communications capability of the Bavarian lowlands in the event of an emergency. Part of the game: a Munich-based fuel cell technology company that ensures the off-grid energy supply in a reliable, clean and sustainable manner.

At first glance, the small mountain station of the material ropeway on the west side of the Watzmannhaus may appear unassuming. Since 1960, it connects the Watzannhaus, located at just under 2,000 meters above sea level, with the valley station, 600 meters below, thus ensuring the supply of the Watzmannhaus. In parallel, however, the mountain station also serves a completely different purpose: it houses all kinds of technical devices and equipment connected by wires and hoses.

The background to this miraculous technology not far from the summit of the Watzmann is the operation of a radio station – but not to provide cottage guests with high-speed Internet or to cover the last radio gaps in the Berchtesgaden Nature Park. Rather, it is a project that is intended to become the central component of fail-safe data transmission in crisis situations. Power outages are a nuisance in everyday life, but real blackouts, i.e. widespread power failures over a longer period of time, can sometimes have fatal consequences for the entire population. This applies in particular to critical infrastructures (KRITIS), i.e. those plants and facilities that play a key role in maintaining everyday life.

The Smart Bavaria Net Kritis

“For economic reasons, public broadband communications cannot be built resiliently to blackouts and thus crisis-proof,” explains Stefan Lichy, Managing Director of Smart Radio Net GmbH. The company, headquartered at Chiemsee, plans, builds and operates high-availability voice and data networks for critical infrastructures or critical operating processes. Radio is transmitted on specially allocated frequencies, independent of the public network. “We enable demand-driven and secure connectivity that is available without interruption even in the event of a prolonged, area-wide power outage.”

In addition to another site at the Kampenwand, Smart Radio Net also operates Germany’s highest radio site on the Zugspitze. The alpine bridgeheads can cover distances inland of up to 180 km. The existing network already covers 90 percent of Bavaria. Customers include municipalities and utility providers who need to be able to send and receive data even in the event of a blackout in order to avoid far worse consequences and damage.

“As a Bavarian company, the further development of this network in Bavaria is particularly important to us. We see our Smart Bayern Net Kritis as a secure communications backbone in harmony with and complementary to public broadband expansion. A blueprint for the whole of Germany,” says Harald Huber, Head of Business Development at Smart Radio Net GmbH. 

Cooperation with the German Alpine Club

The site on the Watzmann is already operated by Smart Radio Net for three years. The fact that the radio station is located in the operating hut of the Watzmannhaus is explained by the cooperation with the Munich section of the German Alpine Club. The partnership originated in a relatively pragmatic way: In order to create a nationwide network, the alpine locations are needed by Smart Radio Net. On the other hand, a fail-safe network that enables even the most remote valleys to be connected is likewise quite relevant for the German Alpine Club.

The area-wide radio coverage would make it comparatively easy to connect refuges in the mountains, as well as significantly facilitate the work of the mountain rescue team in locating injured hikers. At present, however, the site on the Watzmann is still in test operation. Without a power grid connection, in extreme weather conditions and with limited accessibility in winter, the resilience of an important node can be ideally simulated here.

Power supply without grid connection

Compared to conventional telecommunication stations, the radio system consumes little energy. Including the gateway, about 80 watts are required for operation. By comparison, inner-city mobile communications sites consume up to 4 kW, which is about 50 times as much. However, inner-city systems can also simply be connected to the power grid. On the Watzmann, power is supplied by a battery that is charged in summer by a photovoltaic panel.

This presents one of the fundamental challenges of the site: How can a power supply be ensured year-round and independent of weather-related fluctuations? The Munich-based technology company Siqens GmbH provides the answer. A methanol fuel cell is used to reliably recharge the battery during winter.

“In the end, we considered various systems and technologies,” explains Harald Huber: “The Siqens system convinced us, among other things, with its robust design and resistance to low temperatures.” As is usual for critical applications, the site has a redundant design: two fuel cell systems ensure an uninterrupted power supply. A similar setup has already proven itself in Tyrol’s emergency response system. There, an alpine radio relay network ensures the transmission of alarm-relevant data and the connection of individual districts.

Fuel cell as replacement for diesel gensets

“Of course, it’s always exciting for us, when our fuel cells are used under extreme conditions,” explains Volker Harbusch, CEO and founder of Siqens GmbH: ” This is one of the reasons why we designed and developed our technology for use at low temperatures”.

Strictly speaking, the Siqens Ecoport 800 is a hydrogen fuel cell powered by methanol. However, the hydrogen is first derived from methanol in the system. This offers the advantage, especially in remote locations, that liquid methanol in canisters is easy to transport and store. “Methanol is the simplest hydrogen carrier there is and can be produced in a variety of ways based on renewable energy,” Harbusch adds.

Three connected tanks with a total volume of 180 liters allow for more than 150 days of intervention-free operation. Enough to bridge the snowy days on the Watzmann. But the technology is also a building block for combining decarbonization and grid hardening for locations with an existing connection to the power grid. After all, security-relevant communication and data exchange must also be maintained for several days in the event of a power outage.

Currently, diesel generators are still mostly used to safeguard critical infrastructures. In the case of the Watzmann, a 25-liter canister of methanol is sufficient to supply the site with uninterrupted power for over three weeks. “Our goal is to provide an environmentally friendly and economical alternative to diesel generators,” explains Volker Harbusch: “That’s why I’m particularly pleased about the close cooperation with Smart Radio Net and the opportunity to make an important contribution with our technology in setting up a failure-proof communications network

The Watzmann has been fascinating mountaineers from all over the world for more than 200 years. However, the Berchtesgaden monument not only occupies a firm position in alpine sports: the mountain also has the potential to play a very special role in safeguarding the communications capability of the Bavarian lowlands in the event of an emergency. Part of the game: a Munich-based fuel cell technology company that ensures the off-grid energy supply in a reliable, clean and sustainable manner.

At first glance, the small mountain station of the material ropeway on the west side of the Watzmannhaus may appear unassuming. Since 1960, it connects the Watzannhaus, located at just under 2,000 meters above sea level, with the valley station, 600 meters below, thus ensuring the supply of the Watzmannhaus. In parallel, however, the mountain station also serves a completely different purpose: it houses all kinds of technical devices and equipment connected by wires and hoses.

The background to this miraculous technology not far from the summit of the Watzmann is the operation of a radio station – but not to provide cottage guests with high-speed Internet or to cover the last radio gaps in the Berchtesgaden Nature Park. Rather, it is a project that is intended to become the central component of fail-safe data transmission in crisis situations. Power outages are a nuisance in everyday life, but real blackouts, i.e. widespread power failures over a longer period of time, can sometimes have fatal consequences for the entire population. This applies in particular to critical infrastructures (KRITIS), i.e. those plants and facilities that play a key role in maintaining everyday life.

The Smart Bavaria Net Kritis

“For economic reasons, public broadband communications cannot be built resiliently to blackouts and thus crisis-proof,” explains Stefan Lichy, Managing Director of Smart Radio Net GmbH. The company, headquartered at Chiemsee, plans, builds and operates high-availability voice and data networks for critical infrastructures or critical operating processes. Radio is transmitted on specially allocated frequencies, independent of the public network. “We enable demand-driven and secure connectivity that is available without interruption even in the event of a prolonged, area-wide power outage.”

In addition to another site at the Kampenwand, Smart Radio Net also operates Germany’s highest radio site on the Zugspitze. The alpine bridgeheads can cover distances inland of up to 180 km. The existing network already covers 90 percent of Bavaria. Customers include municipalities and utility providers who need to be able to send and receive data even in the event of a blackout in order to avoid far worse consequences and damage.

“As a Bavarian company, the further development of this network in Bavaria is particularly important to us. We see our Smart Bayern Net Kritis as a secure communications backbone in harmony with and complementary to public broadband expansion. A blueprint for the whole of Germany,” says Harald Huber, Head of Business Development at Smart Radio Net GmbH. 

Cooperation with the German Alpine Club

The site on the Watzmann is already operated by Smart Radio Net for three years. The fact that the radio station is located in the operating hut of the Watzmannhaus is explained by the cooperation with the Munich section of the German Alpine Club. The partnership originated in a relatively pragmatic way: In order to create a nationwide network, the alpine locations are needed by Smart Radio Net. On the other hand, a fail-safe network that enables even the most remote valleys to be connected is likewise quite relevant for the German Alpine Club.

The area-wide radio coverage would make it comparatively easy to connect refuges in the mountains, as well as significantly facilitate the work of the mountain rescue team in locating injured hikers. At present, however, the site on the Watzmann is still in test operation. Without a power grid connection, in extreme weather conditions and with limited accessibility in winter, the resilience of an important node can be ideally simulated here.

Power supply without grid connection

Compared to conventional telecommunication stations, the radio system consumes little energy. Including the gateway, about 80 watts are required for operation. By comparison, inner-city mobile communications sites consume up to 4 kW, which is about 50 times as much. However, inner-city systems can also simply be connected to the power grid. On the Watzmann, power is supplied by a battery that is charged in summer by a photovoltaic panel.

This presents one of the fundamental challenges of the site: How can a power supply be ensured year-round and independent of weather-related fluctuations? The Munich-based technology company Siqens GmbH provides the answer. A methanol fuel cell is used to reliably recharge the battery during winter.

“In the end, we considered various systems and technologies,” explains Harald Huber: “The Siqens system convinced us, among other things, with its robust design and resistance to low temperatures.” As is usual for critical applications, the site has a redundant design: two fuel cell systems ensure an uninterrupted power supply. A similar setup has already proven itself in Tyrol’s emergency response system. There, an alpine radio relay network ensures the transmission of alarm-relevant data and the connection of individual districts.

Fuel cell as replacement for diesel gensets

“Of course, it’s always exciting for us, when our fuel cells are used under extreme conditions,” explains Volker Harbusch, CEO and founder of Siqens GmbH: ” This is one of the reasons why we designed and developed our technology for use at low temperatures”.

Strictly speaking, the Siqens Ecoport 800 is a hydrogen fuel cell powered by methanol. However, the hydrogen is first derived from methanol in the system. This offers the advantage, especially in remote locations, that liquid methanol in canisters is easy to transport and store. “Methanol is the simplest hydrogen carrier there is and can be produced in a variety of ways based on renewable energy,” Harbusch adds.

Three connected tanks with a total volume of 180 liters allow for more than 150 days of intervention-free operation. Enough to bridge the snowy days on the Watzmann. But the technology is also a building block for combining decarbonization and grid hardening for locations with an existing connection to the power grid. After all, security-relevant communication and data exchange must also be maintained for several days in the event of a power outage.

Currently, diesel generators are still mostly used to safeguard critical infrastructures. In the case of the Watzmann, a 25-liter canister of methanol is sufficient to supply the site with uninterrupted power for over three weeks. “Our goal is to provide an environmentally friendly and economical alternative to diesel generators,” explains Volker Harbusch: “That’s why I’m particularly pleased about the close cooperation with Smart Radio Net and the opportunity to make an important contribution with our technology in setting up a failure-proof communications network

During natural disasters, rapid response and coordination between emergency responders and government agencies are critical. But how do you establish this connection when the power, and thus the public telecommunications network fails?

In the State of Tyrol, a radio relay network ensures the connection of the various municipal districts and the transmission of alerts in the event of disaster: This ensures that communication can continue between valleys cut-off by avalanches – an essential component of coordinating help. The disaster microwave network serves as the backbone of the digital radio warning and alerting system network in Tyrol.

During planning of the network, special attention was paid to reliability, fail-safety and redundancy: There are currently 128 lines in operation, which enable resilient data transmission over a distance of up to 50 km. The use of underground lines was deliberately avoided to prevent any damage caused by landslides.

For the mostly alpine locations, a combination of photovoltaics and battery is ideal for self-sufficient power generation. The fully charged battery ensures operation for at least 48 hours. However, for a weather-independent and year-round power supply of critical sites, additional measures are necessary.

For this reason, the SIQENS Ecoport 800 is used at the redirection point on the Messelingkogel – at an altitude of just under 2,700 meters. The energy from the fuel cell is fully sufficient to operate the connected directional antennas, as well as a small electric heater which is used to de-ice the antennas in winter. The connected tank with 200 liters of methanol provides sufficient energy to operate the site self-sufficiently for several months.

Rio Tinto mines and produces materials that are essential for the low-carbon transition and works hard to develop innovative solutions that will help them deliver progress. That’s why Valen chose to partner with Rio Tinto to help deliver a solution for one of their sites.

Situation

Rio Tinto had a site gate that required power to operate. At the time, the only option was to dig long trenches to run power lines; however, this brought cost and complexity. They were looking for an option that provided remote power without the hassle of extensive earthworks. Due to the remoteness of the site location, the solution also needed to include remote monitoring to alert to smoke, intruders, theft and tampering, as well as shade and weather protection.

Valen Products

• Valen EnduroGel 12V155Ah
• Enetek ETS+3248
• Valen 300W Solar Panels

Solution

The Valen team recommended our versatile ModX4 system. Designed and developed in house, the ModX package was produced to make our customers’ lives easier. Suiting a range of power requirements, the system comes complete and fully wired, giving our customers the confidence that the system will work from day 1. Valen products were used to create the kit, including Valen Endurogel 155Ah Front Terminal Batteries, outdoor cabinet, Enetek solar controller ETS+3248 and Valen 300W Solar Panels.

Outcome

The ModX package suited Riot Tinto as it allowed remote power without the need for extensive groundwork. An additional benefit was the versatility, where Rio Tinto could request additional specs such as door locks, smoke alarms and shade screens, and installation could be anywhere that suited them. Rio Tinto enjoys no ongoing power bills and the use of green energy. The added benefit is if the gate location was to be moved in the coming years the kit could be disassembled and reassembled at the new location

Rio Tinto Case Study

Energy Australia is one of Australia’s biggest energy retailers. They see their responsibility as ensuring their customers have a renewable energy supply and shielding them from shocks such as the current energy crisis. In part, the current challenges result from heavy rains and geological issues slowing the domestic coal supply.

Situation

Energy Australia has a two-phase plan to transition its energy to more renewable energy. Stage 1 was to support the current grid with renewables; phase two was to expand the current grid capabilities with renewables. Energy Australia approached Valen with a request to support their geological monitoring sites. These sites were currently solar-based. Their current problem that needed solving was to support the sites with low solar output. Whatever option they went with also needed to be a ‘green’ alternative and needed to have the capability to be slab or skid mounted.

Valen Products

• Hyland 920 Wind Turbine

Solution

The Valen team saw an opportunity to introduce Energy Australia to the benefits of wind power. The Hyland 920 wind turbine was the perfect choice to meet the job requirements. A wind turbine can utilise the existing power infrastructure while supporting low solar locations. In addition, generally, solar locations are in elevated positions free from buildings or trees nearby, allowing the customer to harness the power of wind

Outcome

The team at Energy Australia appreciated the ease of installation at the existing site, and were enjoying the benefits of wind power immediately. The option was cost-effective, was compatible with the existing solar infrastructure, increased the current supply of solar power and met Energy Australia’s requirement of being environmentally friendly.

Energy Australia

Fueled by a passion for innovation since 1689, Husqvarna provides professional forest, park and garden products. Performance and usability meet safety and environmental care in our leading-edge innovations, where battery solutions and robotics lead the way. The team at Husqvarna wanted to expand their capability into providing robotic lawn mowing solutions to commercial properties such as cemeteries, golf courses and wineries, and domestic and residential properties.

Situation

These large commercial properties had enormous potential to benefit from using autonomous mowers, however were unable to unlock these benefits. Property managers were turned off this solution as at the time, they required 240V charge stations to be installed which would require ground penetration and power lines to be run. Husqvarna came to Valen looking for a solution to supply remote solar power to charge automowers without the need to break ground.

Valen Products

• Valen ENLiFEN 24V100Ah
• 2x300W Valen Solar Panel
• Victron Phoenix Inverter
• Victron SmartSolar MPPT

Solution

Valen worked with Husqvarna to design a turnkey solution. Utilising a number of quality Valen products, the Valen team developed a complete solar kit with a single part number for ease of reordering. The kit needed to be created in a way that allowed it to be carried to site and installed without heavy machinery. The kit features Valen products: 24 Volt 100Ah ENLiFEN Lithium Battery, Valen Solar panels, enclosure to house battery and Victron inverter and solar charge controller.

Outcome

Now property owners and managers of larger commercial and special-use properties have an option to use an automated mowing system that is tested and can be ordered simply.

Valen Case Study Husqvarna

Completion: October 2019

Scope: Design and supply of modular solar system to extend the radio network to remote areas

Solution: The Valen Team supplied several turn-key packages to provide power to remote telecommunications sites including precast concrete footings, enclosures, solar panels & solar frame, inverters and DC distribution. The customer was so happy with the solution that they extended the project to include additional sites. In addition, photos of the modular system published to our network have generated interest for a complete solution in other areas of the industry.

System supplied: Valen ENLiFEN Energy Storage Optimiser (ESO) 48V300Ah lithium battery system installed within a custom 19-inch cabinet

Solar: Valen 300W Solar Panel complete with ground mount frames to suit
Other: Supply of enclosure & precast concrete footings

Completion: Ongoing

Scope: Design & Supply of off-grid solar system to provide power to the remote radio network.

Solution: The Valen team was awarded this two-year tender in 2018. The Valen team designed and supplied batteries, Inverters, solar frames & panels to the government radio network and was recently acknowledged for their proficiency by being awarded an extension on the contract for a further 3 years.

Batteries supplied: Valen ENDUROGEL 12V155Ah Front Terminal Battery – with Catalyst Life Extender

Solar: Valen 300W Solar Panel complete with ground mount frames to suit

Scope: To supply batteries and racking for telecommunications application

Solution: Valen’s experienced project management team coordinated the supply of OPzV batteries and racking to meet a critical deadline. Ensured sign-off of specifications and managed supply chain risk by effective communication and planning.
System supplied: Valen OPzV 2V800Ah battery

Racking: Valen 48V Battery System 2V800Ah Battery Rack

Completion: March 2020

Customer: TasNetworks

Scope: Supply of lithium batteries to remote off-grid solar sites for Snowy Hydro 1 and 2.

Solution: The Valen team supplied & installed lithium batteries, Inverters & solar panels to provide power to the remote site. To support our execution of the project we developed the specs and ensured a sign-off procedure was followed prior to manufacture. Delivery of the project included multiple support visits to the site by our technical support team.

System supplied: Valen ENLiFEN Energy Storage Optimiser (ESO) 10x 48V100Ah lithium battery system installed within a custom 19-inch cabinet

Completion: March 2020

Customer: Snowy Hydro

Scope: Design and supply solar kit options for water monitoring & weather stations on rural areas such as council areas and farms.

Solution: Valen reviewed their current solution and designed streamlined kits for a low sun option & high sun option + solar bracket options.

Outcome:

• Custom Inventory Kits setup, with single part codes. From what is 17x individual parts.
• Streamline procurement and ETA’s
• Delivery direct to site