PowerSecure talks microgrids and its 98.7% reliability rate. By Chad Elmore, managing editor at Power Progress

There are consumers and industry professionals out there who believe microgrids may be an interesting solution for the future. However, microgrids have already become an increasingly popular solution to an overloaded and aging electrical grid. The source of the misperception could be found in the fact that a company behind more than 1700 deployments – reportedly 85% of the installed microgrid sites in the United States – has deliberately stayed under the radar. Until now, that is.

How PowerSecure Became a Leading Developer of Advanced Microgrids

From the day it was founded, Wake Forest, N.C.-based PowerSecure has focused on developing distributed energy systems and the integration of multiple energy resources for microgrid deployments, including Tier 4 final diesel engines, natural gas engines, fuel cells, batteries and renewable energy such as wind and solar. Its lifecycle approach to microgrids means it designs, builds, owns and operates them.

The company has already installed more than 2 gigawatts and currently controls 1.6 gigawatts of distributed generation systems. They are supported by an in-house service network that covers 29 states with 16 5 technicians on staff.

The firm has long held a close relationship with energy providers nationwide, often working with and for the utilities – indeed, part of its success is predicated on the fact that many of its employees come from that world. That bond is stronger today, as PowerSecure is a subsidiary of Southern Company, an energy firm with 9 million customers.
“We have a lot of experience building microgrids and we believe we are the leader in the industry, but PowerSecure is not well-known,” said Eric Dupont, executive vice president and chief commercial officer, PowerSecure. “A lot of people don’t know about this company, and that was very intentional for a number of years. Early on, we did not want the PowerSecure name out there because we didn’t want the competition to know what we were doing.

“Now we’re part of Southern Company and have a very different mindset. The industry has evolved significantly since our founding in 2000 and it’s important for us to get our brand out there. It’s important to be recognized for what we’ve done throughout our history and what we’re looking to do in the future.”

PowerSecure Reliability Growth Management Program

Several years ago, the company began a Reliability Growth Management program that looked at the complete microgrid system, from engines to switchgear controls. Recent figures show that from January 2016 to February 2019, its fleet registered 64,075 start demands, 5237 system-years in service and 24.5 years of total system run time. The research, conducted by third-party consulting engineering firm MTechnology, showed a 98.7% reliability rating, above the national average of 95.4%.
“I go to a lot of conferences and speak to a lot of different people,” said Mark Martyak, chief sales officer and cofounder of PowerSecure, “and it’s always amazing to me how many people act like microgrids are still a science experiment. They’re not a science experiment to us.”

Microgrid 360: Sharing A Secret

As part of its goal to no longer be the industry’s best-kept secret, PowerSecure introduced Microgrid 360 at its Durham, N.C., campus last year. It is a functional microgrid that’s part of a guided tour given to clients as well as local school groups. It also allows the company to enjoy the cost benefits of peak shaving as well as an uninterrupted flow of power for its office, warehouse and factory buildings when severe weather moves off the Carolina coast and heads inland.

The microgrid consists of the firm’s Power Block gen-set equipped with two Tier 4 final Volvo Penta 16 L diesel engines (there’s room for four but this layout provided room for tours to get a closer look), a solar array atop its main building, Bloom fuel cells, battery energy storage system and its own Nexgear switchgear. It’s managed by the company’s proprietary PowerControl platform. The campus can be taken off the utility and run by the microgrid with nary a flicker in an LED light.

“When customers visit Microgrid 360, it becomes clear to them that we are the product innovators and solution architects that can help them devise the right system to maximize reliability, economic value and durability,” said Dupont during the ribbon cutting last October. “As a company that centrally monitors and manages our customers’ microgrids 24/7/365, we have the unique advantage of knowing what products and components really stand the test of time.”

Monitoring And Data Collection

Customers can opt to have PowerSecure monitor, maintain and manage microgrid and mission-critical power systems. Detailed information from an array of sensors transmit data in real time to one of two operation centers. The data enables the firm to implement proactive maintenance procedures as well as investigate unusual patterns. It’s also proved invaluable when it comes to continuous improvement.

“We’ve been remotely monitoring our systems since 2006, so we know how many times they’ve been called to operate,” said Dupont. “We have 12 terabytes of data sitting in our database related to system profiles, performance, customer load profiles and more. We utilize all of that data to provide better services and solutions for our customers.”

“And because our units are also designed to run for load management, they get up to 300 hours a year of run time on average,” said Martyak,” so we see patterns that nobody else with standby systems get to see. That’s how we’ve been able to do continuous improvements and maintain our dedication to quality.

“We’ re not selling a solution that pulls together random pieces in the hopes that they will work together. Even though we offer highly creative approaches for each application, we manufacturer almost everything in-house and we test everything before it leaves the factory.”

PowerBlock: A Leader in Distributed Energy Solutions

A key component of the company’s installed microgrids is its PowerBlock family of integrated generation paralleling systems. Modular in design and enclosed in purpose-built enclosures, they range in power from 625 kW to 3750 kW with up to six engines in a single enclosure. Each engine is part of a 625 kW power generator assembly, each paralleled and synchronized together with control systems developed by the company and overcurrent protection breakers.

Depending on the application, customers can select between the 16 L Volvo Penta TWD1643GE Tier 2 diesel engine or the 16 L TWD1673GE Tier 4 diesel engine. Stage 5 versions will soon be ready for international customers. Natural gas engines from PSI are also an option.
Depending on the engine, they can be used in emergency standby applications, prime power or peak shaving.

PowerSecure & Volvo Penta: A Strong Partnership

PowerSecure and Volvo Penta have long worked as partners in the power generation market. “We started working together with PowerSecure when they began building their own generators in 201 O,” said Darren Tasker, vice president, Industrial Sales, Volvo Penta of the Americas. “Since then, we’ve seen a steady increase in the segments they do business in, including microgrids, data centers and so on.”

Beginning in 2016, the two companies enhanced their business relationship with a formal partnership agreement. It was renewed recently and runs through 2022.

“This is an agreement where both sides have commitments to achieve ambitious growth targets in strategic segments,” said Tasker. “Volvo Penta is making investments and ensuring the engines and components are suitable for new and existing segments, with many of these unique features only available for PowerSecure. PowerSecure makes investments in the complete generator systems together with sales, service and support for these segments. This is a close partnership using the strengths of both organizations to create added value for customers. I’m convinced the growth we’ll see in the coming years will exceed everyone’s expectations.”