Case Study –Dual UPS Project
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Transcript of Case Study –Dual UPS Project
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Case Study –Dual UPS ProjectPresented by
Matt PhillipsRich Leonardo
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Brief History of OhioHealth’s Infrastructure Upgrades
Current State of Infrastructure Future Plans Case Study Dual Bus UPS Project
◦ NXL (transformer) vs. NX (transformerless) UPS◦ Battery vs. Flywheel
Conclusion / Takeaways
Agenda
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OhioHealth History
• Major Goals Identified:• Increase Capacity
• Larger UPS /Cooling to match• Increase Reliability
• Replace end-of-life equipment• Limit Single Points of failure
• Improve Efficiencies• Hot Aisle / Cold Aisle
• Improve Operations• Move operators from Critical Space• Improve Monitoring
Original Site
Assessment
performed 2005
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OhioHealth History cont.
• 2006 – UPS Upgrade• Set Up for future dual bus UPS design• Replaced existing 300 kVA UPS with New 500 kVA UPS• Installed three (3) sets of Paired PDUs & One (1) STS• Unplug / Replug• Added CRACs• Began Hot Aisle / Cold Aisle Migration
• 2007 – CRAC Replacement & ATS Replacement• Continued replacement of end-of-life CRACs• Completed Hot Aisle / Cold Aisle Migration• Replaced Utility & Emergency Switch gear and end-of-life
ATSs• Reworked Power Distribution beginning to segregate
building from data center
Multi fiscal year
Phased Approac
h
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OhioHealth History cont.
• 2008 – Completed end-of-life CRAC replacement• 2009 – 2x New PDUs
• Breaker / Pole Capacity Increased• 2009 – Completed Relocation of Operators from
Data Center• Best Practice• Improved Security of Data Center
• 2012 – Generator Replacement• Replace end-of-life Generator• Set-up for Dual Bus
Multi fiscal year
Phased Approac
h
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OhioHealth Dual UPS Project
• Project Drivers• Improve Reliability• Battery Failure during
Generator Project• Eliminate Single Points of
Failure• Prepare for 2nd Utility &/or
Generator
2012-2013 Dual UPS
Project
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UPS 1
Typ.PDU
UPSATS
Gen.
Utility SWBD
CRACATS
TYP.CRAC
Gen. SWBD
Typ.PDU
OhioHealth Existing Simplified Electrical One-line
Prior to 2nd UPS Project
SPOF
SPOF
SPOF
SPOF
SPOF
SPOF
Single Point of Failure
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2N - PDUs 2N – UPS – 1 with Batteries, 1 with
Flywheels 2N - ATSs N+2 - Data Center CRACs
◦ All DC - CRAC receive power from 2 sources 2N UPS Room CRACs 1N Generator 1N Utility
Current State of Infrastructure
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Ex. UPS 1
Typ.PDU
Ex. UPSATS
Ex. Gen.
Ex. Utility SWBD
New ATS
Ex. Typ.CRAC
Ex. Gen. SWBD
Typ.PDU
OhioHealth Simplified Electrical One-line
After 2nd UPS Project
New UPS
New ATS SWBD
New CRAC ATS Typ.
Ex. CRACATS
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Second Redundant Generator (2N) Second Redundant Utility Source
Future Upgrades of Infrastructure
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Ex. UPS 1
Typ.PDU
Ex. UPSATS
Ex. Gen.
Ex Utility SWBD
Ex ATS
Ex. Typ.CRAC
Ex. Gen. SWBD
Typ.PDU
OhioHealth Simplified Electrical One-line
Ultimate
Ex UPS - 2
ExATS SWBD
Ex. CRAC ATS Typ.
Ex. CRACATS
New Gen.
New Utility SWBD
New Utility
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OhioHealth Dual UPS Project case study
General Considerations◦ Creating Dual UPS Buses◦ Existing UPS System
500 kVA / 400 kW Liebert Series 610 with 3 VRLA Battery Cabinets includes
Alber Battery Monitoring Quarterly Preventative Maintenance & Inspections
◦ Wet cell Battery Technology not considered Footprint for 2nd UPS & Energy Storage limited 2nd Floor Installation – potential structural concerns
◦ 1N Generator back-up◦ Recent Battery Failure during generator project
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Dual UPS Project Case StudyDecision One – Liebert NXL vs. NX
Liebert NXL UPS (w transformer) 500kVA/450kWPro: Traditional Approach In the 225 – 600 kVA sizes
◦ Been in production since 2009◦ Over 975 units throughout the country
Liebert NX UPS (wo transformer) 500kVA/500kWPro: In all sizes
◦ Been in production since 2007◦ Over 8,500 units are in use worldwide
Weighs less Smaller footprint Higher efficiency (95% at 200-500kW, 93%
at 125kW) Transistorized rectifier has high input power
factor and less current distortion Much easier load for generator to handle No input transformer-low inrush on utility
and on generator Modular component design reduces MTTR Supports much wider load power factor
range: 0.70 leading to 0.70 lagging
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Dual UPS Project Case StudyDecision One – Liebert NXL vs. NX
Liebert NXL UPS Cons: Weighs more than
NX Larger Footprint Lower efficiency
(92% at 225-450kW, 90% at 125kW)
Liebert NX UPS Cons: In the 225 – 600 KVA sizes
◦ Been in production since 2013
◦ Only 80 units in US◦ Field service has less
experience than NXL ◦ New User Interface Screen
to get familiar with◦ No isolation transformer,
input and output is 3W+G only
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Dual UPS Project Case StudyDecision One – Liebert NXL vs. NXLiebert 500kVA/500kW NX UPS (without transformer) chosen as basis of design Main Reasons:
◦ Smaller Footprint◦ Less Weight◦ Higher efficiency◦ Easier on generator◦ Lower cost ≈ 6%
Main Concern◦ Newer US Based Model / Field Service Experience
Mitigation of concerns◦ Creating Dual UPS Buses◦ Local Liebert Training and support for Customer Engineers
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Dual UPS Project Case Study
Decision Two – Flywheel vs. VRLA
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AUTOMATIC STATIC BYPASS
Energy Storage
RECTIFIER /CHARGER
LOADINVERTERDCSOURCE
MAINTENANCE BYPASS
Review of Basic UPS System
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UPS Energy Storage Lead Acid Batteries Most Prevalent
◦ Sealed Valve-Regulated (VRLA)◦ Wet Cell
Emerging Technologies◦ Flywheels ◦ Superconducting Magnets◦ Ultra-Capacitors◦ Other Battery Types (NiCad, Li-Ion, NiMH, etc.)◦ Fuel Cells◦ Micro Turbines
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VRLA Batteries
Typical 5/10-Year Battery
Typical 10-Year BatteryTypical VRLA Batteriesin a Cabinet
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Typical - Flywheel
1. Flywheel - Heart of the system providing a 20-year life with no maintenance.
2. Master Controller - Monitors output demand and controls the various subsystems including charging (monitoring) and discharging (generating) of the flywheel.
3. Magnetic Bearing Controller - Controls the position of the flywheel rotor via a 5-axis active magnetic bearing system.
4. Bi-Directional Power Converter - Interface between the DC bus and the variable frequency, variable voltage AC generated by the flywheel.
5. Vacuum Pump - Evacuates air within the flywheel to reduce windage losses resulting in increased electrical efficiency.
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Dual UPS Project Case StudyDecision Two – Flywheel vs. VRLA General Considerations
◦ Creating Dual UPS Buses◦ Existing UPS System
500 kVA / 400 kW Liebert Series 610 with 3 VRLA Battery Cabinets includes
Alber Battery Monitoring Quarterly Preventative Maintenance & Inspections
◦ Wet cell Battery Technology not considered due to Footprint for 2nd UPS & Energy Storage limited 2nd Floor Installation – potential structural concerns
◦ 1N Generator back-up◦ Recent Battery Failure during generator project
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Dual UPS Install Case StudyDecision Two – VRLA vs. Flywheel
Liebert NX UPS VRLA Battery CabinetsPro: Stored Energy in event of loss of utility
& generator is 10 minutes at full UPS Load
OhioHealth is familiar with battery cabinets
Less upfront cost versus flywheel option
Due to batteries being used at more sites and the long history of battery usage, service technicians have more experience servicing batteries
Companies providing UPSs (Liebert, APC) and companies providing batteries (C&D and EnerSys) have long, established track records
Liebert NX UPS FlywheelsPro: Diversity in energy storage reducing
likelihood of recent outage re-occurring ROI of Flywheels vs. Battery is 4 to 5 years
or when the 1st battery replacement costs occur
Flywheel life expectancy is 20 years Flywheel maintenance is 1 time per year vs.
quarterly battery inspections Less parts using 3 Flywheels vs. using 3
battery cabinets with 40 batteries per cabinet
GREEN solution; efficient Less annual maintenance costs Smaller footprint / Less Weight Faster recharge after discharge Higher reliability than batteries
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Dual UPS Project Case StudyDecision Two – VRLA vs. Flywheel
Liebert NX UPS VRLA Battery CabinetsCon: Higher Maintenance Costs Higher Replacement Cost
(need to replace every 3 - 4 years)
More Maintenance than flywheel quarterly vs. annual
Larger footprint and weight
Bring in a hazardous material (Lead).
Present a higher fire hazard
Liebert NX UPS FlywheelsCon: Most costly upfront ≈ 50% equipment only Flywheels offer minimum
stored energy (20-30 seconds) depending on UPS Load. ◦ On loss of utility & the generator
fails to start Less familiarity for All involved Communications protocols not
as established
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UPS Runtime with flywheel unit(s) or batteries string(s) being down for service or repairIndividual UPS Load
3 Flywheels
2 Flywheels
1 Flywheel
3 Battery Strings
2 Battery Strings
1 Battery String
250 kW 43.5 seconds
28.7 seconds
11.5 seconds
21 minutes 10.5 minutes
0 minutes
Decision Two – VRLA vs. Flywheel – Additional Information
125 250 375 5000
102030405060708090
100
NX 500kVA Runtime Flywheel
3 Flywheels2 Flywheels1 Flywheel
kW Load
Runt
ime
(Sec
onds
)
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Decision Two – VRLA vs. Flywheel – Additional Information
UPS Runtime with 1 Battery Strings
UPS Runtime with 2 Battery StringsUPS Runtime with 3 Battery Strings
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Vycon Flywheel chosen as basis of design Main Reasons for flywheel:
◦ Diversity of energy storage – reducing likelihood of battery failure causing outage
◦ ROI of flywheel vs. batter≈ 5 years or 1st Full Battery replacement
◦ Flywheel life expectancy 20 years◦ Footprint & Weight◦ Less yearly maintenance
Dual UPS Project Case StudyDecision Two – VRLA vs. Flywheel
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Vycon Flywheel chosen as basis of design Concern & Mitigations:
1. Limited stored energy (20-30 seconds) depending on UPS Loada) Dual UPS Bus Designb) Diversity One UPS Bus Battery and other Flywheelc) Generator new and well maintainedd) Facility staff isn’t on site 24 / 7 / 365
2. Upfront costa) Due to weight reduction compared to VRLA structural upgrades not required –
overall budget ≈ 12% higher for flywheelsb) ROI of ≈ 4-5 years3. Field Service Experience
a) Flywheels have minimum parts to failb) Support of Vycon during installationc) Dual Bus UPS Designd) N+1 Flywheel Design
4. Communications protocolsa) Understanding that communication issues are not necessarily critical concernsb) Commitment from vendors to work through issues until resolved
Dual UPS Project Case StudyDecision Two – VRLA vs. Flywheel
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Review all options Do not ignore concerns – look for mitigation Open & honest discussions are key
Dual UPS Project Case StudyKey takeaways
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Case Study –Dual UPS Project
Matt PhillipsRich Leonardo
Questions?Thank you