Data Center Renovation Delaware Kristen Shehab Spring 2005 Mechanical Option Faculty Consultant: Dr. Freihaut

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Building Name and Owner: Withheld at owners request Architect and Engineers: CCG Facilities Integration Contractors General: - Nason - Whiting – Turner Electrical: - Furness Electric Mechanical: - I.D. Griffith

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Originally Built: 1983 Size: 175,000 SF Computer Room: 80,000 SF. Function Type / Occupancy: Data Center Industrial Occupancy Redundancy: Tier III 1.6 hours annual downtime

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Goals: Reliability: Minimize Downtime Increase Power Quality for Sensitive Equipment Efficiency: important with large electric loads 8760 hr/year Emissions: Utility: Fuel - 95% coal Natural Gas Combustion: lower emissions

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Cogeneration Combustion Turbine Generators Inlet cooling Heat Recovery Energy Sell Back Absorption Chillers Cooling Tower Condenser Water Pumps and piping

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Combustion Turbine Generators Total building electric load: 9,089 kW Centaur 40 Performance Quantity: 3 + 1   Electric Output (kWe) Fuel (MMBtu/hr) ISO (59F) 10545 130 Average (54F) 10728 134 Design Day (91F) 9222 115.41 On Design Day 12.5% output decrease

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Inlet Cooling 244 tons excess cooling On design day, can get inlet air to 63 F 1.8% output decrease On cooler days, modulate coil to keep inlet temp at 44F

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Heat Recovery Excess heat from turbines recovered Used to drive Absorption Chillers 14.5 psig Stack Prevent condensation Temperature higher than dew point Average steam mass flow 61,024 lbm/h

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Energy Sell Back Public Utility Regulatory Policies Act (PURPA) Utility must pay “avoided cost” Conectiv Qualifying Facility greater than 1,000 kW Purchases power under special contracts Assume avoided cost (payback) Half charged rate ($7.45/MMBtu) Annual Excess Energy 19,000,000 kWh Revenue from utility: $478,000 per year

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Absorption Chillers Single Stage Utilizes waste heat Reduced emissions No CFC or HCFC refrigerants LiBr/ Water Building Thermal Load: 2,400 Tons Broad: BDS 200, 661 Tons each Quantity: 4+1 Condenser Evaporator Flow rate (GPM) 2869 1257 Temperature (F) 85 - 97.5 56.7 - 44 Input: Electric (kW) 8.4 Input: Steam (lb/h) 10243 Rated COP 0.78

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Redesign Analysis System Analysis Emissions System Efficiency Cost Analysis First Cost Energy Cost data Reliability Maintenance

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Emissions Lean-Premix, Dry, Low Emission (SoLoNOx) Water Injection DOE’s Model Emissions Rule Non-Attainment Area Credit for Cogeneration [lbs/Mwh] Avoided Emissions from HRSG opposed to steam created from Boiler [(boiler limit)/(boiler efficiency)] *[3.412/(power to heat Ratio)]

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Emissions EPA’s AP 42: Stationary Internal Combustion Sources gas turbines Delaware Standard Emissions from turbine Delaware [tpy] NOx 40 VOC CO 100 CO2 - SO2 PM 25 Lead 0.6 *NOx *VOC * For Non-attainment areas Emissions factors With Credit [Tons/year] - 3.515 MW   Uncontrolled Water steam injection lean-premix NOx 2.76 -0.17 -0.64 CO 0.68 -0.12 -0.35 CO2 19958.20 - Lead SO2 0.60 VOC 0.40 PM - condensible 0.89 PM - filterable 0.36 PM - total 1.25 Criteria Pollutants

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions System Efficiency Purpa Qualifying Facility topping cycles: 45% FERC efficiency Federal energy Regulatory Commission (FERC) FERC = Power output + .5 * useful thermal output / energy input all waste heat chillers only Total CHP Efficiency (%), HHV 0.78 Power/Heat Ratio 0.56 Net Heat Rate (Btu/kWh) 4577 Effective Electrical Efficiency (%), HHV 0.75 FERC Efficiency 0.53 Total CHP Efficiency (%), HHV 0.62 Power/Heat Ratio 0.84 Net Heat Rate (Btu/kWh) 7072 Effective Electrical Efficiency (%), HHV 0.48 FERC Efficiency 0.45

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions System Efficiency (3 + 2) Increased Redundancy One running Hot, selling back all energy Cannot Use recovered Steam all waste heat chillers only Total CHP Efficiency (%), HHV 0.81 Power/Heat Ratio 0.52 Net Heat Rate (Btu/kWh) 4154.22 Effective Electrical Efficiency (%), HHV 0.82 FERC Efficiency 0.54 Total CHP Efficiency (%), HHV 0.55 Power/Heat Ratio 1.01 Net Heat Rate (Btu/kWh) 8106.20 Effective Electrical Efficiency (%), HHV 0.42 FERC Efficiency 0.41 ** Not Utilizing Enough Recovered Steam!

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut First Cost Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Existing Equipment Quantity Unit Price Total Cost Source Cooling Tower Pumps 5 7,490 37,450 Means Centrifugal Chillers 142,722 713,610 Carrier Cooling Tower 37,900/ 600ton 189,500 Piping 12" 350 LF 128/LF 44,800 Piping 18" 850 LF 177/LF 150,450 $1,135,810 New Equipment Quantity Unit Price Total Cost Source Cooling Tower Pumps 5 8,000 40,000 B&G Absorption Chillers 256,000 1,280,000 Broad Turbine/Generator 4 970/kW 13,638,200 Solar Cooling Tower 2,400 Ton 333,500 Marley Inlet Cooling Coil 4,000 16,000 Trane Piping 12" 350 LF 128/LF 44,800 Means Piping 24" 850 LF 247/LF 209,950 $15,562,450 Natural Gas interconnection fees

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Energy Cost data Energy Information Administration (EIA) 2001 Energy Prices Electricity: $14.89/MMBtu Natural Gas: $ 6.63/MMBtu Spark Gap = 8 Less than 12, not good Annual Energy Outlook (AEO) 2005 Electricity and Natural Gas follow same trends through 2025 Spark Gap not likely to improve Annual Cost: Electricity $4,000,000 Annual Cost: Natural Gas $8,500,000 - $478,000 = $8,000,000

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Reliability Cost savings due to increased reliability Difficult to quantify Function of: Uptime Power Quality Uptime: Outage duration Extent of outage (for partial outages) Industry Average Cost of Power Outage, Tier III $/hr 1.6 hrs/year Brokerage Operations   6,480,000 10,368,000 Credit Card Operations 2,580,000 4,128,000 Airline Reservations          90,000 144,000 Telephone Ticket Sales     72,000 115,200 Cellular Communications     41,000 65,600 Midwest CHP Application Center Losses can be significant if facility is critical Cogeneration can minimize downtime

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Reliability Power Quality: Sags, and swells Voltage Fluctuations Transient over-voltages at High frequency Harmonics Distorted current from waveforms Can be reduced with properly designed system

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Conclusion Benefits: Increased Reliability Lower Overall Emissions Draw Backs: first cost Spark Gap Payback periods Difficult to Quantify If owner has enough capital and the facility is critical enough to justify higher first costs and utility costs then cogeneration becomes a good option.

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Acknowledgements Penn State Architectural Engineering Faculty Dr. Freihaut Dr. Bahnfleth CCG Facilities Integration Mechanical and Electrical departments AE Senior Class 2005 Alicia Carbin Jesse Fisher Fellow Thesis Lab Regulars Family Mom Dad Laura

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Heat Recovery Excess heat from turbines recovered b CH4 + a ((2O2 + .52N2)+0.0015H2O) = b CO2 + b 2H2O + a 0.0015H2O + 2(a – b)O2 + a 7.52N2 Minimum stack temperature: 275 F Qg = S (Mdot*((CP1*Texh)-(CP2*280))) Qs = Qg - system inefficiencies Msteam = Qs / (hs – hf) hs = enthalpy saturated steam hf = enthalpy water Average steam mass flow: 61,024 lbm/h

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Determine Electric Load building thermal load: 2,400 Tons (8,440 kW) Envelope load insignificant -assume zero Cooling therefore supports 8,440 kWe Electric Load: Unconditioned Spaces 320 kW running cooling towers rooftop air handling units Non-renovated Space office space Energy Information Administration 18.7 kWh/sf Converts to: 310 kW The total electric load: 9,089 kW

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Mechanical Equipment Pumps Cooling Towers Quantity 4 + 1 Flow rate (GPM) 2869 Head (ft) 100 Motor (BHP) 88 Size 8G Series 1510 RPM 1770 Brand B&G Quantity 4 + 1 Flow rate (GPM) 2869 Temperature (F) 97.5 - 85 Wet Bulb 79 Range 12.5 Model NC8312N1 RPM 1800 Fan Motor Output BHP 100 New Piping, 18” to 24”

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Maintenance O&M, Turbine/generators Electric Capacity, kW 10,000 Variable (service contract), $/kWh 0.0045 Variable (Consumables), $/kWh 0.0001 Fixed, $/kW-yr 7.5 Fixed, $/kwH @ 8000 hrs/year 0.0009 Total O&M Costs, $/kWh 0.0055 $550,601/year

Data Center Renovation, Delaware Kristen Shehab Mechanical Option Spring 2005 Faculty Consultant: Dr. Freihaut Outline Project Team Existing Conditions Redesign Goals System Redesign Redesign Analysis Conclusion Acknowledgements Questions Synchronization Circuit breakers isolate problems at the load and protect network Relays signal circuit breakers voltage, power, current, frequency, phase imbalances, flow direction The Centaur 40 is equipped with auto synchronizing. anticipatory synchronizer parallels generator to bus Causes closure at a minimum phase difference corrects for speed and voltage Overrides included for emergency or black-start operations