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Published byPranav Eldon Modified over 9 years ago
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Presented by Matt Phillips Rich 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
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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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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 Approach
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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 Approach
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Project Drivers Improve Reliability Battery Failure during Generator Project Eliminate Single Points of Failure Prepare for 2 nd 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 2 nd 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
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Ex. UPS 1 Typ.PDU Ex. UPS ATS Ex. Gen. Ex. Utility SWBD New ATS Ex. Typ. CRAC Ex. Gen. SWBD Typ.PDU OhioHealth Simplified Electrical One-line After 2nd UPS Project NewUPS New ATS SWBD New CRAC ATS Typ. Ex. CRAC ATS
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Second Redundant Generator (2N) Second Redundant Utility Source
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Ex. UPS 1 Typ.PDU Ex. UPS ATS Ex. Gen. Ex Utility SWBD Ex ATS Ex. Typ. CRAC Ex. Gen. SWBD Typ.PDU OhioHealth Simplified Electrical One-line Ultimate Ex UPS - 2 Ex ATS SWBD Ex. CRAC ATS Typ. Ex. CRAC ATS New Gen. New Utility SWBD New Utility
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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 2 nd UPS & Energy Storage limited 2 nd Floor Installation – potential structural concerns ◦ 1N Generator back-up ◦ Recent Battery Failure during generator project
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Liebert NXL UPS (w transformer) 5 00kVA/450kW Pro: 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/500kW Pro: 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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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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Liebert 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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Decision Two – Flywheel vs. VRLA
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AUTOMATIC STATIC BYPASS Energy Storage RECTIFIER / CHARGER LOAD INVERTER DCSOURCE MAINTENANCE BYPASS Review of Basic UPS System
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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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Typical 5/10-Year Battery Typical 10-Year Battery Typical VRLA Batteries in a Cabinet
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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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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 2 nd UPS & Energy Storage limited 2 nd Floor Installation – potential structural concerns ◦ 1N Generator back-up ◦ Recent Battery Failure during generator project
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Liebert NX UPS VRLA Battery Cabinets Pro: 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 Flywheels Pro: Diversity in energy storage reducing likelihood of recent outage re-occurring ROI of Flywheels vs. Battery is 4 to 5 years or when the 1 st 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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Liebert NX UPS VRLA Battery Cabinets Con: 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 Flywheels Con: 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 repair Individual UPS Load 3 Flywheels2 Flywheels1 Flywheel3 Battery Strings 2 Battery Strings 1 Battery String 250 kW43.5 seconds 28.7 seconds 11.5 seconds 21 minutes10.5 minutes 0 minutes Decision Two – VRLA vs. Flywheel – Additional Information
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UPS Runtime with 1 Battery Strings UPS Runtime with 2 Battery Strings UPS 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
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Vycon Flywheel chosen as basis of design Concern & Mitigations: 1.Limited stored energy (20-30 seconds) depending on UPS Load a)Dual UPS Bus Design b)Diversity One UPS Bus Battery and other Flywheel c)Generator new and well maintained d)Facility staff isn’t on site 24 / 7 / 365 2.Upfront cost a)Due to weight reduction compared to VRLA structural upgrades not required – overall budget ≈ 12% higher for flywheels b)ROI of ≈ 4-5 years 3.Field Service Experience a)Flywheels have minimum parts to fail b)Support of Vycon during installation c)Dual Bus UPS Design d)N+1 Flywheel Design 4.Communications protocols a)Understanding that communication issues are not necessarily critical concerns b)Commitment from vendors to work through issues until resolved
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Review all options Do not ignore concerns – look for mitigation Open & honest discussions are key
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Matt Phillips Rich Leonardo Questions? Thank you
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