ABB UPS 3. November 2014
Modular Architectures Centralized Parallel Architecture (CPA) In a Centralized Parallel Architectures the system is composed of common system building blocks: MAINS 1 MAINS 2 CENTRAL PROCESSING UNIT CENTRAL CONTROL PANNEL CPU Control Panel Static Bypass Switch Battery Redundant POWER UNIT Redundant POWER UNIT CENTRAL BATTERY PACKS The only Decentralized Parts are the Power Units. Redundant POWER UNIT CRITICAL LOAD CENTRAL STATIC BP SWITCH November 20, 2012 Slide 2
ABB UPS Concepts True Modularity Decentralized Parallel Architecture (DPA) TM distributes the entire UPS Hardware and Software into each module. MAINS 1 MAINS 2 DPA CONTROL PANNEL DPA CENTRAL PROCESSING UNIT DPA POWER UNIT DPA STATIC BP SWITCH DPA BATTERY PACKS A DPA systems includes distributed/decentralized: CPU; Control Panel; Static Bypass Switch; Power Unit and Separate Battery DPA CONTROL PANNEL DPA CONTROL PANNEL DPA CENTRAL PROCESSING UNIT DPA CENTRAL PROCESSING UNIT DPA POWER UNIT DPA POWER UNIT DPA STATIC BP SWITCH DPA STATIC BP SWITCH DPA BATTERY PACKS DPA BATTERY PACKS CRITICAL LOAD November 20, 2012 Slide 3
Decentralized Parallel Architecture DPA DPA UPScaleTM HIGHLIGHTS and Benefits High level of decentralization Multi Master and Slave Technology through a simplified BUS Communication Full redundancy on inverter Full redundency on Static Bypass Switch (SBS) 27 March 2011 DPA UPScale 4
Standardization benefits and finally: System reliability and availability The Causes of CRITICAL UPS FAILURES Standardized solution can improve most of these 33% Failures caused by lack of design 28% Failures caused by equipment failure 36% Failures caused by Human Error Commissioning or Test Deficiency Natural Disaster 4% 3% System Design 20% Equipment Failure 28% Maintenance Oversight 4% Installation Error 10% Reference: EYP Mission Critical Facilities Equipment Design 13% Human Error 18%
Rightsizing Standalone vs modular - Example Modular design allows the power protection capacity to be added when needed to meet the existing/actual demand, instead total up front deployment. Slide 6
Top-of-the-line Performance High double conversion efficiency High efficiency reaching - and exceeding 96% Having the curve flat means that high efficiency is reached already at low load levels 95.8% at 25% load November 3, 2014 Slide 7
The mission for increased availability Advantages of the modular UPS concept Add redundancy to the system Minimize chance for human error Select high quality, reliable equipment Minimize or eliminate need for downtime Secure simplicity and easiness of service Modular architecture introduces redundancy to the system automatically With decentralized paralleling architecture all modules are automatically redundant with each other à single points of failure in the UPS are eliminated Simplicity of service + maintenance of ABB s modular UPS mitigates human error Modular architecture allows for implementation of simple and standardized power protection and service concept across installations Use reliable double conversion UPS technology High Swiss made quality with 20 years experience on modular UPS UPS with modular architecture secures concurrent maintenance With decentralized paralleling architecture all modules are capable to function independently With on-line swappable modules, critical load does not need to be shut down or transferred to raw mains during when UPS is being serviced Modular UPS allows also for simplifying and standardizing the complete service concept across installation and sites! Same technology base and UPS concept can be used across load segments and applications! November ABB 3, 2014 Slide 8
Standardization benefits Operation and maintenance UPS service with online swappable modules: Concurrent maintenence by swopping the modules Concurrent repair by swopping the module Limited spare parts inventory in quantities, different articles and total value Minimized human errors Standardised service training Operator training can be standardized and simplified since the UPS system is a standard solution.
Conceptpower DPA 500 Advantages of the modular UPS concept Optimize and save on capital investment Combines the right-sizing approach with scalability, Pay-as-you-grow solution lowers your capital costs and increases utilization rates Innovative technology allows for maximal power density that frees space for other critical equipment. Accelerate speed of deployment Electrical and physical modularity allows for rapid installation with minimal engineering. Same product and technology base can be selected to match the needs of each data center and each load segment Decrease complexity and costs of service and maintenance Modular architecture allows for implementation of simple and standardized power protection and service concept across installations. On-line swappable modularity ensures need for scheduled and unscheduled downtime is minimized Decrease the operating costs With efficiency of 96% in double conversion and 99% in ECO mode, the operating costs can be >40% less compared to UPS of previous generation Increased availability and load uptime result in increased utilization Slide 10
TCO Energy Efficiency Efficiency (%) 97 96 95 94 93 92 91 90 95 95 95 25% 50% 75% 100% Modular 90 Load (%) 92 96 93 Freestanding (Legacy) For optimum efficiencies UPS systems should be greater than 75% loaded Month DD, Year Slide 11
TCO Energy Efficiency (Example) Energy Cost typical commercial tariff 0.10 $/kwh Cooling factor 0.4 Freestanding Modular Percentage load 50% 75% Efficiency 90% 95% Critical load 1,000 kw 1,000 kw Total UPS input power 1,111 kw 1.052 kw Total UPS heat loss 111 kw 53 kw UPS losses cost per year $ 97,333 $ 46,105 Cooling costs per year $ 38 933 $ 18,442 TOTAL COST PER YR $ 136,267 $ 64,547 Electricity saving over 5 years $ 358,596 Month DD, Year Slide 12
Total Cost of Ownership Energy efficiency Don t look only at the initial costs, but take also into consideration the TCO Efficiency difference 1% 3% 5% Load (kw) 5 years 10 years 5 years 10 years 5 years 10 years 1,000 $ 68k $ 686k $ 210k $ 2,104k $ 358k $ 3,585k 5,000 $ 343k $ 3,433k $1,052k $10,524k $1,792k $17,929k Energy cost savings kwh cost $0.10 Cooling factors 0.4 Month DD, Year Slide 13
Input PF (%) DPA UPScale TM / Environmental Friendly Reduced TCO Input Power Factor versus load Advanced Booster PFC circuit to provide near-unity Input PF even with partial loads. 1 0.9 0.8 0.7 0.6 0.5 0.96 0.985 0.99 25% 50% 75% 100% Load %) 0.99 Benefits: No phase compensation filter required Respect power grid regulations Energy savings 27 March 2011 DPA UPScale 14
Scalability & Flexibility Right Sizing?? 8 Large space required : expensive 8 Large cables : expensive 8 Lower efficiency : high losses 8 Dedicated cooling system: expensive 8 Redundancy far from load UPS 1 UPS 2 Cooling System INITIAL INVESTMENT COST.. HIGH TCO... HIGH. 28 Conceptpower March DPA 15 2011
Scalability & Flexibility Right Sizing with Modules!! O O O O O O O O O 8 Modular UPS design (pay as you growth) 8 Simpler and less expensive cabling 8 Redundancy close to point of use 8 Reduced floor space utilization 8 No dedicated cooling system 8 Easy to service - replacement modules 8 High speed of deployment O O O O O O FREE SPACE - UPS ROOM REQUIRED INITIAL INVESTMENT COST LOWER TCO... LOWER 28 Conceptpower March DPA 16 2011
Standardization benefits Energy efficiency, over capacity vs. right sizing 1200kW + 1200kW system 3000kW + 3000kW system Centralized power protection concept: Power demand can vary greatly, from 500kW up to 3 MW and above. Only a modular UPS is capable to adapt changes in power demand in a changing infrastructure
DPA 500 Modular Scalability Enables Standardization of the Power Protection in Data Centers
Centralised large tier 4 system using monobock UPS in parallel G G G G UPS System A UPS System B 6 x 500kW 6 x 500kW Mechanical loads A PDU s A Load PDU s B Mechanical loads B 19
Modular UPS development leads to higher power Module of 100kW a complete UPS Bypass input 100kW UPS module Rectifier input Critical Load November 3, 2014 Slide 20
Bypass input Rectifier input 500 kw Frame IA1 100 kw Critical Load 100 kw 100 kw 100 kw 100 kw November 3, 2014 Slide 21
Newave SA 22 Master your power
Concept Further scalability up to higher power (3MW) Frames can be connected in parallel to achieve 3 MW system total power. Multiple benefits follow from the advanced scalability: Adding capacity to system is easy Adding redundancy to increase availability and reliability becomes easy Standardizing UPS system to serve load segments of different sizes is reality
Benefits of standardization Savings w/o surprises both when building and when operating a data center Modular scalability enables the users with various types and sizes of data centers to: Optimize the solution according to the needs of each data center or each load segment Increase the system availability and gain savings due to simple and standardized power protection concept and due to very efficient service concept Small or big growing modular
PCS100 4000kVA UPS-I Mega Sized UPS November 3, 2014 Slide 25
4000kVA UPS-I SLD Drawing The 4000kVA UPS-I is made up of 3 x 1350 kva Energy delivery units (EDU s) and one utility disconnect (SCR Switch) The System master controls the Energy delivery units and the Utility Disconnect (SCR switch) The system is fault tolerant with many levels of redundancy November 3, 2014 Slide 26
Mega UPS Integration Supply A 22kV Supply B 22kV Single 4000kVA system advantages 22kV 22kV Reduced infrastructure cost Only two 22kV ACB s required 0.480kV K 0.480kV Small footprint Features Multi level redundancy Storage string redundancy Inverter redundancy 4000kVA UPS-I DC protection Utility Disconnect Energy delivery unit redundancy Storage Inverters Coupling TX Charger Redundancy Fail safe protection integrated into the maintenance bypass Protected Loads November 3, 2014 Slide 27
Mega UPS Integration Distributed loading on loading on dual 22kV supplies No Backup UPS-I required due to the integrated redundancy in UPS-I Supply A 22kV Supply B 22kV 22kV 22kV 22kV 22kV 22kV 22kV 22kV 22kV 0.48kV 0.48kV 0.48kV 0.48kV 0.48kV 0.48kV 0.48kV 0.48kV 4000kVA UPS-I 4000kVA UPS-I 4000kVA UPS-I 4000kVA UPS-I Load Load Load Load November 3, 2014 Slide 28
Mega UPS Plant Integration With Maintenance Backup UPS-I Additional UPS-I for Maintenance and redundant backup Maintenance and redundant backup UPS-I 22kV 22kV 22kV 22kV 22kV 22kV 22kV 22kV 0.48kV 0.48kV 0.48kV 0.48kV 0.48kV 0.48kV 0.48kV 0.48kV 4000kVA UPS-I 4000kVA UPS-I 4000kVA UPS-I 4000kVA UPS-I Load Load Load November 3, 2014 Slide 29
4000kVA Layout 5 Minute Design No maintenance bypass or storage Coupling Transformer EDU 1 Coupling Transformer EDU2 Coupling Transformer EDU 3 This area for AC and DC internal power cabling where there is no cable trench System Master Inverter Modules EDU 1 Inverter Modules EDU 2 Inverter Modules EDU 2 Utility Disconnect Circuit Breakers Customer Connections November 3, 2014 Slide 30 System Master Inverter Modules EDU 1 Inverter Modules EDU 2 Inverter Modules EDU 2 Utility Disconnect Circuit Breakers
4000kVA Layout 5 Minute Design No maintenance bypass or storage Most compact layout, Cable trenches required November 3, 2014 Slide 31
Utility Disconnect Overload Capability Preload of 4.0MVA @ 27 degrees Celsius Amps Overload capability 13000 60 seconds 5052 Amps 12000 11000 30 seconds 6315 Amps 10000 10seconds 8420 Amps 9000 8000 5 seconds 12630 Amps 7000 Not more than once every 10 minutes 6000 5000 Fault current 4000 0 10 20 30 40 50 60 Seconds 65kA 25 milli seconds Power Flow Utility Load November 3, 2014 Slide 32
Utility Disconnect Utility Disconnect Current rating 4810amps (4000kVA, 480V) at 27 o C Current rating 4330amps (3600kVA, 480V) at 40 o C Utility Disconnect Temperature V s KVA Rating Inlet air filters kva 4100 4000 3900 3800 3700 3600 3500 3400 3300 3200 3100 3000 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Degrees Celsius November 3, 2014 Slide 33
Energy Delivery Unit (EDU) Specifications Capacity Rating 3 x 1350 kva (4050 kva) Displacement Power Factor of Connected Load 0.5 lagging to 0.9 leading (dependent on battery available) Crest Factor for Rated kva 2.2 Maximum allowed directly connected motor <1.8ms transfer Overload Capability 25% of rated kva Contact ABB for applications with greater than directly connected motors 122% for 30 s Displacement Power Factor of Connected Load 0.5 lagging to 0.9 leading EDU s November 3, 2014 Slide 34
Downstream Fault While the EDU s are supporting the loads EDU system nominal rating 4050 kva, 4870 amps 3 x EDU s into a short circuit 133% for 500ms (6479 Amps) 2 x EDU s into a short circuit 133% for 500ms (4319 Amps) If the fault does not clear in 500ms the Utility disconnect (Static Switch) will be turned on, this will allow the utility voltage to clear the fault When the fault clears the UPS-I will continue operation The EDU units will not be damaged by this event Loads Utility Loads Power Flow Loads Loads Power Flow Power Flow Power Flow Fault November 3, 2014 Slide 35
4000kVA UPS-I Energy Delivery Unit Rating. EDU s kva 5000 EDU Duration on Batteries Verses Load 4500 4000 3 x EDU s functioning 3500 3000 2500 2 x EDU s functioning 2000 1500 1000 1 x EDU functioning 500 0 Minutes November 3, 2014 Slide 36
4000kVA Float Charger Redundancy Float Charger To maximize system efficiency the inverter chargers shut down after the bulk charge is complete. Then the low power float charger continues to charge the batteries to 100% charge The float charger cycles to maintain the float voltage on the batteries at 780VDC (adjustable to suit specific battery chemistry) Inverter Charger If a float charger fails the inverter chargers will maintain the battery charge. Normal inverter redundancy applies during charger function November 3, 2014 Slide 37