HIGH-RELIABILITY
DESIGNS
FOR ECONOMICAL
DATA CENTERS
Design Features that Add
Reliability to Data Centers
while Reducing Costs per kW
Michael Mosman, PE
CCG FACILITIES INTEGRATION INCORPORATED
Vice President, Chief Technology Officer
Baltimore, MD
Discussion Topics
 Raise the System Voltage
 Transform Big, Close and Wet
 Eliminate Stranded Capacity
 Protect More with Less
CCG FACILITIES INTEGRATION INCORPORATED
Raise the System Voltage
Voltage makes a big difference in the amount of copper.
Each of these ductbanks can carry 2500 kVA.
480 VOLT, 3-PHASE, 4-WIRE
4160 VOLT, 3-PHASE, 3-WIRE
4000 AMP, 75’ LONG
(8) SETS: (4) 750kCM XHHW in 4” PVC
600’ of 4” PVC
2720’ of 750kCM CU WIRE
6 CU YD of CONCRETE
(64) 600 V TERMINATIONS
500 AMP, 75’ LONG
(3) 500kCM 5kV XLPE in 5” PVC
75’ of 5” PVC
180’ of 500kCM CU SHIELDED CABLE
2 CU YD of CONCRETE
(6) 5 kV TERMINATIONS
$72,000*
$10,000*
*
INCL. LABOR, MATERIAL, O&P (YOUR MILEAGE MAY VARY)
CCG FACILITIES INTEGRATION INCORPORATED
Raise the System Voltage
A progression of design and construction techniques
From this
To this
CCG FACILITIES INTEGRATION INCORPORATED
Raise the System Voltage
A little bit of transformation buys a lot of copper.
UTILITY SERVICE
E
SERVICE
TRANSFORMER
G
UTILITY SERVICE
E
MAIN SWBD
ESSENTIAL
LOAD
UPS
MAIN SWGR
DISTRIBUTION
TRANSFORMERS
ESSENTIAL
LOAD
CRITICAL
LOAD
TYPICAL 480 VOLT SYSTEM
2500 kVA TRANSFORMER
2000 kW, 480V E-G
4000A, 480V MAIN SWBD
1000 kVA, 480V UPS
$1,250,000
CCG FACILITIES INTEGRATION INCORPORATED
SERVICE
TRANSFORMER
G
UPS
CRITICAL
TYPICAL 4I60 VOLT SYSTEM
LOAD
2500 kVA TRANSFORMER
2000 kW, 4160V E-G
1200A, 4160V MAIN SWGR
(2) 4160 – 480V TRANSFORMERS
1000 kVA, 480V UPS
$1,050,000
Transform Big, Close and Wet
Close-coupled, liquid-filled, indoor unit-substations save money.
• High efficiency
• Biodegradable, high
flashpoint fluid
• Integrated primary &
secondary protection
• Dual primary selection
CCG FACILITIES INTEGRATION INCORPORATED
Transform Big, Close and Wet
Hardened data center (HDC) transformers are the most reliable.
High primary
impulse levels
with both
insulation and
wire spacers
Incorporated
protection CTs
Welded and braced
secondary leads
Immersed vacuum
fault interrupters
and source
selection switches
Immersed tap
changers
CCG FACILITIES INTEGRATION INCORPORATED
Transform Big, Close and Wet
(1) 4160V PDU in a closet replaces (5) 480V PDUs on raised floor
1000kVA 4160V –
230/400V PDU with
1500kVA continuous
overload capability
(without cooling fans)
and 99.5% efficiency
Secondary feeder #1 overhead
Protective relay and power meter
Secondary bushings, two
sets (cabinet not installed)
Cooling vent (from
computer room)
Containment basin
(partially installed)
Primary feeder UG
CCG FACILITIES INTEGRATION INCORPORATED
Dual primary bushings
(cabinet not installed)
Secondary feeder #2 under slab
Transform Big, Close and Wet
Next Generation MV PDU – 1.5/2 MVA, 4160 V
CCG FACILITIES INTEGRATION INCORPORATED
Eliminating Stranded Capacity
What Is “Stranded Capacity”?
Future
capacity
earmarked
for growth is
NOT
stranded
capacity.
“Red-lined”
portion of
capacity is
NOT
stranded
capacity.
Unit
“A”
Unit
“B”
A B
“Dual-Corded” Load
Stranded capacity IS the unused capacity
of one system which is not available to
serve another system’s load.
Stranded capacity cannot be
eliminated by simply deferring
equipment deployment.
CCG FACILITIES INTEGRATION INCORPORATED
1
2
Reserved
capacity for
redundancy
is NOT
stranded
capacity.
Eliminating Stranded Capacity
Traditional system configurations may have stranded capacity.
E
E
UTILITY
UTILITY
MAIN SWB
MAIN SWB
G
NORMAL
LOAD
G
ESSENTIAL SWB
E
G
E
ESSEN SWB A
ESSENTIAL
LOAD
G
NORMAL
LOAD
ESSEN SWB B
ESSENTIAL
LOAD A
ESSENTIAL
LOAD B
STS
CRITICAL
LOAD “A”
CRITICAL LOAD
PARALLEL-REDUNDANT
CCG FACILITIES INTEGRATION INCORPORATED
SINGLE-CORDED
CRITICAL LOAD
DUAL REDUNDANT (N+N)
CRITICAL
LOAD “B”
Eliminating Stranded Capacity
New Iso-Parallel configuration eliminates stranded capacity.
UTILITY
UTILITY
MAIN SWB 1
E
G
NORMAL
LOAD
ESSEN SWB 1
ESSENTIAL
LOAD 1
MAIN SWB 2
E
MAIN SWB 3
E
G
ESSEN SWB 2
ESSENTIAL
LOAD 3
IP BUS
CRITICAL LOAD 2
ISOLATED-PARALLEL REDUNDANCY
CCG FACILITIES INTEGRATION INCORPORATED
G
ESSEN SWB 3
ESSENTIAL
LOAD 2
IP CHOKE
CRITICAL LOAD 1
UTILITY
CRITICAL LOAD 3
Eliminating Stranded Capacity
Advantages of an IP design
• All loads shared equally by all
modules
• No single point of failure
• No designated redundant
modules
• Higher module efficiency
• Modules operate independently
• Faults isolated to one module
• Loads always on UPS
CCG FACILITIES INTEGRATION INCORPORATED
Protect More With Less
Traditional MV Protection Scheme
OVERCURRENT
PROTECTION (6)
587Z
DIFFERENTIAL
PROTECTION (2)
CCG FACILITIES INTEGRATION INCORPORATED
587Z
Protect More With Less
Economical Protection Scheme
CCG FACILITIES INTEGRATION INCORPORATED
COMBINED DIFFERENTIAL AND
OVERCURRENT PROTECTION
Products That Lead to Economical Reliability
Medium voltage arc-containing switchgear
FR3 liquid cooled transformers
Iso-Parallel configured UPS systems
Multi-function protective devices
CCG FACILITIES INTEGRATION INCORPORATED
For more information, please contact:
CCG FACILITIES INTEGRATION INCORPORATED
1500 S. Edgewood Street, Baltimore, MD 21227
Phone (410) 525-0010