ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011
METRO POWER COMPANY
PERTH DATA CENTRE
A report submitted to the School of Engineering and
Energy, Murdoch University in partial fulfilment of the
requirements for the degree of Bachelor of
Engineering
Student Name: Raymond Kilgariff
Student Number: 30759032
November 2011
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Acknowledgements
I would especially like to acknowledge the Managing Director of Metro Power Company, Mr. Timothy Edwards.
Without his guidance, teachings and understanding, this report would not be possible.
I would also like to acknowledge Dr. Gregory Crebbin, my academic supervisor, whose support and teachings have
been invaluable.
I would also like to acknowledge the following business employees and associates of Metro Power Company;
Matt Terry (Mazda Computers)
Kevin Allan (Corporate Backup)
Michael Henderson (Metro Power)
Steven Gee (Metro Power)
Helen Joyce (Department of Commerce WA)
Most of all I would like to acknowledge my beautiful fiancé for her patience, support and understanding during
this internship process.
Thank you all!
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Abstract
The Perth Data Centre (‘PDC’) project’s aim is todetail the design and engineering of power reticulation,
including backup power (generator & UPS) for a new data centre at 1020 Wellington Street West Perth.
The following initial project deliverables are as follows:
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Master single line diagram of 415v and 240v distribution using Microsoft Visio
Cable sizing and selection calculations, protection system calculation and grading
Basic scaled layout drawings using sketch tools
Material selection and quantities B.O.M
Generator control system parameterization design for automatic transfer switching on
mains failure, including fault monitoring to Metro Operation & Control Centre (‘OCC’) and
remote control
UPS control system parameterization design, including fault monitoring to Metro OCC
Energy and current monitoring design, equipment research and selection
Integration design of monitoring and control of system status to Metro OCC
Installation and commissioning support
This report introduces Metro Power Company and Perth Data Centres PTY LTD. The project
management methodology, scope and change management issues are discussed.
The body of this report contains the project analysis, describing the execution of the project
deliverables; objectives, research/literature review, progress/analysis, problems/issues and scheduling.
Following this are the recommendations and conclusion.
The project scope has expanded not through requirement for the internship but through the
requirement of the project itself. For the purpose of the internship, the scope remains constrained
within the initial deliverables, plus necessary additions to fulfil the deliverable requirements. However,
for the purpose of completing the whole project, whereas the internship was only assigned a subset as
per the aim and objective above, the responsibility has been undertaken to assist in the expanded
works to complete the required task, as the internship contract runs significantly past the due date of
this report (Report Due Date: 18 November 2011, Contract Termination Date: 1st February 2012).
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Contents
List of Figures .............................................................................................................................. 6
1.0 Introduction ...................................................................................................................... 7
1.1 Metro Power Company& Perth Data Centres PTY LTD..................................................... 7
1.2 Project Aim ..................................................................................................................... 8
1.3 Project Type ................................................................................................................... 8
1.4 Literature Review ........................................................................................................... 8
2.0 Project Management ......................................................................................................... 9
2.1 Methodology .................................................................................................................. 9
2.2 Scope & Change Management ........................................................................................ 9
2.3 Scheduling .................................................................................................................... 11
3.0 Project Analysis ............................................................................................................... 12
3.1 Drafting - Basic Layout Diagrams .................................................................................. 12
3.1.1 Scope & Objective .................................................................................................. 12
3.1.2 Progress/Analysis ................................................................................................... 12
3.2 Energy and current monitoring design, equipment research and selection .................... 14
3.2.1 Scope & Objective .................................................................................................. 14
3.2.2 Research/Analysis/Issues ....................................................................................... 14
3.2.3 Optioning, Selection & Procurement ...................................................................... 17
3.2.4 Schedule, Installation & Commissioning ................................................................. 18
3.3 Uninterruptible Power Supply (UPS) Procurement ........................................................ 19
3.3.1 Scope & Objective .................................................................................................. 19
3.3.2 Literature Review / Research ................................................................................. 19
3.3.3 Optioning, Selection & Procurement ...................................................................... 26
3.3.4 Schedule, Installation & Commissioning ................................................................. 30
3.4 Master single line diagram of 415v and 240v distribution using Microsoft Visio ............ 31
3.4.1 Scope & Objective .................................................................................................. 31
3.4.2 Design & Analysis ................................................................................................... 31
3.5 Power System Analysis ................................................................................................. 34
3.5.1 Scope & Objective .................................................................................................. 34
3.5.2 Power Availability .................................................................................................. 34
3.5.3 Load Analysis ......................................................................................................... 34
3.5.4 Schedule, Installation & Commissioning ................................................................. 38
3.6 Automatic Transfer Switch (ATS)................................................................................... 39
3.6.1 Scope & Objective .................................................................................................. 39
3.6.2 Analysis .................................................................................................................. 39
3.6.3 Schedule, Installation & Commissioning ................................................................. 39
3.7 Generator ..................................................................................................................... 42
3.7.1 Specifications ......................................................................................................... 42
3.7.2 Cable sizing and selection calculations and installation ........................................... 43
3.7.3 Battery Charger ...................................................................................................... 49
3.7.4 Exhaust .................................................................................................................. 53
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3.8 Electrical installation, standards, protection system calculation and grading ................ 58
3.8.1 Scope & Objective .................................................................................................. 58
3.8.2 Research, Design & Analysis ................................................................................... 58
3.9 UPS Distribution & Fire Protection System .................................................................... 70
3.9.1 Scope & Objective .................................................................................................. 70
3.9.2 Design & Analysis ................................................................................................... 70
3.9.3 Schedule, Installation & Commissioning ................................................................. 72
3.10 Monitoring & Control Design, Implementation & Integration ....................................... 73
3.10.1 Scope & Objective .................................................................................................. 73
3.10.2 Research, Design, Analysis & Issues ........................................................................ 73
3.10.3 Schedule, Installation & Commissioning ................................................................. 78
3.11 Bill of Materials (BOM) ................................................................................................. 78
3.11.1 Scope & Objective .................................................................................................. 78
3.11.2 Analysis, Schedule & Commissioning ...................................................................... 78
4.0 Engineering Competencies Addressed .............................................................................. 79
4.1 Engineering Practice & Engineering Business Management ........................................... 79
4.2 Engineering Planning and Design .................................................................................. 79
4.3 Engineering Operations ................................................................................................ 79
4.4 Materials/Components/Systems & Research/Development/Commercialisation ........... 79
4.5 Self-Management in the Engineering Workplace& Engineering Project Management ... 79
4.6 Environmental Management ........................................................................................ 80
4.7 Investigating and Reporting .......................................................................................... 80
5.0 Recommendations ........................................................................................................... 80
5.1 Communication ............................................................................................................ 80
5.2 Planning ....................................................................................................................... 80
5.3 Product Assessment Matrices ....................................................................................... 81
6.0 Conclusion ....................................................................................................................... 81
Bibliography & References ........................................................................................................ 82
Appendix A.1 – Initial Gantt Chart Draft .................................................................................... 90
Appendix A.2 – Final Gantt Chart ............................................................................................... 91
Appendix B – Energy Metering Options – Product Assessment Matrix ....................................... 92
Appendix C – UPS Options – Product Assessment Matrix ........................................................... 93
Appendix D – MTX UPS System – Specifications......................................................................... 94
Appendix E – Generator Specifications ...................................................................................... 95
Appendix G.1 – Battery Charger – Product Assessment Matrix .................................................. 99
Appendix G.2 – Project IC-800-24 Specifications .......................................................................100
Appendix H – Ceramic Quoting – Product Assessment Matrix and Costing Estimate .................101
Appendix I – UPS Distribution Diagram .....................................................................................102
Appendix J – Monitoring & Control Diagram .............................................................................103
Appendix K – PDC Web Interface Screen Shots .........................................................................104
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List of Figures
Figure 1 – Traditional Project Management Methodology (Haugan 2011) .................................................................................................... 9
Figure 2 - 1020 Wellington St Building Provided 3D Layout ......................................................................................................................... 12
Figure 3–Initial PDC Layout Plan - VISIO ....................................................................................................................................................... 13
Figure 4 - Internal Fit-out – Partially Complete ............................................................................................................................................ 13
Figure 5 - Lanx Australis - Energy Meter Specifications - (LANX AUSTRALIS 2010) ...................................................................................... 18
Figure 6 - Table of UPS Architectures (Rasmussen, The Different Types of UPS Systems - White Paper 1 2011) ........................................ 20
Figure 7 - Modular UPS System (Emerson Network Power 2004) ................................................................................................................ 21
Figure 8 - 1+1 Parallel Redundancy (Emerson Network Power 2004) .......................................................................................................... 22
Figure 9 - 1+1 Parallel Redundancy – (Socomec, 2011) ................................................................................................................................ 22
Figure 10 – Scale of availability and cost for UPS configurations - (McCarthy and Avelar 2011) ................................................................. 23
Figure 11 - UPS Configurations – Tiers I and II (McCarthy and Avelar 2011) ................................................................................................ 23
Figure 12 - UPS Configurations – Tiers III and IV (McCarthy and Avelar 2011)............................................................................................. 24
Figure 13 - PDC UPS Configuration – “1+1 Load Distributed” ...................................................................................................................... 25
Figure 14 - Maximum Load Capacity of Various Common Circuits Used Globally (Avocent, 2011) ............................................................. 26
Figure 15 - MTX Standard Backup Time (Alpha Power Systems PTY LTD 2008) ........................................................................................... 29
Figure 16 - UPS External Bypass Switch Configuration (Chu 2011) .............................................................................................................. 30
Figure 17 - Draft SLD ..................................................................................................................................................................................... 32
Figure 18 - Master Single Line Diagram - Final ............................................................................................................................................. 33
Figure 19 - Data Centre Density Example ..................................................................................................................................................... 35
Figure 20 - Available Rack Calculation .......................................................................................................................................................... 36
Figure 21 - Per Rack Power Density Trend (Patterson and Fenwick 2008) ................................................................................................... 37
Figure 22 – Air conditioning rack air flow ..................................................................................................................................................... 38
Figure 23 - ATS Installation Progress ............................................................................................................................................................ 40
Figure 24 - DSE-705 Wiring Diagram (DEEP SEA ELECTRONICS PLC 2003) ................................................................................................... 41
Figure 25 - X-Ray Side View Standby Generator Placement ......................................................................................................................... 42
Figure 26 - Voltage Drop Calculation AS/NZ 3000 ........................................................................................................................................ 44
Figure 27 - Graph & Table of Voltage Drop vs. Cable Size ............................................................................................................................ 45
Figure 28 - Voltage Drop Table for 3 Phase Multi-core Cable ...................................................................................................................... 45
Figure 29 - Short Circuit Temperature Rise Equation – AS3008 ................................................................................................................... 46
Figure 30 - Cable Sizing Based Upon Current Carrying Capacity Table 13 AS3008 ....................................................................................... 47
Figure 31 - Cablesizer.com solution (www.cablesizer.com 2011) ................................................................................................................ 48
Figure 32 - Cable Installation ........................................................................................................................................................................ 49
Figure 33 - Battery Charger Calculation (Livingston 2007) ........................................................................................................................... 50
Figure 34 - Battery Charger Sizing Table....................................................................................................................................................... 51
Figure 35 - CTEK MXT 4.0 Battery Charger Stages ........................................................................................................................................ 51
Figure 36 - Generator Exhaust External ........................................................................................................................................................ 53
Figure 37 - Generator Exhaust Internal ........................................................................................................................................................ 54
Figure 38 - Exhaust Pipe Layout 2D – Final (After Modification) .................................................................................................................. 54
Figure 39 - Exhaust Pipe Error ...................................................................................................................................................................... 55
Figure 40 - Exhaust Gas Back Pressure Calculation ...................................................................................................................................... 56
Figure 41 - Exhaust Installation .................................................................................................................................................................... 57
Figure 42 - Protection Against overload current - (AS300, P77) ................................................................................................................... 60
Figure 43 - Time for short circuit to raise conductor temperature (Standards Australia 2009) ................................................................... 61
Figure 44 - Master SLD - 1020 Wellington St (GRAY 2000) ........................................................................................................................... 62
Figure 45 - Cascading & Discrimination Coordination (Schneider Electric PTY LTD 2003) ........................................................................... 63
Figure 46 - Table 4.0.2 Schneider Product Catalogue ................................................................................................................................... 64
Figure 47–Clipsal (Left) vs. Merlin Gerin (Right) - Circuit Breaker Time-Current Curves .............................................................................. 64
Figure 48 - MEN System ............................................................................................................................................................................... 66
Figure 49 - Earth Fault Loop Impedance Diagram (ElectroTECHnik Pty Ltd 2009) ....................................................................................... 67
Figure 50 - Earth Fault Loop Impedance Calculation (ElectroTECHnik Pty Ltd 2009) ................................................................................... 68
Figure 51 - UPS Power Distribution .............................................................................................................................................................. 71
Figure 52 - Table of PyroRack Alarm Signals ................................................................................................................................................. 71
Figure 53 - Monitoring and Control Diagram ............................................................................................................................................... 73
Figure 54 - MOXA Device configurations ...................................................................................................................................................... 74
Figure 55- SVG Objects ................................................................................................................................................................................. 77
Figure 56 - PDC Web Interface Overview Screen ......................................................................................................................................... 78
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1.0 Introduction
1.1 Metro Power Company& Perth Data Centres PTY LTD
Metro Power Company’s main business driver is the provision of smart energy management services
using its proprietary intelligentE2M smart grid technology as described on the company’s website (Metro
Power Company 2011).
The E2M technology facilitates:
• Predictive Energy Management (PEM)
• Energy Efficiency Control
• Automated Demand Side Management
Metro Power Company also provides Engineering, Procurement and Construction Management (EPCM)
services specialising in (Metro Power Company 2011):
Generation Options (Feasibility Studies)
Peak Shaving Generation EPCM
Tri-gen/Co-gen EPCM
Standby - Emergency Generation (ATS / Bumpless / Synchronising)
Western Power Connection Applications
Power Station control system upgrades
Peak Demand Limiting, shedding and protection schemes
Automated power management systems
Energy monitoring and targeting system implementation (multi-vendor)
Power measurement and recording implementation (HV, MV, LV)
Industrial & Resource electrical contracting and consulting
Design drawing and 3D modelling
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The Perth Data Centres PTY LTD is a new venture that the Managing Director of Metro Power Company
has started together with Matt Terry (Mazda Computers) and Kevin Allan (Corporate Backup) to provide
niche co-location data centre services for the Perth metropolitan area. The results of this project shall
prepare Perth Data Centres to offer the following competitive advantages:
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POWER from the PMH Hospital grid, the most reliable in Perth
EASE OF NETWORK ACCESS
DEAL DIRECT with Owners.
Japan-made generation
Modular redundant UPS
VSD-driven cooling
E2M-energy management
Fire suppression
Co-location options available
High-density rack space also available.
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1.2 Project Aim
The aim of the project is to complete the detailed design, engineering and implementation of the power
reticulation, including backup power (generator & UPS), for a new data centre (‘PDC’) at 1020 Wellington
Street West Perth.
1.3 Project Type
The PDC project is a standard engineering research, design and implementation project.
The research entails:
•
•
•
Review and procurement of the available products and infrastructure required to complete the
deliverables leading to a solution that is the most suitable economically and with respect to the
required design parameters.
Investigation into the engineering methods and standards necessary to complete the tasks.
Investigation into the industry trends and practices with respect to data centre infrastructure.
This report reflects the nature of the project providing a review of the process and tasks involved as well
as the progress, results and outcomes of the project deliverables.
1.4 Literature Review
The literature review for this engineering report includes the information from technical whitepapers
with respect to data centre technology and power reticulation.
Rather than presenting the literature as one complete ‘review’, literature reviews are presented for each
respective project analysis deliverable objective where applicable.
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2.0 Project Management
2.1 Methodology
The project management methodology incorporated for this project is a traditional approach as depicted
in Figure 1.
Figure 1 – Traditional Project Management Methodology (Haugan 2011)
The traditional approach was utilised for this engineering project as it most accurately reflects the
process of iteration throughout the project lifecycle. The project approach is very cyclical as the project
progressed the scope of the required deliverable became further defined and the planning and design
stage was revisited.
2.2 Scope & Change Management
The fundamental scope of the project remains consistent with the initial project brief as provide by the
Managing Director, Mr Timothy Edwards.
Change management has incorporated the management of the expansion of scope, which has arisen due
to the enhanced comprehension and definition of the project deliverables as well as linked project tasks
(such as the generator exhaust design) requiring design and completion for the project aim to be
fulfilled. Coupled with the overall larger project, which has the fundamental objective of opening the
PDC as a commercial enterprise, being a priority, the project deliverables have been re-structured to
more accurately reflect the flow of work, the scope change and to allow for logical and succinct
reporting. These ‘expansions of scope’ could be considered as scope creep, however the project brief
provided the initial deliverables, and it was the definition of these deliverables that required refining. As
per the recommendations in Section 5, the communication in the project management should have been
better established from the project manager’s perspective (the author) to clearly define the scope and
objectives of the deliverables. In contrast, the deliverables were further defined as the project
progressed and deliverables required fulfilment with the supervision of the Managing Director. The
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project deliverables have been slightly re-structured to more accurately reflect the project requirements
and process.
The initial deliverables as given in the project brief are:
•
•
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Master single line diagram of 415V and 240V distribution using Microsoft Visio
Cable sizing and selection calculations, protection system calculation and grading
Basic scaled layout drawings using sketch tools
Material selection and quantities B.O.M
Generator control system parameterization design for automatic transfer switching on mains
failure, including fault monitoring to Metro Operation & Control Centre (‘OCC’) and remote
control
UPS control system parameterization design, including fault monitoring to Metro OCC
Energy and current monitoring design, equipment research and selection
Integration design of Monitoring and control of system status to Metro OCC
Installation and commissioning support
The report layout and the final deliverables are given as:
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Drafting - Basic scaled layout drawings using sketch tools
Energy and current monitoring design, equipment research and selection
UPS optioning, selection & procurement
Master single line diagram of 415V, 240V and UPS distribution using Microsoft Visio
Power System & Load Analysis – added to illustrate the power and load constraints for the
PDC project
Auto Transfer Switching (ATS)
Generator
o Specifications
o Cable sizing and selection calculations.
o Battery Charging
o Exhaust/Flue System design, optioning, selection & procurement
Electrical installation, standards, protection system calculation and grading
UPS Distribution &Fire Protection System – the fire protection system is integrated with the
UPS electrical reticulation and therefore is presented as a distinct sub-section
Monitoring & Control Design, Implementation & Integration
o Security System Design
Bill of Materials
Assistance with Installation & Commissioning
The final layout of deliverables more accurately reflects the interconnection between project tasks and
was only clarified as the project reached its final stages.
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Certain tasks outlined in the report (such as the Security System Design) are not necessarily part of the
required project deliverables, however they are described in this report to highlight their relationship
with essential tasks (such as Monitoring & Control) and the overall PDC project.
The ‘Fire Protection System’ deliverable has been included as a necessary requirement that provides the
scope and constraints for the power reticulation deliverable as will be described in section 3.0.
For this final report the initial layout drawings as provided will be introduced, and the software tools
utilised for drafting. However the discussion on particular layout will be given in the respective
deliverable tasks as part of the design process.
Furthermore, the installation and commissioning deliverable will be described as a sub-task of each of
the individual tasks, though it is depicted as a separate task on the Gantt chart for resourcing.
2.3 Scheduling
The project is managed by Microsoft Project to ensure changes in scheduling and tracking are
maintained within the project scope.
The project schedule has been delayed and extended mainly due to issues with equipment procurement
(as discussed in the following sections) and availability of resources necessary to complete the PDC
deliverables (mostly installation tasks that require the Managing Directors time), as well as the more
important/significant business commitments and projects of Metro Power Company taking precedence.
Of note, the Managing Director identified that the project schedule could have been maintained if:
a) he had assigned or delegated further resources to the project; and
b) procurement of long-lead items could have been authorised earlier
The comparison of the previous schedule (provided in the progress report) and the current schedule is
given in Appendix A.1 and A.2. Significant differences exist predominately due to the deliverables
restructure as given above and obviously the timing of completion of the milestones.
Detailed scheduling information with respect to each project deliverable is given in the respective subsections of section 3.
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3.0 Project Analysis
The main section of the internship report incorporates the analysis of the project deliverables.
3.1 Drafting - Basic Layout Diagrams
3.1.1
Scope & Objective
The objective of this task is to provide scaled layout diagrams of the physical installation
components as part of the project documentation and referencing. The Managing Director
considered the competence of the Project Manager (Author) in using AutoCAD® or
MicroStation® and the availability of suitable drafting resources to define the drafting
software for the task.
The drafting design component of the project was completed in Google SketchUp and
Microsoft VISIO, with electrical diagrams and researched product schematics also provided
in MicroStation® (DGN) and AutoCAD® (DWG) formats, these were used for engineering
references and checking product specifications. This task was scheduled to run for the
duration of the project, as planning documents would be revised to provide ‘as built’ final
plans for the completion of the project.
3.1.2
Progress/Analysis
The master layout of the proposed project location was already designed in SketchUp, which
provided an appropriate template to design the individual project tasks and their layout
requirements as given in Figure 2. The initial layout plan of the PDC was also provided in
Microsoft VISIO as shown in Figure 3.
Figure 2 - 1020 Wellington St Building Provided 3D Layout
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Figure 3–Initial PDC Layout Plan - VISIO
These layouts depict the complete building architecture. Figure 2 shows Unit 18, which is directly above
the driveway entrance to the private car park. To the left of the driveway is the PDC commercial unit,
where the rack infrastructure and internal electrical fit out (switchboards, ATS, UPS etc. see example
Figure 4) are housed. Figure 2 also shows the location of the proposed generator installation. This area
was designed as the rubbish bin area, however the location was flawed as the waste management truck
could not enter the area.
Figure 4 - Internal Fit-out – Partially Complete
As defined in section 2.3.2, the remaining layout diagrams are presented in their respective project task /
deliverable analysis sections where relevant.
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3.2 Energy and current monitoring design, equipment research and selection
3.2.1
Scope & Objective
The objective of this task is to design the energy monitoring requirements of the PDC. This
includes the main incomer and generator monitoring, UPS output and customer segregated
energy monitoring with the potential of per rack, half rack or Per Outlet Monitoring (‘POM’)
of the individual customer servers in the data centre racks.
The requirements as set out in the project brief and clarified with further discussion with the
Managing Director include the requirement for monitoring the energy usage/demand of
customers IT equipment with the objective of determining their costs based on
energy/demand coupled with physical rack space requirements. This provides more cost
reflective indication, with the ever increasing rack densities physically and in terms of
energy, of the infrastructure associated with hosting the customer’s equipment in a data
centre.
This task was achieved by researching the available products on the market for current,
power and energy monitoring, and determining the required economic and technical
specifications and attributes that are most suited for the PDC application.
3.2.2
Research/Analysis/Issues
The fundamental research for this task was an investigation into the various product
specifications that could potentially fulfil the task requirements.
There are many methods for determining the customer’s energy/demand requirements
including measuring power (kW), energy (kWh) and maximum current demand (A).
The idea of measuring maximum current demand was considered as a simple method for
assigning a metric to the customer IT load requirements. The idea as presented by one of the
PDC director’s, was to simply measure the customers equipment as it was presented for
installation, with a current clamp meter. The measurement taken would be the maximum
current of the server/equipment as it starts up which would measure the ‘inrush’ current.
Inrush current results from filter capacitor impedance produced from the switching power
supplies in IT equipment, the ‘inrush current’ can be several orders of magnitude greater
than the circuit’s steady state current (Chauvin Arnoux, Inc d.b.a AEMC Instruments 2003).
This measurement provides a method to determine the absolute peak current demand of
the equipment and therefore ensure the rack density is maintained to the threshold limit
(see section 3.5). This method was considered as the only means of measurement to fulfil
the requirements of the task, however it was determined to be insufficient in terms of
auditing requirements from both the customers and the PDC directors perspectives,
although this measure may still be employed, as stated, to ensure the absolute peak demand
is constrained within the rack density threshold.
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Research into products available revealed two main ‘types’ of energy monitoring candidates;
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kWh meters with digital output (mainly pulse, Modbus RTU, Modbus TCP/IP) or,
dedicated Power Distribution Units (‘PDUs’) with per strip or Per Outlet Monitoring
(‘POM’)
The later POM PDU’s provided an attractive option in terms of providing the level of
granularity that can lead to the ability of having multiple customers in the single rack
housing, and therefore provided for a niche data centre co-location service that the PDC
directors would ideally prefer.
The issue with the PDUs is that they only provide current or power (kW) meter readings and
while it is obviously possible to calculate the energy (kWh) values from time indexed kW
data records, there are potential accuracy issues and complexity of implementing the system
utilising the monitoring and control system described in section 3.10. Also, any product that
did provide kWh data required purchase of proprietary software/hardware that would
significantly increase the cost per monitoring point, which was an important metric in
optioning the various products as per the following section.
Another issue that was important in selecting the appropriate energy monitoring device was
the current rating and the ambiguity with the current rating. The current rating is given as
rated/peak value such as 5/45A where it was interpreted that the device could run
continuously at say 5A and cope with transient currents up to 45A. As is further illustrated in
section 3.5 for the load analysis the ‘half rack’ that was settled on as the required granularity
for customer energy measurement is required to handle a continuous load of 7.5A and
therefore the example device given here (5/45A rating) would not be suitable.
This was resolved by contacting a supplier of energy monitoring devices where the following
quote was provided which clarified the issue:
“For kWh meters, following the international standards, they have to be defined in this
way.
The [sic] are 3 main points:
Ib= nominal current, the accuracy class is based on this value.
Starting current: is a % of the nominal current, and it is the lower value.
IMAX(X)= the number inside of the parenthesis indicating the maximum current that you
can measure continuosly [sic].
For instance a kWh meter with 5(50)A is better than another with 20(50)A, because
although the maximum range is the same, the starting current, for the same % will be
lower in the first type than in the second type and the accuracy will be lower in the first
type than in the second type.”
(SACI, Sociedad Anónima de Construcciones Industriales 2011)
Not relying on this source of information, further research was conducted and resulted in
obtaining the appropriate International (IEC 62052-11) and corresponding Australian
Standards (AS 62052.11-2005) which provides the following definitions:
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“3.5.1 Reference current
3.5.1.1
starting current(Ist)
the lowest value of the current at which the meter starts and continues to register
3.5.1.2
basic current(Ib)
value of current in accordance with which the relevant performance of a direct
connected meter are fixed
3.5.1.3
rated current(In)
value of current in accordance with which the relevant performance of a
transformer operated meter are fixed
3.5.2
maximum current(Imax)
highest value of current at which the meter purports to meet the accuracy
requirements of this standard”
(Standards Australia 2005)
The following article was also found which clearly stipulates the relative comparison of the
current ratings.
“The current specification is an important parameter for energy meters as it signifies a
meter’s ability to accurately measure the power consumed by a user’s electrical load. There
are generally two parts to this specification: the basic current (Ib) for direct-connected
meters or the rated current In for transformer-operated meters, and the maximum current
Imax. Of these current ratings, you will typically see the current specification defined in
terms of Ib with the Imax value shown in parentheses. For example, some common values
for the energy meter current specification include 5 (20) A and 5 (30) A.”
(Yao, Ding and Pu 2011)
Furthermore, Yao, Ding & Pu, ran a dynamic range test on a meter with a current rating of
1(100)A and tested the % error for a range of current from 0.2-100A, indicating that the Imax
rating can be measured with the device and therefore theoretically be a constant load.
The device selected in section 3.2.3 technical specifications also state that it has a built in
shunt, a small resistance used to measure the current, therefore this would have a maximum
current rating that can be measured. The maximum rating of current would be that at which
the thermal insulation properties of the meter would break down from the heat dissipation
in the shunt and is related to the IMAX value as above. Therefore, while it would be obviously
detrimental to use a meter with 45A IMAX rating on a 45A continuous load as this would put
the device in its limit, the device should safely be able to handle say a 15A continuous load.
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3.2.3
Optioning, Selection & Procurement
To assist in the decision making process to determine the appropriate equipment for energy
monitoring included creating an assessment matrix of the available energy metering
products with the most significant parameters that affected the decision as listed. Along with
the basic data such as product name, website location, contact name, price, cost/input etc.
The significant energy monitoring device attributes listed are:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
TYPE – PDU, DIRECT, CT or CT required.
Phase – single or three.
Output – Pulse, Modbus, Telnet, Ethernet, RS232.
Accuracy Class – 0.5, 1.
Current Rating - Basic(Max)
Over-Current Tolerance
Voltage Range
AC/Impulse voltage withstand
Power Consumption
Temperature Range
Humidity (AV%/Max%)
Dimension/Weight
Max Cable Size(mm2)
Resettable – Yes or No
Relevant Tech Spec – any other relevant technical specification or note that is
significant to the device operation.
For many devices there was only a few of these specifications, however for completeness all
these attributes were listed to assist in identification of the appropriate device, the full
assessment matrix is attached as Appendix B.
The final selection was determined by the most economical and fit for purpose solution. The
Lanx Australis 5/45A kWh meter was selected at $38 each. This provided a very economical
unit with a small 1 module DIN profile and the following technical specifications:
Standard compliance
IEC62053-21: 2003
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Specifications
Accuracy Class
Reference Voltage ( Un)
Operating Voltage
Impulse Voltage
Rated Current (Ib )
Maximum Rated Current (Imax)
Operating Current Range
Operating Frequency Range
Internal Power Consumption
Operating Humidity range
Storage Humidity range
Operating Temperature range
Storage Temperature range
Overall dimensions(mm)
Weight(kg)
Display
1
230V AC
160-300V AC
6KV 1.2μS waveform
5A
45 A
0.4% Ib~ Imax
50Hz± 10%
<2W/10VA
<75%
<95%
-10º C ~+50º C
-30º C - +70º C
117.5×18×58.5
about 0.12kg (net)
LCD
Figure 5 - Lanx Australis - Energy Meter Specifications - (LANX AUSTRALIS 2010)
3.2.4
Schedule, Installation & Commissioning
The installation and commissioning time for all electrical works was subject to arrival of parts
and the managing directors availability with respect to other business commitments. The
estimated completion time for this task was 10/10/11.A schedule of final installation works is
made for 14/11/11 – 25/11/11 in which time the energy meters will be procured and
installed.
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3.3 Uninterruptible Power Supply (UPS) Procurement
3.3.1
Scope & Objective
The scope of this task was to research the technologies and issues associated with UPS
systems and their implementation in Data Centre Infrastructure, with the objective of
optioning, selecting and procuring the appropriate system for the PDC.
3.3.2
Literature Review / Research
The literature review and research undertaken for this task was the most extensive for the
project. There is a wealth of information particularly from manufacturer’s whitepapers with
respect to UPS installation and in particular data centre power management (see section
3.5). The research undertaken was to inform and assist in understanding the relevant
technologies associated with UPS’s and ensure that the correct equipment was presented for
optioning, selection and procurement. The following is just the most significant and relevant
subset of research undertaken to determine UPS parameters and specifications and does not
represent the complete range of UPS technical and engineering issues addressed as part of
this project.
3.3.2.1 UPS Architecture
One of the first research tasks was to distinguish between the various types of UPS.
UPS technology comes in various topologies, of which, as described in Rasmussen,
“The Different Types of UPS Systems - White Paper 1”(2011), these are the most
common types:
•
•
•
•
•
Standby
Line interactive
Standby-Ferro
Double conversion online
Delta conversion on-line
The description of the architectures, advantages, disadvantages and block
diagrams, as adapted from Rasmussen (2011),are illustrated in Figure 6 - Table of
UPS Architectures ( Adapted from Rasmussen, The Different Types of UPS
Systems - White Paper 1 2011) (this is a brief summary of the features of these
architectures, for more complete descriptions, see Rasmussen, “The Different
Types of UPS Systems - White Paper 1”(2011)).
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Type
Standby
Typical office
type.
Line
Interactive
Dominant
type of UPS in
the 0.5-5 kVA
power
range.
Standby Ferro
once the
dominant
form of UPS
in the 3-15
kVA range
Double
Conversion
Online
common type
of UPS above
10 kVA
Delta
Conversion
Online
available in
sizes
ranging from
5 kVA to 1.6
MW
Description
Advantages
Disadvantages
Switch to the
battery/inverter upon
mains failure with
transfer switch (TS).
High Efficiency.
Small size.
Low Cost.
With good filters, noise and
surge suppression.
Transfer Time
Most common for small
business, web and
departmental servers.
Battery/Inverter always
connected,
Inverter in reverse for
battery charging when
mains on. Upon mains fail
– TS opens and power
flows from battery.
Reduced switching transients,
usually tap changing
transformer –gives voltage
regulation by adjusting taps as
input V changes, can be
designed so that it still permits
power flow if inverter fails. High
efficiency, small size, low cost
and high reliability coupled with
the ability to correct low or high
line voltage conditions.
Transfer Time
FRT provides limited voltage
regulation and waveform
shaping, isolation from input
power transients provides good
filtering.
FRT creates
severe output V
distortion that
can be worse than
input transients.
Very low
efficiency
combined with
instability when
used with some
generators and
newer
power-factor
corrected
computers (can
create ‘tank’
circuit and
therefore ‘ringing’
and high
currents).
Always online, no transfer
switch. Input is charging
battery which in turn is
supplying power to
inverter.
No transfer time, as no TS.
Nearly ideal electrical output
performance.
Constant wear on
power
components
reduce reliability.
Input power
drawn by battery
charger can be
non-linear which
can cause
problems with
wiring.
Similar to double
conversion online with
additional delta
transformer which also
contributes power to
inverter.
Control input power to reduce
harmonics, heating loss, and
component wear. Controls
input current to regulate
battery charging. Reduces
energy losses and generator
over sizing, dynamically
controlled power factored
corrected input.
Inverter is in standby,
energised when the input
power fails and the
transfer switch is opened.
Utilises “Ferro-resonant”
transformer (FRT) a
special saturating
transformer that has
three windings.
Diagram
Protected by
patents therefore
not available to all
manufactures.
Figure 6 - Table of UPS Architectures ( Adapted from Rasmussen, The Different Types of UPS Systems - White Paper 1 2011)
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The different types of UPS topologies have distinct advantages and disadvantages
that needed to be considered when determining the UPS for the application
required and this information was important in the final decision for this project.
3.3.2.2 UPS Considerations
Further to the architecture of the UPS required, many other factors were needed to
be considered including:
•
Modularity – Many of the high end UPS products offered a structured
modular system. This is where the original capital expenditure was
significantly larger, usually involved the purchase of a full or semi rack
type system, where modules of inverters and batteries could be
purchased to increase the capacity of the system as it grows as indicated
in Figure 7. This is the ideal model that is required for the PDC, however
the trade-off is as stated the initial capital expenditure which was a
major constraint for this task. The reasoning for not acquiring this
system initially was that a smaller system can be used to start off the
PDC business and as the business grows and the customer base
increases, and hence the revenue, the profit can be put back into the
business to purchase a larger modular system to increase the capacity
and reliability of the system as needed.
Figure 7 - Modular UPS System (Emerson Network Power 2004)
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•
Redundancy & Availability – The redundancy configuration is a
significant attribute requirement for the directors of the PDC. The
specification was that of a 1+1 redundant system initially assumed to be
as illustrated in Figure 8.The 1+1 or N+1 specification of redundancy,
presented some confusion with respect to the requirements of this task.
Upon extensive research into the definition of N+1 and 1+1 redundancy
the model constantly presented was depicted as in Figure 8 or similar as
in the simpler Figure 9.
Figure 8 - 1+1 Parallel Redundancy (Emerson Network Power 2004)
Figure 9 - 1+1 Parallel Redundancy – (Socomec, 2011)
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The director’s specification was initially indicated as a ‘truly’ 1+1 redundancy with
A+B feeds, which as described in (McCarthy and Avelar 2011) is a Tier III system
whereas the N+1 redundancy as depicted in Figures 8 and 9 is a Tier II system. The
fundamental difference being the presence of multiple distribution paths for Tier III
and the potential risk incurred by a ‘single point of failure’ in the Tier II system for
the common load bus provided by the paralleling circuit. The Tier III system provides
higher availability of supply as indicated in Figure 10 from McCarthy and Avelar
(2011).
Figure 10 – Scale of availability and cost for UPS configurations - (McCarthy and Avelar 2011)
As adapted from McCarthy and Avelar (2011), they define the distinctions between
the different UPS configurations as given in Figures 11 and 12.
Single Module Capacity “N”
Parallel Redundant
Isolated Redundant
Figure 11 - UPS Configurations – Tiers I and II (McCarthy and Avelar 2011)
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Distributed Redundant – “Catcher” Configuration
System + System Redundant
Figure 12 - UPS Configurations – Tiers III and IV (McCarthy and Avelar 2011)
The Uptime Institute provides a clear definition of the various ‘Tiers’, their
document;
“The Institute Tier Standard: Topology is an objective basis for comparing the functionality,
capacity, and expected availability (or performance) of a particular site infrastructure
design topology against other sites, or for comparing a group of sites.”
(Uptime Institute Professional Services 2009)
With the fundamental requirements of a Tier III Topology given as;
“a) A Concurrently Maintainable data center has redundant capacity components and
multiple independent distribution paths serving the computer equipment. Only one
distribution path is required to serve the computer equipment at any time.
b) All IT equipment is dual powered as defined by the Institute’s Fault Tolerant Power
Compliance Specification, Version 2.0 and installed properly to be compatible with the
topology of the site’s architecture. Transfer devices, such as point-of-use switches, must be
incorporated for computer equipment that does not meet this specification.”
(Uptime Institute Professional Services 2009)
Therefore the required PDC redundancy configuration should be considered a hybrid
of distributed redundant and parallel redundant and considered a Tier III
configuration. It has “redundant capacity”, the main grid and the generator, and
“multiple independent distribution paths serving the computer equipment” and “Only
one distribution path is required to serve the computer equipment at any time”.
Therefore, adapting the diagrammatic representation utilised in (McCarthy and
Avelar 2011) the final redundant configuration is labelled arbitrarily as “1+1 Load
Distributed” and presented in Figure 13 (with the load consistent with the preceding
UPS configuration examples and not representative of the PDC required load).
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Figure 13 - PDC UPS Configuration – “1+1 Load Distributed”
Therefore, the main issue in terms of specifying the UPS redundancy configuration
was that the initial specification as stated above was given as; a ‘truly’ 1+1
redundancy with A+B feeds, and after extensive research it was interpreted and
assumed to be the parallel redundant configuration in Figure 11 above. This became
an issue when the final selection and procurement decisions were made as
described in section 3.3.2.
Phase Configuration – The phase configuration is particularly important in the
consideration for the UPS selection. The phase configuration is simply the input and
output phase setup of the UPS of which there is logically three possibilities:
•
•
•
Single In : Single Out (1:1)
Three In : Single Out (3:1)
Three In : Three Out (3:3)
There are two main issues here with the benefit of three phase power being
identified:
•
Available Power - as three phase power capacity is greater than single
phase, simply by the factor √3 and the line to line voltage in the power
formula:
𝑃3∅ = 𝑉𝐿𝐿 𝐼√3 cos 𝜃
𝑃1∅ = 𝑉𝐿𝑁 𝐼 cos 𝜃
An example of the significance of deciding on the phase configuration and
available power is given in the following table from (Avocent, 2011);
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Figure 14 - Maximum Load Capacity of Various Common Circuits Used Globally (Avocent, 2011)
The table clearly shows the benefit of utilising 3 phase power to the load (although
there is a clear misprint for line two of the International Electrical circuits it should
probably be 230V, 15A, 1-ph).
•
Phase Balancing – By providing three phase power at least up to the input of
the UPS the three phases can be balanced through the inverter. If the UPS is
single phase input and only one UPS is utilised in the data centre, for
example, then the phases can be extremely unbalanced and/or the phase
balancing requires careful planning, with perhaps the HVAC and other
requirements to try and evenly balance the phases.
Balance of Technical Specifications – The balance of technical specifications includes the
efficiencies and magnitudes of the UPS performance and is presented in the following
section as part of the UPS Optioning Assessment Matrix description.
3.3.3
Optioning, Selection & Procurement
The UPS optioning, as per the energy metering optioning, involved creating an assessment
matrix comparing of the significant attributes of the UPS’s. The final balance of technical
specifications that were presented in the UPS Optioning Assessment Matrix, along with the
basic data such as manufacturer, part numbers, price breakdown etc., (see Appendix C for
full Assessment Matrix) includes:
•
•
•
•
•
•
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Architecture – UPS type/topology, as in section 3.3.1.1.
kVA/kW – The main power rating ratings of the UPS (with the comparison of
W and VA indicating power factor)
Efficiency (η) – The overall AC/AC conversion efficiency.
Voltage Regulation.
Total Harmonic Distortion – The measure of harmonic components
(distortion) on the input and output buses.
Crest Factor – The ability of the UPS to supply the ratio of the peak/RMS
current to the load;
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“…if a UPS is not sized to supply the crest factor desired by the load, the output
voltage waveform of the UPS will be distorted” (Rasmussen, Understanding Power
Factor, Crest Factor, and Surge Factor - White Paper 17, 2011)
•
•
•
•
•
•
•
Protection
o Overload (Surge Factor) – Percentage and time UPS can handle
overload conditions.
o Short circuit– Rating or method of short circuit protection.
o Thermal - Rating or method of thermal protection.
Phase Configuration – as described in section 3.3.1.2.
Battery
o Autonomy (mins) – The amount of autonomy available from the
battery options specified in the matrix.(15mins desired to allow for
Auto Transfer Switching and overhead)
o Load % - The percentage of load able to be provided for the
autonomy time above.
o Recharge Time
Bypass – External bypass requirements, price and part number.
Dimensions – of all units, power module and any EBMs.
Mass – of all units.
Note – Any further significant technical or logistical information associated
with the device.
Whilst there are more technical parameters that can be attributed to the UPS specifications
such as battery voltage and configuration (i.e. 12V/7Ah x 20), operating temperature and
humidity range, noise level, IP rating etc. The parameters include in the matrix were
considered the most important in terms of selection and procurement, it was also
anticipated that those systems that made the ‘short list’ from the assessment matrix would
be further investigated, by inspecting the datasheet specifications, to reveal these
parameters if desired.
The major issue involved in the final decision was the confusion in terms of the redundancy
configuration (as described in section 3.3.2.2), and as such, ‘redundancy configuration’
should have been included as a parameter of the assessment matrix. The result of the
confusion is that most of the UPS systems in the assessment matrix were optioned for the
parallel redundant configuration as opposed to the hybrid “1+1 Load Distributed”
configuration as described in section 3.3.2.2. Even for some of the larger modular systems, in
this case N+1 meant there is always 1 extra module capacity, e.g. if the modular system is
based on 20kVA modules and you require, say 60kVA + another 60kVA for
redundancy,install6 modules, this is not possible, you will have 100kVA plus one extra 20kVA
module for redundancy. This is where the redundancy configuration can be confusing and
vary depending on how the product is marketed and requires careful interpretation and
clarification.
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The initial UPS system selected (as stated in the progress report) was the Socomec NeTYS RT
11kVA system (a 1:1 phase configuration), with the predominate factor being the cost, and
was optioned for the parallel redundant configuration. Initially it was assumed the parallel
redundant configuration was preferred (despite the initial specification clearly stated by the
directors, at this stage overlooked), as there is the benefit of the single output bus reducing
the cabling requirements distributed to the loads. However in the midst of the procurement
of the Socomec system a discussion with the Managing Director in regards to this issue
revealed the flawed assumption. Furthermore, the Managing Director highlighted the fact
that the parallel redundant configuration introduces a single point of failure, which reduces
the availability of supply, a point discussed in section 3.3.2.2, but only investigated after the
problem arose.
Therefore, the “1+1 Load Distributed” UPS configuration would require the addition of a
extra EBM and external bypass module at extra cost, as the initial system was quoted and
selected as it could share one EBM to provide 15mins Autonomy at full load 1. Due to the
extra cost, coupled with late arrival of a new quote option which was significantly lower cost
and had the added benefit of being a 3:1 phase configuration (providing load phase
balancing), the procurement of the Socomec system was withdrawn “at the 11th hour".
Although this may have caused business relationship integrity to be potentially affected, as
the UPS was sourced through one of the director’s primary business suppliers, the decision
was made to procure the MTX UPS system (specifications Appendix D) instead.
The MTX system was ordered on the 13/10/2011. The cost trade-off for the MTX system
(compared to the Socomec system) is a less powerful system (10kVA/7kWvs. 11kVA/8kW),
with slightly lower conversion efficiency (90% vs. 92%) and input power factor (0.95 vs. 0.99),
however it is still a double online conversion architecture and the difference in technical
specifications and performance ratings is outweighed by the cost reduction, although the
actual ‘real’ performance and quality of the system can only be assessed once commissioned
and installed and with load time.
As part of the procurement process, lead time was an issue. The supplier stated that the UPS
needed to be shipped from the overseas manufacturer and will be a minimum of two weeks.
Since this time they have had an issue with ‘an internal board’ that was apparently damaged
on shipment (which they identified through testing) and are waiting on a replacement from
the manufacturer which further delays the UPS delivery.
1
The shared EBM was also identified as a single point of failure, after the initiation of the purchase, in speaking to a Socomec
representative engineer. Battery failure is also considered a leading cause of UPS failure, with the upgrading of capacity a
requirement for the future, mixing the age of batteries can cause issues, in terms of the batteries internal resistance changing
over time and therefore mixing old and new batteries can cause problems particularly in the charge cycle. Basically as the older
batteries have a higher internal resistance, their voltage is higher and it will appear to the battery charger that new batteries are
charged when they are not, this reduces the life of the new batteries as they are constantly undercharged, also resulting in
power loss.
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Another issue with the procurement of the MTX system is that the initial quote requested
was for 15mins autonomy at 100% load (which is in writing – on email). Due to the issues
with the Socomec system, the complete user manual was requested to double check the UPS
specifications and provide a head start on planning the UPS monitoring and control. The user
manual identified the battery autonomy as in Figure 15 below. This graph clearly shows the
backup time as significantly less than 15mins at 100% load (<50% at 15mins or 5mins at
100%), therefore an email was sent to the supplier requesting that they ensure 15mins
autonomy at 100% load. They replied confirming they will provide extra batteries to provide
the required autonomy.
Figure 15 - MTX Standard Backup Time (Alpha Power Systems PTY LTD 2008)
Finally, as the initial correspondence with the supplier included the request for 1+1 parallel
redundancy, just before shipping, the invoice was issued and only one external maintenance
bypass switch was included as the supplier assumed it would be configured this way (i.e.
with a common output bus). This was despite the official purchase order requesting two
bypass switches and two UPSs, they assumed that as we were using 1+1 parallel
configuration and we would only need one. This issue was identified by the Managing
Director upon inspection of the invoice and a request was put in to the supplier to include
the second bypass switch. The second switch was able to be added to the freight package,
the invoice was adjusted and the supplier’s engineers provide a modified SLD for the bypass
switch configuration (Figure 16). This issue provided another lesson in ensuring the specific
requirements of the project task is communicated throughout the complete supply chain.
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Figure 16 - UPS External Bypass Switch Configuration (Chu 2011)
3.3.4
Schedule, Installation & Commissioning
This task initially designated as “UPS Control System Parameterisation” was scheduled to be
complete on 4/11/11. The actual task of “UPS Control System Parameterisation” has been
rolled into the “Monitoring & Control Design, Implementation & Integration” and the UPS
procurement has been designated as this distinct task.
Due to time constraints with respect to other business commitments and the delay in UPS
delivery, the UPS has only just been delivered to the PDC, therefore is not yet installed or
commissioned. The task is now scheduled to be complete by 25/11/2011.
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3.4 Master single line diagram of 415v and 240v distribution using Microsoft Visio
3.4.1
Scope & Objective
The scope of this task incorporates determining the required main power reticulation of the
415V and 240V electrical distribution with the objective of creating a master single line
diagram (SLD).
The fundamental concept for the master SLD was provided by the Managing Director with
the potential reticulation to be determined through research and comprehending the
electrical protection (addressed in section 3.8) and existing and future load requirements.
This task was scheduled to be completed on 3/10/2011, however due to changes during
installation and commissioning, this has been altered and reviewed by the Managing
Director to be approved and finalised on the 14/11/2011.
3.4.2
Design & Analysis
The SLD shows the power reticulation and the Automatic Transfer Switch utilised to switch
between the grid and the generator and distributed to the loads.
The SLD has been through various revisions as the project has progressed.
These revisions are:
•
•
•
•
The required number of terminals
Circuit breakers and kWh meters for the essential and non-essential services
including the provision of two three phase HVAC terminals and
The predicted balancing of the phases for the non-essential single phase services.
The reticulation for the non-essential services.
The final SLD is as shown in Figure 18, with the previous draft in Figure 17, and, as can be
seen, there are significant changes:
•
•
•
•
The main Western Power circuit breaker was determined to be 50A as opposed to
85A (as depicted in Figure 17).
The main PDC meter is actual upstream of the main isolator switch.
The generator main circuit breaker is rated at 165A not 85A, and all other circuit
breaker sizes have been adjusted to actual existing values and those required for
electrical protection (as in section 3.8).
The single phase Air Conditioning Unit has been switched to the essential services as
it will be utilised as the main cooling system for the PDC equipment until the other
HVAC units are commissioned and therefore it has become an essential service.
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•
•
•
•
The grid main incomer is switched through the 80A isolator to the ATS.
The essential circuit has the combination MCB/RCD or Residual Current Circuit
Breaker with Overcurrent Protection (RCBO) devices include for the GPO that will
service the Fire System UPS and required for the Amcom ISP Fibre Optic Distribution
board.
The non-essential service reticulation is represented, as wired on site, including
residual current protection requirements as discussed in section 3.4.5.2.
The surge protection device is represented.
Figure 17 - Draft SLD
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Figure 18 - Master Single Line Diagram - Final
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3.5 Power System Analysis
3.5.1
Scope & Objective
The scope of this task is to calculate the available power at the PDC site, with respect to
potential load requirements. Investigate data centre loading trends in the market to
estimate the constraints and potential upgrades required to fulfil future customer
requirements. The objective is to ensure the PDC project boundaries are understood, in
terms of power availability matching load requirements for customer needs.
This task was not explicitly defined in the project brief and scope, however it is implicit in
ensuring the electrical installation complies with the constraints of the supply and demand
of the PDC in terms of initial configuration and future expansion prospects.
3.5.2
Power Availability
The absolute maximum available power from the grid at the PDC site is simply the
three phase power calculation with the limit of the 50A circuit break at the incomer,
therefore calculating available apparent power.
𝑆 = √3 × 𝑉 × 𝐼
3.5.3
Load Analysis
= √3 × 415𝑉 × 50𝐴 ≅ 36𝑘𝑉𝐴
Based upon the available existing power, it is necessary to determine the current and
potential load profile of the PDC.
Determining the anticipated load in a data centre can be achieved by many methods. The
most common and understood methods include:
•
•
Data centre density
Rack Power Density
Data Centre Density
Discussed extensively in (Rasmussen, Guidelines for Specification of Data Center Power
Density 2005) the specifications for data centre power density can be extremely “ambiguous
and misleading” when improperly defined.
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Rasmussen presents an example that clearly shows this ambiguity, and that using the
traditional
𝑊
𝑚2
can have many different values depending upon how the ‘area’ is defined and
the ‘power’ is defined, as shown in the following table excerpt from (Rasmussen, Guidelines
for Specification of Data Center Power Density 2005).
Figure 19 - Data Centre Density Example
“All of the definitions for density… …are used in published literature and specifications. The four
definitions that use W / ft2 or W / m2 are ambiguous unless accompanied by a clear explanation
of what is included in area and what is included in power. Yet published values for density
routinely omit this information. This has led to tremendous confusion in the industry, and
common miscommunication between IT personnel and facilities designers and planners. The
data… …clearly shows that density specifications for the same facility can vary by almost a
factor of 8 depending on the density definition used.”(Rasmussen, Guidelines for Specification of
Data Center Power Density 2005)
Rack Density
As shown above the power consumption per rack “eliminates much of the variation when
defining power density”, therefore this is the measure employed for the PDC project.
The rack density is simply determined by the estimated current demand per rack. This has
been chosen as a reasonable value to allow for the utilisation of the installed physically
present racks, of which there are currently 9.
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Therefore 15A per rack has initially been designated, which gives:
𝑆 = 𝑉𝐼 = 240𝑉 × 15𝐴 = 3.6𝑘𝑉𝐴/𝑟𝑎𝑐𝑘
Therefore, based upon the available grid supply power of 36kVA, this provides for a
maximum of 10 racks.
However, this is assuming there are no other power requirements for the data centre, which
is an invalid assumption as there is at least the required cooling for rack equipment.
An Air Conditioning (AC) unit’s performance has two main indicators in Australia which
provide a measure of input power required for a particular amount of output power. These
include its Energy Efficiency Rating (EER) and Coefficient of Power (COP) for heating and
cooling performance (Commonwealth of Australia 2011).
The currently installed single phase AC unit that will be utilised, initially until upgrades are
required, has an EER = 3.
Therefore, calculating the balanced breakdown of power based upon what is available, the
calculated rack density and required cooling(which is approximately a 1:1 relationship, every
kW of power drawn, produces a kW of heat load) gives (using Microsoft Excel – Solver Add
In) two main scenarios.
Power Factor
Available Power
1
Rack Density
36
36
3.6
Number of Racks
7.5
Required Cooling
27
Power Factor
kVA
kW
kVA
kW
Available Power
Rack Density
36
28.8
3.6
Number of Racks
6
Required Cooling
21.6
EER
3
Cooling Input
9
kW
Cooling Input
36
kW
Power Matching
Power Matching
0.8
EER
kVA
kW
kVA
kW
3
7.2
kW
28.8
kW
Figure 20 - Available Rack Calculation
The ‘Power Matching’ value was solved to equal the available power by changing the
number of racks. These two scenarios estimate a best and worst case (assuming 0.8 PF is
worst case) for the number of available racks, this also assumes lighting and other auxiliary
equipment power requirements are negligible (e.g. UPS for fire protection system, Amcom
distribution board etc.), as well as not accounting for any inefficiency or de-rating factors.
This is an obvious constraint based upon the power available to the PDC.
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The estimation of rack density may also pose a potential problem and may be an underestimation, depending upon the customer requirements and the constraints placed upon
them from a supplied business service perspective.
Figure 21, from Patterson and Fenwick (2008), “Adapted from ASHRAE’s projected density
loads (kW per Rack) for IT equipment”, shows the predicted trend in heat load per rack
(which as discussed is equivalent to power drawn).
Figure 21 - Per Rack Power Density Trend (Patterson and Fenwick 2008)
Rasmussen also discusses the increase in average rack power density;
“In particular, the historical power density specification does not answer the key question:
“What happens when a rack is deployed that exceeds the density specification?” This is a very
practical question because the typical data center today has a density rating of 1.5 kW per rack
while typical IT equipment has a greater power density of 3-20 kW per rack.”(Rasmussen,
Guidelines for Specification of Data Center Power Density 2005)
The issue of per rack power density may be more relevant for the larger competitors of data
centre infrastructure though it still should be considered for the PDC in terms of potential
expansion and customer uptake.
Fundamentally, if further power is required due to customer demand a potential upgrade of
the main grid incomer may be required. The considered PDC market segment is a niche
market for smaller co-location services, with a CBD presence, based on per rack, half-rack
and potentially per socket/server solutions. However as illustrated comprehensively in data
centre power density research, with the advent of high density IT equipment such as the
blade servers the rack density requirements are increasing rapidly. As technology advances,
corporate/business uptake of the new technology is fairly quick and, as the PDC will be
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providing a new data centre installation service for its customers the potential for them to
want the latest high density servers installed is high.
“The distribution of air within a data center is a primary factor limiting rack power density. IT
equipment requires between 100 and 160 cfm (47.2 - 75.5 L / s) of air per kW.”(Rasmussen,
Guidelines for Specification of Data Center Power Density 2005)
The PDC will utilise individually delivered-to-rack air conditioning to mitigate the distribution
of air volume required, see Figure 22. The interim solution is to re-route the existing air
conditioning ducting to a small boxed space under the row of racks. Each rack will have a
vent flap that is spring locked open (so it can be shut if there is a fire in the rack described in
section 3.9.2, with the hot air extracted from the top of the racks. The vents will only be
open for the racks that are being utilised (for the initial stages, this will be just two.
Eventually, new 3 phase AC systems will be added to increase the cooling capacity. The
currently installed system is a 3kW system and will meet 1/3 of the proposed load, and
therefore 3 racks can initially be installed.
Figure 22 – Air conditioning rack air flow
3.5.4
Schedule, Installation & Commissioning
This task was not explicitly required as part of the initial project brief deliverables. However,
it is a required process to fully comprehend the power utilisation in the PDC. The air
conditioning design and installation component is not part of the internship project
deliverables but again is part of the overall PDC project requirements and needs to be
implemented to enable the PDC to get up and running, this installation of this task is
schedule to be complete as part of the final installation works over the period 14/11/201125/11/2011.
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3.6 Automatic Transfer Switch (ATS)
3.6.1
Scope & Objective
The scope of this task was to investigate and comprehend the operation of the Automatic
Transfer Switch (ATS), including determining the required electrical connections between the
mains and the generator and the monitoring and control signals required to operate the
device for the PDC project. This was achieved by investigating the documentation and
manuals for the ATS supplied and determining the appropriate parameterisation and
connection for the monitoring and control as specified in section 3.10.
3.6.2
Analysis
The ATS for the PDC project was pre-selected and supplied through the generator supplier as
the Deep Sea Electronics DSE-705. The DSE-705 is actually only the digital control board, the
switchgear was designed and manufactured by the generator supplier which included the
enclosure, contactors, control relays, associated wiring and accessories as per the DSE-705
wiring diagram provided by the manufacturers (Figure 24).
The contactors are mechanically and electrically interlocked to ensure the main grid supply
and generator supply is completely isolated. As per the wiring diagram in Figure 24 the relay
to switch the contactors are run off phase L1 of the respective input supply (grid and
generator), with the grid supply being a normally closed relay and the generator a normally
open relay, providing the switching mechanism to facilitate automatic transfer switching.
The controller will detect the ‘phase failure’ from the grid and upon a designated time period
(to prevent unwarranted switching) will send the start signal to the generator. Once the
generator has started and is the correct frequency the controller will switch in the generator
to supply the load. A remote start signal is able to be supplied for manual starting remotely
as a supplementary method of starting the generator and switching if required.
The ATS was supplied and assumed to be sufficient for simple installation and connection as
per the wiring diagram, connect the main incomer, the generator, the remote start signal
wire and then the 24VDC battery. However during installation some significant issue were
discovered, as discussed in the following section:
•
•
•
3.6.3
Enclosure too small
Contactor coil voltage incorrect
No fuses supplied for coil switching
Schedule, Installation & Commissioning
The ATS installation was commenced on the 24/10/2011. However, upon inspection of the
enclosure it was evident to the Managing Director that the enclosure would not be sufficient
to route the cables into and out of the enclosure, basically insufficient physical space was
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available to fit the large generator and mains cable and bend them around to attach to the
contactors and also feed the load bus out. Therefore, another enclosure was sourced from
Metro Power’s main electrical distributor at the companies expense basically double the
height was required. A Hager enclosure measuring approximately 600x300x300 was
purchased and the original ATS was dismantled to be re-assembled in the new enclosure.
It was during the disassembly that the managing director also noticed the coil voltage rating
on the contactors was incorrect. The coil voltage was 415V and the control circuitry to switch
the contactors was 240V. This was rectified by contacting the suppliers of the ATS and
requesting the correct 240V coils replace the 415V ones. During the disassembly/ reassembly process, the managing director also noticed that the 240V voltage switching the
coils and phase inputs to the controller required fusing and these were not supplied (as per
the wiring diagram in Figure 24 on the terminals numbered 16-20 on the controller), again
the suppliers were notified and asked to supplier the correct fuses and housing.
These issues were compounded because the original supplier contact had resigned and
therefore a new supplier liaison had to determine particulars of the job to provide the
correct parts, providing another interesting business experience.
This task was originally covered under the “Generator control system parameterization
design for automatic transfer switching on mains failure, including fault monitoring to Metro
Operation & Control Centre (‘OCC’) and remote control” deliverable; however this electrical
installation component and device comprehension has been now allocated as a distinct task
and the monitoring and control of the ATS is covered in the monitoring and control
deliverable as per section 3.10.
As part of the original task it was scheduled to be completed by 4/11/2011; however the
aforementioned issues, limited installation time and resource constraints have delayed the
installation schedule for this task. This task is now schedule to be complete as part of the
final installation works over the period 14/11/2011-25/11/2011. The current installation
progress can be seen in Figure 23.
Figure 23 - ATS Installation Progress
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Figure 24 - DSE-705 Wiring Diagram (DEEP SEA ELECTRONICS PLC 2003)
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3.7 Generator
The generator for this project was already selected and physically installed on site as well as drafted into
the initial scaled layout provided as per Figure 25.
Figure 25 - X-Ray Side View Standby Generator Placement
3.7.1
Specifications
The standby generator was pre-selected by the Managing Director as a Nissha NES60EH with
the following basic 3 phase specifications (full specifications, given in Appendix E):
• Alternator
o 3 Phase 50/60kVA (Standby: 55.0 / 66.0 kVA)
o Power Factor – 0.8 Lagging
o Voltage – 200,400/220, 440V
o Current – 144.72/157.79 A
o Frequency – 50/60Hz
• Engine
o Model: HINO W04D-TG
o Type – Direct injection with turbo charger Diesel
o Cylinders Bore x Stroke – 4-104 x 118 mm
o Total Displacement – 4.009L
o Rated Output – 50.4/59.6 kW
o Rotational Velocity – 1500/1800 rpm
o Fuel Consumption (Load) L/H
 100% - 11/13
 75% - 8.6/10
o Engine Oil Volume – 16.5L
o Battery – 2 x 55B24L
o Fuel Capacity – 125L
• Dimensions (HxLxW) - 1190x2245x880 mm
• Dry Weight – 1200kg
• Noise Level (Power/Pressure) – 92/63 dB
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3.7.2
Cable sizing and selection calculations and installation
3.7.2.1 Scope & Objective
The objective of this task was to determine the cable size from the generator to the
ATS in the PDC. This incorporated researching the appropriate Australian Standards
and ensuring the cable was sized accordingly. Following the determination of cable
size this task also included the procurement of the cable, design and procurement of
the cable tray required to install the cable and selection and procurement of control
cable required for monitoring and control.
3.7.2.2 Design & Analysis
The main generator electrical cable was sized according to AS/NZS 3008.1.1:2009
(hereafter AS3008), “Electrical installations—Selection of Cables; Part 1.1: Cables for
alternating voltages up to and including 0.6/1 kV—Typical Australian installation
conditions” as 4 core and earth 35mm2Cross-Sectional Area (‘CSA’) with the limiting
factor in determination of cable size being the current carrying capacity of the
required length for distribution of the generator power to the PDC (illustrated in
Figure 29).
AS3008 specifies 3 criteria to determine minimum cable size as:
a) Current-carrying capacity
b) Voltage Drop
c) Short-Circuit Temperature Rise.
These three criteria provide separate methods of determining the minimum cable
size. As stated in AS3008“The minimum cable size will be the smallest cable that
satisfies the three requirements”, the predominate method for this project is the
current-carrying capacity as the length of the circuit is only 40m. The voltage drop
method is for longer cable runs and the short-circuit temperature rise condition only
occurs “in special situations” according to AS3008, however all three methods are
calculated here.
Following the procedure as outlined in AS3008 section, the maximum demand for
the generator circuit was determined as:
∴𝐼=
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𝑆 = √3𝑉𝐼
50𝑘𝑉𝐴
√3 ∙ 415𝑉
≈ 70𝐴
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This is also clear in the generator specification for the 3 phase maximum current,
specified as 72A for 400V application.
Voltage Drop Method
From AS3000 the process involves;
Determine the current requirements of the circuit, which is the maximum demand as
above 72A.
Route Length = 40m (actually less but use maximum value)
Maximum voltage drop is 5% unless otherwise stated which is equal to;
𝑉𝑑 = 415𝑉 × 0.05 = 20.75𝑉
Using equation 4.2(1) from AS300 section 4.2;
Figure 26 - Voltage Drop Calculation AS/NZ 3000
𝑉𝑐 =
1000𝑉𝑑 1000 × 20.75𝑉
=
≈ 7.205 𝑚𝑉/𝐴𝑚
𝐿×𝐼
40𝑚 × 72𝐴
Olex® V-90 PVC/PVC 0.1/1kV is the standard cable type supplied from the Metro
Power electrical distributor and will be the cable type procured for this project.
Although the V-90 cable can handle up to 90°C for short periods, AS3008 suggest
using 75°C as the maximum temperature for this cable.
Therefore, using the appropriate Table 42 from AS3000 (Figure 28) the nearest cable
size less than 7.205mV/Am is the 6mm2.
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If less than 5% voltage drop is required the cable size obviously changes, a study was
done using Microsoft Excel spreadsheet with the results shown in Figure 27.
Cable Size(mm2)
Minimum Cable Size vs. % Voltage Drop - 3 Phase - 415V
185
180
175
170
165
160
155
150
145
140
135
130
125
120
115
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0.0%
1.0%
2.0%
3.0%
4.0%
5.0%
6.0%
Voltage Drop
Voltage Drop
0.1%
0.4%
0.6%
1.0%
1.6%
2%
3%
4%
5%
Cable Size(mm )
185
95
50
35
25 16 10 10
Figure 27 - Graph & Table of Voltage Drop vs. Cable Size
6
2
Figure 28 - Voltage Drop Table for 3 Phase Multi-core Cable
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Therefore using the standard 5% maximum voltage drop due to the small route
length the cable size can be reasonably small; however a tighter tolerance of say 1%
requires 35mm2.
Short Circuit Temperature Rise
This method uses the equation 5.3(1) from AS3008 given as;
Figure 29 - Short Circuit Temperature Rise Equation – AS3008
The temperature limit for V-90 cable determined from AS3008 Table 53 is 160°C, and
therefore the value K is determined from AS3008 Table 52 as K=111 for copper.
Initially it was assumed the short circuit current was based upon the generator
circuit breaker, which has a short circuit breaking capacity of 15kA for 460V as
specified on the device which, assuming a conservative disconnection time for the
circuit breaker of 0.4s, Equation 5.3(1) from AS3008 rearranged to be solved for S
(cable CSA) gives:
𝑆 = ��
𝐼2𝑡
150002 ∙ 0.4
��
=
�
� ≈ 85𝑚𝑚2
𝐾2
1112
This seemed far too large a CSA, after further research and discussion with the
Managing Director it was determined that the generator can only supply a short
circuit current proportional to its power rating (50kVA).
The fault current of the generator could be calculated simply if the sub transient
reactance (𝑋𝑑")of the generator was known, using;
𝐹𝑎𝑢𝑙𝑡 𝑉𝐴 =
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𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝑉𝐴
𝑋𝑑"
𝐹𝑎𝑢𝑙𝑡 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 =
𝐹𝑎𝑢𝑙𝑡 𝑉𝐴
√3 ∙ 𝑉
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ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011
Where, V is the voltage of the generator (415V).
An attempt to find this information was made, however it could not be found.
However, according to BAKER (1982):
“The maximum symmetrical current that a generator will deliver on the initial bolted threephase fault is determined by the subtransient reactance Xd". This reactance will range from
a minimum of 9 percent for a two-pole round rotor machine to 32 percent for a low-speed
salient pole hydro generator. Thus the initial symmetrical fault current (1 to 5 cycles) can be
as great as 11 times the generator full load current.”(BAKER 1982)
Therefore, using a conservative value of 11 X the full load current (72A) as the short
circuit current gives:
𝑆 = ��
(792)2 ∙ 0.4
𝐼2 𝑡
��
=
�
� ≈ 4.5𝑚𝑚2
𝐾2
1112
This seems a more likely value.
Current Carrying Capacity
The cable installation method is determined in section 3.5.2.3 as ‘unenclosed on
cable tray’ and therefore utilises the de-rating factors from AS3000 Table 24 and was
determined as 0.97 for an unperforated tray for one cable.
Therefore the current capacity required= 72𝐴 / 0.97 ≈ 74.23𝐴.
From Table 13 AS3008 (Figure 30), the required cable size is therefore 25mm2.
Figure 30 - Cable Sizing Based Upon Current Carrying Capacity Table 13 AS3008
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The initial determination was incorrectly based upon the 85A rating of the contactor
in the ATS as it was assumed the circuit breaker rating of the generator at 165A
provided sufficient current that this would be the limiting factor in terms of demand.
This resulted in 87A de-rated which was decide to be too close to the 91A limit for
25mm2 cable and hence 35mm2 was chosen, as current-carrying capacity was
considered the most significant limiting factor for cable sizing at the time.
Therefore, it is now apparent that the cable for the generator is over specified in
terms of current carrying capacity.
The advantage is that the cable is sufficient for significant future expansion of
standby generation in terms of current carrying capacity. Control cable was also
selected based upon the control, monitoring and fire system requirements as a 6
core (estimated for control and monitoring signals required from the generator) and
2 core cable (for Modbus RTU is required).
The calculated cable sizing was checked with free online cable sizing application
www.cablesizer.com (based on IEC standards) and demo cable sizing software
(Powerpac Pro, based on AS3008), and confirmed the result for 25mm2 and 35mm2
respectively. The full ‘Powerpac Pro’ solution is presented in Appendix F, and the
cablesizer.com in Figure 31.
Figure 31 - Cablesizer.com solution (www.cablesizer.com 2011)
3.7.2.3 Changes/Issues
An extension of this task was the design, selection and installation of the cable tray
required to house the main electrical and control cable requirements. This
incorporated determining a suitable cable tray enclosure and determining the path
for the cable to be routed to the PDC. Measurement determined the amount of
cable tray needed to be ordered. Field inspection determined an appropriate route.
The installation was drafted ‘As Built’.
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3.7.2.4 Schedule, Installation & Commissioning
The cable sizing and selection, procurement and installation were completed by
24/08/2011.The cable has been installed at the site as can be seen in Figure 32.
Figure 32 - Cable Installation
3.7.3
Battery Charger
3.7.3.1 Scope & Objective
The objective of this task was to determine and size the correct battery charger to be
permanently connected to the generator batteries, then optioning, selecting and procuring.
This task was completed through researching battery charger sizing methodologies and
battery charger products to determine the most economical and technical suitable battery
charging device, then providing a product assessment matrix to determine the most suitable
battery charger for the project and for the directors to make a decision.
3.7.3.2 Research & Analysis
The batteries in the generator are 2 x 55B24L with the following specifications:
•
•
•
Ah Capacity = 55Ah
Voltage = 12V each (24V in series)
CCA = 360A
Extensive research revealed numerous battery charging methods described by different
sources.
The first method that was discovered to size the battery charger involved in determining the
following steps (Newland 2006):
•
•
A -Battery Voltage – 24V
B -Number of batteries – 2
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•
•
•
•
•
•
C - Battery Capacity – 55Ah x 2 =110Ah
D -Recharge Time – Maximum battery life is obtained when the 0-100% recharge
time is between 8-12 hours therefore, choose 10 hours.
Charging Current = C/D = 110 / 10 = 11A
Add 20% for battery in-efficiency = 11 x 1.2 = 13.2A
Add any additional load – the ATS can draw up to 1.2A, however after
correspondence with the Deep Sea Electronics manufacturers the standby draw is in
the order of 20mA = 0.02A
Choose the next closest biggest charger available, say 14A.
The extensive methods of battery charger sizing available led to an attempt at contacting
battery supplier companies for advice.
A simpler method advised by correspondence with a Bainbridge Technologies consultant
(Andersen 2011), contacted online, was given as a rule of thumb method to simply take 1025% of Ah rating which gives 5.5A minimum to 11A maximum as a safe charging current.
Finally many sources referred to the equation in Figure 33 as the method of determining the
battery charger size. The contentious issue being the AH value, is it the total Ah of the
batteries, the series combination, or the Ah drawn from starting the engine. Contact with the
local Challenge Batteries company (Herbert 2011) to obtain quotes for the optioning process
revealed the flaw in the initial calculation method that, in series 2 x 45Ah batteries = 45Ah
not 90Ah, and the calculation it is for deep cycling batteries not an engine starting
application. Further research revealed in the Davidson Sales company website (Davidson
Sales Company 2008) a method which is particular to engine starting, which incorporated the
equation in Figure 33.
Figure 33 - Battery Charger Calculation (Livingston 2007)
A table was created based upon this method with the AH removed from the battery
determined from the starter current, the maximum cranking time and the maximum number
of starts. The uncertain component was the value of the starter current, based upon starter
motor power, CCA or the generator rating and all three were utilised in a table to compare.
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Starter Motor Power
Starter Motor
Voltage
Starter Current
Max Cranking Time /
Start
Max Number Starts
Ah Drawn
De-rating
Desired Recharge
Hours
ATS Constant Load
Output Current
Battery Charger Sizing Engine Starting Calculation
Using Engine Starter
Motor Output Rating
Using CCA
Using Gen Rating
4500 W
48000
24
187.5
30
5
7.81
1.4
V
A
seconds
Ah
410
30
5
17.08
1.4
A
seconds
Ah
1.25 hours
3 hours
0.02 A
0.02 A
8.77
7.97
Figure 34 - Battery Charger Sizing Table
24
2000
30
5
W
A
seconds
83.33
1.4
Ah
10
0.02
11.67
hours
A
Clearly the desired recharge time is different for each case in the table of Figure 34 and has
been selected arbitrarily. Ultimately, the research of battery charger sizing, and through
correspondence with industry specialists, reveals the application for this battery charger will
require predominately a maintenance ‘float’ charge cycle as the probability of the generator
requiring staring is very low (the PDC is on the Princess Margaret Hospital Grid). The Ah
removed from the batteries from engine starting will be minimal, therefore the recharge
time and hence required output current of the charger can be relatively small.
3.7.3.3 Optioning, Selection & Procurement
The research into different batteries chargers revealed many products with various
characteristics with the most significant, besides the current output rating, being the number
and type of battery charge stages.
As with previous optioning selection and procurement tasks a product assessment matrix
has been assembled to assist the directors in determining the best solution for this task.
It is beyond the scope of this report to fully describe the various battery charging stages
available, although a popular product such as the CTEK MXT 4.0 (Bainbridge Technologies
2011) stages are clearly shown in Figure 35.
Figure 35 - CTEK MXT 4.0 Battery Charger Stages
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Despite the research into battery charger sizing methods, the realisation was made that the
when the generator starts it provides a boost charge into the battery and therefore, the
current output needs to be low so as not to overcharge the battery and reduce it life. The
most desirable characteristics of the battery charger will be the ‘smart’ capability in terms of
the maintenance charging, which is the float and pulse stages, not overcharging the battery
and increasing the life of the battery while still supplying the standby current required for
the ATS.
Based upon these characteristics the most favourable solution is the either the CTEK MXT 4.0
as discussed or a Project IC800-24. The later product has been suggested to the directors as
the best solution as it is nearly 30% cheaper than the CTEK unit (although the suppliers have
suggested the CTEK is a better built unit), has a selectable output of 2,4,6 and 8A, a power
supply mode and temperature compensation probe (which may be desirable in the hot
summer months).
The product assessment matrix is attached as Appendix G.1 and the Projecta Specifications
Appendix G.2.
3.7.3.4 Schedule Installation & Commissioning
This task can be considered part of the initial project deliverable task “Generator control
system parameterization design for automatic transfer switching on mains failure, including
fault monitoring to Metro Operation & Control Centre (‘OCC’) and remote control”, as part
of the parameterisation for the generator. Now assigned a distinct task deliverable the
battery charger is scheduled to be procured and installed as part of the final installation
works over the period 14/11/2011-25/11/2011.
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3.7.4
Exhaust
3.7.4.1 Scope & Objective
This task incorporated the design, layout, procurement and installation of the
generator exhaust/flue system at the PDC. Initially, utilizing the site plans, actual
measurements and 3D design layout, the exhaust was modelled in Google SketchUp
to determine the dimensions of the exhaust system. The exhaust was then
translated into a 2D plan for fabrication. The exhaust also required coating for heat
removal and aesthetic purposes which again required optioning, selection and
procurement
3.7.4.2 Analysis
3.7.4.2.1
Drafting/Layout
3.7.4.2.1.1 3D
The 3D layout was designed as mentioned in Google SketchUp by using the
Master Layout as provided. Measurements were taken on site to check the
dimensions of the master layout and the exhaust was routed on the diagram
accordingly.
Figure 36 - Generator Exhaust External
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Figure 37 - Generator Exhaust Internal
3.7.4.2.1.2 2D
Once complete, the 3D dimensions were translated into a simple 2D layout
which was required to provide a simple plan for the fabricators to work off
(Figure 38).
Figure 38 - Exhaust Pipe Layout 2D – Final (After Modification)
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3.7.4.3 Changes/Issues
Due to a simple incorrect assumption as part of the design process (it was assumed
that half way between the window and the balcony was the centre of the wall that
runs up to the roof, whereas in reality the wall is offset from the window as can be
seen at the top of Figure 39), the design of the exhaust was incorrect and was
fabricated this way. This was mitigated by the on-site trial fitting as recommended
by the Managing Director, before ceramic coating was undertaken. The solution was
to adjust the pipe work at the non- flange ends to ensure the exhaust fitted
correctly. The required changes were made by the supplier at no extra cost.
Figure 39 - Exhaust Pipe Error
3.7.4.4 Calculations
The exhaust pipe diameter was determined based upon required backpressure
calculation and the radius bends were limited by the generator specifications
(proportional to the pipe diameter).
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The exhaust backpressure calculation was completed by the Managing Director as
per Figure 40 based on the generator specifications and fundamental physics.
Exhaust system restriction calculator (equivalent length of pipe method)
Inputs
Output
Line
1
1. Total length of straight pipe in metres ( l )
15
2
2. Total length of flexible pipe in metres ( lf )
0
3
3. Number of 90 deg bends ( n )
5
4
4. Number of 45 deg bends ( nf )
5
5. Length of exhaust bellows in metres ( B )
6
6. Equivalent length of silencer in metres ( S )
0
7
7. Equivalent length of transition units in metres (T)
0
8
Calculated equivalent length of total exhaust system (L)
9
2. Diameter of system in mm ( D )
0
0.3
21.975
89
10 4. Exhaust gas mass flow rate ( Q ) kg/sec
0.062724
11 If not known refer to line 14 to calculate the mass flow in kg/sec
12 Calculated exhaust back pressure in kPa ( P )
0.557099
13 Where: P = L x Q^2 x 158.267 x 10^9/D^5.33
14 To find exhaust gas mass flow in kg/s given volumetric flow rate in m3/min
15
Inputs
Output
16 1. Exhaust gas flow rate in m3/min ( F )
5.5
17 2. Exhaust gas temperature in deg C ( T )
200
18 3. Maximum allowable exhaust back pressure (gauge) in kPa (P).
0.98
19
20 Calculated exhaust gas mass flow rate in kg/sec ( Q )
21
22 Where Q = (P + 100) x 1000 x F / 312 / (T + 273)
23
24 Note: R for exhaust gas = 312 Nm / kg deg K
0.062724
OK
Figure 40 - Exhaust Gas Back Pressure Calculation
The full explanation of the derivation of the equations is beyond the scope of this
report however, the basic operation of the calculation is to determine Q as above
(Line 20), place the value into Line 10, and using the other parameters such
calculated equivalent length, diameter of pipe etc., the value P (Line 12, orange cell)
will be calculated. If the P value on Line 18 (derived from the generator
specifications, blue cell) is less than the P value on Line 12 then the backpressure is
within the acceptable boundaries of the generator specification and the yellow cell
will indicate “OK”.
3.7.4.5 Optioning, Selection & Procurement
The exhaust pipe has been designed and fabricated using simple flanged ends with
pipe clamps for connection between sections, after some required modifications
(section 3.7.4.2.2) the exhaust pipe was procured from Cannington Performance
Exhausts.
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The ceramic coating for heat transfer and aesthetic purposes was optioned
(Assessment Matrix - Appendix H.) and the most economic, practical quote was
selected, with some weight given to the maximum size of exhaust piece a ceramic
coating oven could accept. The exhaust was couriered to Victoria for coating on the
20/9 and returned on the 18/10/2011.
3.7.4.6 Schedule, Installation & Commissioning
The exhaust was installed on the 26/10/2011, which is one and a half weeks longer
than anticipated in the Gantt chart estimation as submitted in the progress report.
As this was a scope change request, the management of this task is considered
successful despite the issues with measurement and manufacture as stated above.
The exhaust is functionally and aesthetically sound and was produced at a relatively
economical expense.
Figure 41 - Exhaust Installation
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3.8 Electrical installation, standards, protection system calculation and grading
3.8.1
Scope & Objective
The scope of this task is to plan, design and implement the electrical protection and
installation requirements for the PDC project, with the objective of complying with the
required state and federal electrical installation standards.
3.8.2
Research, Design & Analysis
Initially given as part of the combined task with determining the cable sizing requirements,
the initial investigation revealed extensive research was required to ensure the electrical
protection requirements are understood and met.
From Part 1 of the Australian & New Zealand Wiring Rules AS/NZ 3000:2007 (hereafter
denoted as AS3000) section 1.5 defines the three major types of risk in electrical installations
as:
•
•
•
Shock Current – “significant magnitude and duration” to cause electric shock in
normal or fault conditions.
Excessive temperatures – “likely to cause burns, fires and other injurious effects”
Explosive atmospheres – “Equipment installed in areas where explosive gases or
dusts may be present shall provide protection against the ignition of such gases or
dusts.”
To remove and/or mitigate these risks occurring, the AS3000 stipulates protection
comprising of 2 major components.
•
•
Physical Protection – Direct Contact
Fault Protection – Indirect Contact
Physical Protection
Considered ‘basic protection’ against direct contact, “dangers that may arise from contact
with parts of the electrical installation that are live in normal service”, the methods of
protection suggested in AS3000 Section 1.5.4.2 are:
“(a)
(b)
(c)
(d)
Insulation, in accordance with Clause 1.5.4.3.
Barriers or enclosures, in accordance with Clause 1.5.4.4.
Obstacles, in accordance with Clause 1.5.4.5.
Placing out of reach, in accordance with Clause 1.5.4.6.”
(Standards Australia 2009, 41)
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The WA Electrical Requirements (hereafter WAER) define physical protection for equipment
in section 6.5.2.
“Switchboard-mounted service and metering equipment must be protected from:
• The weather, including direct sunlight;
• Mechanical damage;
• Salt or dust-laden air or corrosive atmospheres; and
• Vandalism.”
(Energy Safety Division (EnergySafety) of the Department of Consumer & Employment Protection 2008)
These requirements have a fundamental ‘common sense’ approach to protecting electrical
installation components from physical interaction with unwanted environmental situations
(e.g. water intrusion) and unqualified people.
This component of the electrical installation is described in section 3.8.3 and clearly complies
with the requirement of AS3000 and the WAER. The specific provision of the requirements of
these standards was referred to the experience of the Managing Director as the licensed
electrical contractor.
Fault Protection
“Protection shall be provided against dangers that may arise from
contact with exposed conductive parts that may become live under
fault conditions.” (Standards Australia 2009, 46)
The methods of protection suggested include:
“
(a)
Automatic disconnection of supply, in accordance with Clause 1.5.5.3.
(b)
The use of Class II equipment or equivalent insulation, in accordance with Clause 1.5.5.4.
(c)
Electrical separation, in accordance with Clauses 1.5.5.5 and 7.4.”
(Standards Australia 2009, 73)
Section 1.4.28 describes Class II equipment as simply equipment that does not rely on basic
insulation alone, but utilises additional safety such as double or reinforced insulation.
Part 2 of AS3000 describes the “Installation Practices” that apply.
The most relevant sections of Part 2 of AS3000 and the WAER that needed to be addressed
are in terms of the electrical protection under fault conditions and equipment selection.
This is governed by 5 major components that need to be addressed:
•
Overcurrent
“
a)
b)
•
•
•
overload current, in accordance with Clause 2.5.2 and 2.5.3;
short-circuit current, in accordance with Clause 2.5.2 and 2.5.4.”
(Standards Australia 2009, 75)
Over voltage
Under voltage
Earthing Requirements & Earth Fault Leakage (Residual Current Devices)
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Overcurrent
“An overcurrent protective device or devices ensuring protection against
overload current and short-circuit current shall be placed at the origin of
every circuit and at each point where a reduction occurs in the current carrying capacity of the
conductors.”(Standards Australia 2009, 76)
Overload Current
The basic requirement for overload current is a device or method for automatic
disconnection or limiting of the circuit if the current is greater than the prescribed value
which is less than the current carrying capacity of the transmission path of that circuit such
that:
Figure 42 - Protection Against overload current - (AS300, P77)
Simply put, the Maximum demand has to be less than the current rating of the circuit
breaker, which again has to be less than the current carrying capacity of the conductor in the
circuit. As stated in Appendix B3.2.2.2 in AS3000 the AS/NZS 60898 standard ensures that
the required tripping current for circuit breakers, when designed, complies with equation
2.2.Therefore, as long as the circuit breaker has been designed to Australian or equivalent
International standards then this will always be the case.
Therefore the limiting factor in ensuring overload protection is selection of the devices
nominal current rating to that greater than or equal to the maximum demand of the load
and less than or equal to the current carrying capacity of the conductor.
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Short Circuit Current
The determination of the short circuit current ratings for protective devices is determined by
the prospective short circuit current upstream of the electrical installation.
AS3000 states in section 2.5.4.5 the characteristics of short-circuit protective devices
(‘SPDs’):
“Short-circuit protective devices shall meet the following conditions:
(a) The breaking capacity shall be not less than the prospective short circuit current at the point where the
devices are installed.
Exception: A device having a lower breaking capacity is permitted if another protective device having the
necessary breaking capacity is installed on the supply side. In this case, the characteristics of the
devices shall be coordinated so that the energy let through by these two devices does not exceed that which
can be withstood without damage by the device on the load side and the conductors protected
by those devices. NOTE: In certain cases, other characteristics may need to be taken into account, such as
dynamic stresses and arcing energy, for the device on the load side. Details of the characteristics needing
coordination should be obtained from the manufacturers of the devices concerned.”
(b) All currents caused by a short-circuit occurring at any point of a circuit shall be interrupted before the
temperature of the conductors reaches the permissible limit. For short-circuits of duration up to 5 s, the time in
which a given short circuit current will raise the conductors from the highest permissible
temperature in normal duty to the limit temperature may, as an approximation, be calculated from the
following equation:”(Standards Australia 2009, 80-81)
Figure 43 - Time for short circuit to raise conductor temperature (Standards Australia 2009)
Initially an investigation was undertaken to determine the possibility of calculating the
prospective short circuit current based upon the incoming supply. Referring to notes for
“ENG348 Power Transmission and Distribution Networks” from Murdoch
University(Murdoch University 2010), the determination of short circuit current would
require a network study determining the Thevenin impedances, sequence network
components and in particular the positive sequence impedance for short circuit studies, the
sub transient impedance, and therefore the positive-sequence fault current. Alternatively,
the network study can be conducted utilising power system analysis software such as
DIgSILENT’s PowerFactory®. However, these studies require knowledge of the upstream
network components and while theoretical possible by contacting Western Power, further
research into AS3000, WAER and also the West Australian Distribution Connections Manual
(Western Power 2011), revealed the prospective short circuit current is stated.
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The West Australian Distribution Connections Manual states the low voltage (LV) prospective
short circuit current as 25kA.
“The declared LV fault level at the customer's point of supply (POS) is 25kA where supplied from one
transformer.” (Western Power 2011)
However, the West Australian Distribution Connections Manual also states;
“…the WAER provides for lower fault ratings for direct connected metered equipment, subject to the Service
Protection Device for that installation satisfying specific criteria.”(Western Power 2011)
Therefore the WAER section 6.8.3 SPD for Direct Metering provides the short circuit current
ratings for circuit breakers specified as;
“Consumers wishing to use circuit breakers as an SPD may do so. Such circuit breakers shall be of an approved
manufacture and type and shall have:
• A maximum let-through fault current of 6ka;
• A rated short circuit breaking capacity equal to or greater than the prospective short circuit current at their
point of installation, and in any case, except as follows, shall not be less than 25ka. A circuit breaker with a
rating lower than 25ka may be used if the installation configuration is:
• Single phase with a minimum of 15 metres of 16 mm2 (or smaller size) of consumer mains – 6ka;
• Three phase with a minimum of 20 metres of 10 mm2 (or smaller size) of consumer mains – 6ka.”
The common practices on providing overcurrent (overload and short-circuit) protection is
the installation of circuit breakers and/or fuses.
“Protective devices may be one of the following:
(a) Circuit-breakers incorporating short-circuit and overload releases.
(b) Fuse-combination units (CFS units)
(c) Fuses having enclosed fuse-links (HRC fuses).
(d) Circuit-breakers in conjunction with fuses.”(Standards Australia 2009, 76-77)
The Electrical Engineering Drawings for 1020 Wellington St, Figure 44, shows the short circuit
current as 22kA with 1 sec clearance time, the main incoming cable size to the commercial
unit (the PDC) is 16mm2.
Figure 44 - Master SLD - 1020 Wellington St (GRAY 2000)
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The circuit breaker selection requires determining the circuit breaker coordination which can
be achieved by comparing the time-current curves for cascading or discrimination as shown
in Figure 44.
Figure 45 - Cascading & Discrimination Coordination (Schneider Electric PTY LTD 2003)
The actual point of supply or ‘consumer mains’ is the metering point for the whole 1020
Wellington St Distribution, therefore the radial feeder layout provides current discrimination
(Nereau 2001). Time discrimination is not necessarily applied as the circuit breakers are
based on instantaneous short circuit current ratings. The limiting factor for this installation is
the main incomer circuit breaker which is a Merlin Gerin multi 9 C60N, C50, a 6kA 50A.
To provide coordination between the main circuit breakers and the selected circuit breakers
for the PDC the time-current curves needs to be able to be coordinated which based upon
the provided Merlin Gerin Curve (Figure 47) is difficult to determine. However, Table 4.0.2 in
the Schneider Electric Australian Catalogue (Schneider Electric (Australia) Pty Limited 2011)
can be utilised to provide the required short circuit current determination based upon the
upstream short circuit current (6kA based on the incoming CB), CSA and cable length
between upstream and downstream components. The PDC main switchboard is very close to
the incoming circuit breaker therefore 3.5m is a reasonable estimate, the main incomer
cable CSA is 16mm2 and using the table results in 6kA as the required short circuit breaking
capacity for the installed circuit breakers as shown in Figure 46.
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Figure 46 - Table 4.0.2 Schneider Product Catalogue
Figure 47–Clipsal (Left) vs. Merlin Gerin (Right) - Circuit Breaker Time-Current Curves
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Therefore, Clipsal MCBs with 6kA short circuit current rating were selected with the
appropriate nominal current rating for the position in the circuit (with respect to the
SLD as in section 3.4.1.2 Figure 17) as per equation 2.1 of AS3000, as the overload
and short-circuit overcurrent protection.
Overvoltage
AS3000 notes the “causes of overvoltage in an electrical installation” as:
“(a) an insulation fault between the electrical installation and a circuit of higher voltage.
(b) Switching operations.
(c) Lightning.
(d) Resonant phenomena” (Standards Australia 2009, 103)
AS3000 discusses methods of protection for overvoltage as:
•
•
Insulation or separation
Protection Devices
The insulation component for overvoltage is provisioned by the Australian and
International standards for the manufacturing of electrical devices including cable
insulation and active devices equipment insulation, such as the protective casing of
MCBs. Separation is provisioned by the segregation of circuits in the electrical
installation itself.
The AS3000 standard “does not require installations to be protected against
overvoltages from lightning” or surge protection devices (SPDs) to be installed.
However as part of the installation SPDs will be installed on the ‘essential services’
switchboard for this purpose to increase the reliability of supply for the critical
customer loads.
Undervoltage
“Suitable protective measures shall be taken where—
(a) the loss and subsequent restoration of voltage; or
(b) a drop in voltage; could cause danger to persons or property.
(Standards Australia 2009)
For this electrical installation undervoltage will not cause any danger to persons or
property; however, the PDC concept is to ensure against undervoltage for the
customer IT loads as loss of supply can potentially interrupt their business service.
Therefore undervoltage is mitigated in this case through the provision of UPSs and
standby power generation via the installed diesel generator and ATS.
Earthing Requirements, Earth Fault Loop Impedance& Earth Fault Leakage
(Residual Current Devices)
The requirements in terms of residual current device are that they are to offer
additional protection and it does not replace aforementioned protection.
The latest RCD requirements state that;
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“(vii) Expansion of the use of residual current devices (RCDs) to all socket outlet and lighting circuits
rated up to 20 A.
(viii) Limiting the number of circuits connected to any one RCD to three.
(ix) Requiring the division of lighting circuits between RCDs where the
number of both RCDs and lighting circuits exceeds one.”(Standards Australia 2009, 4)
The RCD requirements have been provided in the non-essential circuit for the
lighting and GPOs and the essential GPOs as per the requirements and as in
indicated in the SLD in section 3.2.
The WAER requires the earthing system to be a Multiple Earthed Neutral System
(MEN) as described in AS3000 and shown Figure 5.1 in AS300 (Figure 48):
“…the earthing system to be used in all low voltage installations shall be the Multiple Earthed Neutral
(MEN) system as defined by the Wiring Rules.
The MEN connection is to be located at the consumer’s main switchboard unless otherwise approved
or directed by the network operator”
(Energy Safety Division (EnergySafety) of the Department of Consumer & Employment Protection,
2008)
Figure 48 - MEN System
AS3000 requires the Earth Fault Loop Impedance (EFLI)be sufficiently low enough to
ensure enough current flows during an active to earth fault to activate the protective
device.
“Effective fault protection by means of automatic disconnection of supply is based on
disconnecting supply from the section of the installation concerned in such a way as to limit
the time/touch voltage relationship to safe values in the event of an insulation fault.
Automatic disconnection is dependent on the characteristics of the circuit protective device
and the impedance of the earthing system.”(Standards Australia 2009, 240)
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AS3000 states the disconnection times are;
•
•
0.4s - for sockets <63A, hand held class 1 equipment or portable
equipment intended for manual movement during use.
5s – where people are not exposed to touch voltages that exceed safe
values.
EFLI involves the following path:
“(a) The active conductor as far as the point of the fault, including supply mains, service line,
consumers mains, submarines (if any) and the final subcircuit.
(b) The protective earthing conductor (PE), including the main earthing terminal/connection or bar
and MEN connection.
(c) The neutral-return path, consisting of the neutral conductor (N) between the main neutral
terminal or bar and the neutral point at the transformer, including supply mains, service line and
consumers mains.
(d) The path through the neutral point of the transformer and the transformer winding.”
(Standards Australia 2009, 240-241)
The earth fault loop path is also illustrated in the following diagram from
(ElectroTECHnik Pty Ltd 2009);
Figure 49 - Earth Fault Loop Impedance Diagram (ElectroTECHnik Pty Ltd 2009)
“Total earth fault loop impedance is approximately equal to the sum of impedances of all of the
circuit components in the fault loop impedance current path shown” (ElectroTECHnik Pty Ltd 2009)
The EFLI can be calculated or measured. Calculating the maximum EFLI can achieved
with the following equation:
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Figure 50 - Earth Fault Loop Impedance Calculation (ElectroTECHnik Pty Ltd 2009)
Table 8.1 of AS3000 also gives approximate maximum values of EFLI for various
protective device ratings. This can be used in conjunction with calculating (requiring
knowledge of all the EFLI values in the path as per Figure 36, i.e. the sum of the
individual impedances if known or specified) or measuring the EFLI (a dedicated EFLI
instrument can be used for measurement of the final installed circuit to ensure
compliance) and ensuring the value is below the maximum allowed value.
For this project the EFLI will be measured upon completion of the final installation to
ensure compliance under the maximum values for the relevant points in the circuit.
Other Requirements - WAER
•
•
•
•
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Power Factor - >0.8 – The UPS input power factor is >0.95
Generator installation must conform to AS/NZS 3010.1
Maximum inrush current
o Three Phase – 33A plus 3.2A per kW > 6kW
This is equal to 33A + (3.2 x 30kW) = 129A, this is a sufficient limit as
the maximum input current of the UPSs is 50A and the circuit
breakers are rated at 50A.
>75kW demand requires network operator approval – If an upgrade to the
main incomer is required, to increase power capacity, network operator
approval will be required anyway.
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3.8.3
Scheduling, Installation & Commissioning
This task was scheduled to be completed by 14/10/2011. The procurement of the
MCBs to facilitate the essentials switchboard, UPSs and up to four racks was
completed on 27/10/2011. Surge protection has not yet been procured and is
scheduled for installation once procured. The overall electrical distribution (essential
and non-essential switchboards, ATS, UPS Distribution Switchboards and load
distribution) installation is approximately 80% complete with the UPS and load
distribution only partially initiated.
Again, the delay in the scheduling of electrical installation is due to resource
constraints and equipment procurement delay as discussed in section 2.3 and the
required ATS modifications as discussed in section 3.4.4.2.
The electrical installation is now estimated to be completed by 25/11/2011.
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3.9 UPS Distribution & Fire Protection System
3.9.1
Scope & Objective
This task involved determining the UPS electrical distribution, the 240V (actually 220V)
distribution, of the output of the UPSs to the rack loads). The distribution had to take into
consideration the kWh metering and the ‘hard wired’ fire protection system. The objective of
this task was to produce a UPS distribution diagram to be used as the installation schematic
for the UPS distribution followed by the actual installation process.
3.9.2
Design & Analysis
3.9.2.1 Fire Protection System
As a condition of building approval from the City of Perth the PDC had to maintain a
2hr fire rating. As part of facilitating this rating and to isolate fire breakout within the
racks the fire protection system utilised in the PDC is based upon an ‘in rack’
methodology using a ‘PyroRack’ device from PYROGEN™. (Buckley 2002)
The ‘PyroRack’ is an autonomous 19” rack mounted automatic fire extinguishing
system which sits at the top of each rack and through a two stage; two zone
monitoring and alarm procedure will release an extinguishant upon the event of a
fire and signal alarms. The two stage process ensure there is no false triggering of
the extinguishant by having two separate zones monitored as well as a delay
between detection zones and allowing for manual shutdown of the extinguishing
process.
This system protects the remaining rack from damage as would occur in a traditional
whole room fire suppression system while also isolating the potential fire more
rapidly. The system conforms to international standards and is manufactured under
an ISO 9002 quality assurance system.
3.9.2.2 UPS Distribution
To accommodate the fire protection system the UPS distribution was configured
according to Figure 51 (full size Appendix I). The diagram represents how each rack is
distributed off the UPS A and B output busses. The UPS are 3 phase in, single phase
out as described in section 3.3.3. The UPS distribution switchboard consists of the
main 40A circuit breaker providing a radial feed to the individual per rack 16A circuit
breakers. Initially only four racks are provisioned, however the switchboards are 17
pole providing room for expansion.
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Figure 51 - UPS Power Distribution (see full size in Appendix I).
If the PyroRack detects a fire, there is a DB-9 control port which provides the
following signals:
D-CONNECTOR FEMALE J1
PIN No.
CONNECTION
1
BELL - POSITIVE
2
SIREN POSITIVE
3
NOT USED
4
GAS RELEASED RELAY N/O
5
GAS RELEASED RELAY N/C
6
BELL – NEGATIVE
7
SIREN – NEGATIVE
8
NOT USED
9
GAS RELASED RELAY COMMON
D-CONNECTOR MALE J2
PIN No.
CONNECTION
1
GENERAL FAULT RELAY N/C
2
GENERAL FAULT RELAY N/O
3
SECOND KNOCK RELAY COMMON
4
GENERAL FIRE RELAY N/C
5
GENERAL FIRE RELAY N/O
6
GENERAL FAULT RELAY COMMON
7
SECOND KNOCK RELAY N/C
8
SECOND KNOCK RELAY N/O
9
GENERAL FIRE RELAY COMMON
Figure 52 - Table of PyroRack Alarm Signals
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The PyroRack has a dedicated UPS system which powers the PyroRack and the rack
extractor fan through the Normally Closed (NC) contact of the ‘gas released’ relay. A
4 Pole NC contactor is connected to the Normally Open (NO) contact of the gas
released relay and therefore will only be energised, opening the contacts which feed
the A and B UPS power to the racks via the top and bottom (for half rack energy
monitoring), upon a fire event. The rack vent actuator will also be powered which
will release the latch holding the vent open. Therefore the fire will be extinguished,
the power will be removed from the rack equipment and the rack will be sealed from
the air conditioning system as required.
Initially the PyroRack was going to be feed off the UPS A feed, it was then
determined that this would obviously cause a problem, if UPS A went down then the
PyroRack would not be operational therefore a dedicated UPS was required for the
fire protection system. Although this UPS could possibly fail, the power drawn for
the PyroRack is negligible and this UPS will be alarmed for notification remotely.
However, for the PDC project the most important factor is the availability of supply
for the customer racks, this is why a NC contactor was chosen, if there is no power
on the PyroRack the NC contactor is closed and the power to the rack is still
supplied.
3.9.3
Schedule, Installation & Commissioning
This task was initially encapsulated in the ‘UPS control system parameterization design,
including fault monitoring to Metro OCC’ deliverable. The Monitoring and Control of the UPS
is discussed in the following section and the ‘UPS Distribution & Fire Protection System’ was
created. The initial task was scheduled to be complete by 7/11/2011, the installation
component has commenced and is approximately 25% complete, however due to the
aforementioned delays and resource constraints, it is scheduled to be finalised as part of the
final installation works over the period 14/11/2011-25/11/2011.
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3.10
Monitoring & Control Design, Implementation & Integration
3.10.1 Scope & Objective
The objective of this deliverable is to research, design and implement the Monitoring and
Control (hereafter ‘M&C’) for the PDC. This task is achieved by researching the designated
M&C equipment, determining the required M&C signals, designing the connectivity of these
signals, then implementing and programming the M&C system and interface.
3.10.2 Research, Design, Analysis & Issues
The primary equipment designated for this task is the use of data logger / web server and
various digital input and output peripheral devices.
The brief from the Managing Director was to utilise the data logger / web server (hereafter
simply referred to as data logger)to monitor and control the PDC power infrastructure,
obtaining the key alarms and measures of the PDC and providing remote control of key
equipment where required (for example the generator remote start). The potential to utilise
currently available devices (spare Input-Output (‘IO’) devices at the Metro Power Operation
and Control Centre (OCC) and other identified commonly used devices.
The initial process of determining the M&C involved researching the data logger device
extensively to determine its operation and programming procedures.
During the research of the data logger device, the main M&C points were identified and
mapped according to the connectivity required. The M&C diagram was created of which the
final draft is shown in Figure 53 (full size Appendix J).
Figure 53 - Monitoring and Control Diagram (see full size in Appendix J).
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The MOXA devices come in various IO configurations as in Figure 54 (RTDs are Resistance
Temperature Detectors and TCs are Thermocouple inputs).
Figure 54 - MOXA Device configurations
The M&C diagram has been through many revisions as the potential devices employed have
been re-configured, some of the initial plans and changes include:
•
•
•
•
•
•
Initially the various MOXA devices were planned for all IO.
The IO configuration included one MOXA E1210 for per 8 racks of energy
monitoring and one MOXA E1210 for 16 racks of fire alarm monitoring.
The Generator room was planned for analogue IO to measure;
o Fuel Level
o Oil Pressure
o Water Temperature
o Engine Temperature
o RPM
o Room Temp
o Room Humidity
o Battery Voltage
Remote Emergency Power Off (EPO) circuit was planned to be implemented
with switching through the data logger Digital Output and signal sent to the
UPS EPO input (when the Socomec system was thought to be the desired
UPS).
Main PDC Energy Meter Changed from ION6200 to JX-51.
Security System Interfaces
The changes that have resulted in the final configuration in Figure 53 have arisen from the
realisation that the available NOVUS devices (4 Input Digital Counter - 4C, 2 Relay Output 2R, and 2 Analogue Input – 2A) could be utilised therefore preventing extra expenditure and
cost. This is coupled with reducing the required initial outlay of purchased devices by utilising
one E1210 to facilitate the energy and fire monitoring for the first 5 racks, which, in light of
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the potential racks available with the existing power supply as calculated in section 3.5.3
being only around 6 or 7, seems appropriate.
The EPO remote circuit was deemed unnecessary and was a potential point of failure for
power system availability which is the highest priority for the PDC project.
Extensive research was conducted and advice sought online with respect to whether the
existing metering on the Generator which includes the analogue measurements above could
be ‘piggybacked’ i.e. the signal wires attached to the various meters could be read/measured
and input (scaled if required) into a MOXA analogue and digital inputs. The most common
advice given from reputable forums such as EEWEB (www.eeweb.com) was that there could
be potential pitfalls when attempting this, and the general consensus was that any metering
that is required should use a new device rather than trying to ‘interface’ to the existing
metering without extensive tracing of the generator circuit. The reasons were varied and
could only be general and not specific, but included some of the issues that may arise, such
as:
•
•
•
•
•
Unequal earth potentials and grounding issues
Common mode voltage problems
Input impedance of the device attached (going “soft” or low if powered down)
Accuracy and calibration issues
Galvanically isolated inputs, large enough input voltage isolation
The specification for the MOXA analogue and digital inputs are:
”Analog Input
Type: Differential input
Resolution: 16 bits
I/O Mode: Voltage / Current
Input Range: 0 to 10 VDC, 4 to 20 mA
Accuracy:
±0.1% FSR @ 25°C
±0.3% FSR @ -10 and 60°C
Sampling Rate (all channels): 12 samples/sec
Input Impedance: 10M ohms (minimum)
Built-in Resistor for Current Input: 120 ohms”
Digital Input
Sensor Type: NPN, PNP, and Dry contact
I/O Mode: DI or Event Counter
Dry Contact:
• Logic 0: short to GND
• Logic 1: open
Wet Contact:
• Logic 0: 0 to 3 VDC
• Logic 1: 10 to 30 VDC (DI COM to DI)
Isolation: 3K VDC or 2K Vrms
ioLogik E1200 Series Introduction
1-6
Counter/Frequency: 250 Hz, power off storage”
(Stemple 2011)
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From these specifications it was reasoned that the input impedance is high enough on the
analogue inputs and the 3KVDC Isolation fairly robust for the digital input, and the question
was posed:
Is it not similar to using a digital multimeter to measure a voltage or current (obviously in
series with the circuit) and if the voltage range was larger than the input range on the MOXA
could it not be scaled with a simple voltage divider?
However, a resolution to this issue has not been determined.
The generator also includes some ‘lamp indicators’ for:
•
•
•
•
Low oil pressure
High water temperature
Battery Charge Low
Low Fuel Level
The Nissha Generator Operation and Maintenance Manual (NIPPON SHARYO, LTD (NISSHA)
2006) includes a basic wiring diagram of the electrical system which while it does not
indicate the operation of the analogue ‘VU’ type meters or fuel level meters etc. it does
clearly show that these indicator are switched between the 24VDC bus and ground.
These ‘lamp’ indicators can be used as digital inputs as they have sufficient digital logic levels
4 to 35VDC for ‘1’ and isolation properties, and therefore these are the only inputs from the
generator planned to be monitored at this stage.
Although not included in the scope of the internship project, the security system interfaces
will require interfacing and implementing as part of the PDC M&C and therefore are included
in the diagram.
The programming of the data logger device incorporates commissioning the interface
devices (Modbus RTU and Modbus TCP/IP), and adding configuration parameters, addresses
of registers (data points), data size and formats to provide successful communication and
interfacing.
The data logger provides the following main internal functionality that can be utilised with
the input and output interface:
•
•
•
•
•
•
Alarming – Trigger alarms based on monitored conditions
Scheduling – of events, manipulating inputs and output based upon daily, weekly
and monthly schedules.
Data Logging – recording data points
Pulse Metering – energy metering
Analogue Function Blocks – mathematical and logical operations
Type Translators – connecting different data types.
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Of these functions the main ones used for the PDC include:
•
•
•
Data Logging of the pulse counts from the MOXA digital inputs that are from the
pulse outputs of the kWh meters and recording of the energy data from the JX-51
devices (which offers a myriad of information including Frequency, Power Factor,
total harmonic distortion (THD), Active-import and export, Reactive and Apparent
power, total and per phase, through the MODBUS RTU interface).
Alarming – configured to alarm via the web interface and potentially SMS indication
for major alarms and security.
Analogue Function Blocks & Type Translator – required to translate the data from
the devices into real world values. For example the PDC Meter value for V1 voltage
requires the following calculation using an analogue function block and type
translator; V1= V1_r×(PT1/PT2)/10 (Unit: V).
The Human Machine Interface (HMI) is basically a web server and can be programmed through the
custom web programming software. It is a basic html web interface except it can be programmed to
connect to Scalable Vector Graphics (SVG) objects which can directly interface to data points for
indication or manipulation.
Figure 55- SVG Objects
The data logger interfaces have been commissioned via the web programming interface and the web
HMI interface is almost complete, the overview screen is shown in Figure 56 (No data has been
recorded yet; further screen shots are given in Appendix K).
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Figure 56 - PDC Web Interface Overview Screen
3.10.3 Schedule, Installation & Commissioning
This task was initially sub-tasks associated with the Generator and UPS Parameterisation,
and the “Integration design of Monitoring and control of system status to Metro OCC” task,
now interpreted as one complete M&C task. This task is approximately 50% complete.
Initially schedule for completion was the 2/11/2011 this task is now estimated to be
complete by 2/12/2011.
3.11
Bill of Materials (BOM)
3.11.1 Scope & Objective
The objective of this deliverable was to collate all of the projects expense for tabulation and
record keeping for the PDC project.
3.11.2 Analysis, Schedule & Commissioning
The BOM is almost complete, and has been tabulated in Microsoft Excel, however the
directors have determined that this information will be not be presented for the internship
report or presentation due to business confidentiality.
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4.0 Engineering Competencies Addressed
All the following engineering competencies have been addressed as part of this project.
4.1
Engineering Practice & Engineering Business Management
Working within the Metro Power Company inherently provides instruction, comprehension and
exposure to engineering practice and business management, including but not limited to,
professional conduct, professional documentation, communication, teamwork, engineering safety
and standards, client liaising and business process decision-making.
4.2
Engineering Planning and Design
This project provides a complete traditional project pathway (see section 3.8) including significant
engineering planning and design requirements.
4.3
Engineering Operations
The PDC project tasks coupled with other project tasks (such as DSM audits) provide exposure to
many facets of engineering operations within Metro Power Company and through observing client
site operations.
4.4
Materials/Components/Systems & Research/Development/Commercialisation
The planning and design of the PDC project, and as previously stated other project tasks (such as
DSM audits) requires research, development and application of many materials, components and
systems to facilitate successful completion of the deliverables. The inherent nature of the PDC
project is as a commercial project that is anticipated to be the pilot project for future commercial
instances of the PDC for future business development.
4.5
Self-Management in the Engineering Workplace& Engineering Project Management
The nature of the assigned work I have been given is that of a supervised Project Engineer, which
means the majority of project tasks are conducted autonomously and require self-management,
including the planning and design as instructed by the Managing Director, Mr Timothy Edwards. The
PDC project is following a traditional project management process as outlined in the project proposal
(Project initiation, Project planning and design stage, Project execution and construction stage,
Project monitoring and controlling systems, Project completion). The installation phase of the project
is conducted by the Managing Director with my assistance as he has the required electrical
contractors licence and is the owner of the assets. All project decisions are reviewed, checked and
authorized by the Managing Director.
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4.6
Environmental Management
The PDC project site is a residential building and therefore the PDC project is subject to
environmental management constraints including visual and noise pollution that must be considered
and mitigated as part of the project design.
4.7
Investigating and Reporting
The fundamental nature of engineering planning, design and implementation of the PDC project
requires significant investigation and reporting as part of the process to achieve the completion of
the deliverables.
5.0 Recommendations
5.1 Communication
As in all work environments, communication is, if not the key, then a major component of project
management. As discussed in this report, many issues and problems that arose could have been
mitigated or alleviated through more in-depth communication, particularly when dealing with quotes
and suppliers and defining project particulars. In terms of supplier communication the imperative is that
they know what you want and when you want it and include as many details as possible to ensure the
correct product or service is provided. Internal communication requires that the right questions are
asked at the appropriate times, only after investigation and research has been conducted if allocated for
the project and/or the required information to complete the task is lacking, or if an executive decision is
required to move forward on the critical path of the task. Therefore, a recommendation for project
management for future projects such as the PDC project is to ensure that all internal and external
communication is comprehensive and succinct.
5.2 Planning
While there is something to be said for ‘getting on with tasks at hand’, the planning process is essential
in ensuring the correct deliverables and methods to facilitate those deliverables are achieved. In
retrospect much of the work done to formulate this report should have been completed as part of the
planning process. The deliverable re-structure for example, provided a more logical comprehension of
the required deliverables. Although many of the scope expansion points arose from a clearer
understanding of the project as it progressed, some time spent in the initial stages planning the scope
and boundaries by, as above, communication and asking the right questions may have improved the
project progression.
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5.3 Product Assessment Matrices
A recommendation provided by the Managing Director was to include a weighted scoring system based
on the assessment matrix attributes so that an overall ‘winner’ is easily identifiable. This was planned to
be included (after being recommended) in the final assessments and report but was not possible due to
time and resource constraints.
6.0 Conclusion
Whilst the PDC project is a relatively small project, it has provided a wealth of engineering, project management,
business operations and liaising experience. Although the project was not finished on schedule, the scope
change, equipment delays and resource management constraints have been managed effectively so that the
project completion date is set back by only a few weeks. The experience and exposure to electrical engineering,
energy management, information technology and industrial process control (to name but a few) provided
outside of the PDC project has also been an invaluable contribution to the internship process. The PDC project
has provided a steep learning curve in terms of practical engineering project management and electrical
engineering experience, and as discussed above the PDC project has more than addressed the relevant
engineering competencies required for the internship unit and has provided a potential employment pathway for
the future.
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Appendix A.1 – Initial Gantt Chart Draft
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Appendix A.2 – Final Gantt Chart
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Appendix B – Energy Metering Options – Product Assessment Matrix
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Appendix C – UPS Options – Product Assessment Matrix
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Appendix D – MTX UPS System – Specifications
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Appendix E – Generator Specifications
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Appendix F – PowerPac® Software Cable Sizing Solution
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Appendix G.1 – Battery Charger – Product Assessment Matrix
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Appendix G.2 – Project IC-800-24 Specifications
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Appendix H – Ceramic Quoting – Product Assessment Matrix and Costing Estimate
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Appendix I – UPS Distribution Diagram
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Appendix J – Monitoring & Control Diagram
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Appendix K – PDC Web Interface Screen Shots
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