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 Raymond Kilgariff – 30759032 Page 1 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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! Raymond Kilgariff – 30759032 Page 2 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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: • • • • • • • • • 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). Raymond Kilgariff – 30759032 Page 3 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 4 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 5 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 6 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 • • • • • • • • • • • • 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: • • • • • • • • • • 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. Raymond Kilgariff – 30759032 Page 7 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 8 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 9 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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: • • • • • • • • • 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: • • • • • • • • • • • • 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. Raymond Kilgariff – 30759032 Page 10 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 11 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 12 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 13 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 14 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Research into products available revealed two main ‘types’ of energy monitoring candidates; • • 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: Raymond Kilgariff – 30759032 Page 15 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 “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. Raymond Kilgariff – 30759032 Page 16 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 17 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 18 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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)). Raymond Kilgariff – 30759032 Page 19 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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) Raymond Kilgariff – 30759032 Page 20 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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) Raymond Kilgariff – 30759032 Page 21 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 • 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) Raymond Kilgariff – 30759032 Page 22 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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) Raymond Kilgariff – 30759032 Page 23 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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). Raymond Kilgariff – 30759032 Page 24 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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); Raymond Kilgariff – 30759032 Page 25 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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: • • • • • • Raymond Kilgariff – 30759032 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; Page 26 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 “…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. Raymond Kilgariff – 30759032 Page 27 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 28 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 29 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 30 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 31 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 • • • • 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 Raymond Kilgariff – 30759032 Page 32 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Figure 18 - Master Single Line Diagram - Final Raymond Kilgariff – 30759032 Page 33 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 34 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 35 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 36 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 37 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 38 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 39 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 40 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Figure 24 - DSE-705 Wiring Diagram (DEEP SEA ELECTRONICS PLC 2003) Raymond Kilgariff – 30759032 Page 41 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 42 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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= Raymond Kilgariff – 30759032 𝑆 = √3𝑉𝐼 50𝑘𝑉𝐴 √3 ∙ 415𝑉 ≈ 70𝐴 Page 43 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 44 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 45 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 = Raymond Kilgariff – 30759032 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝑉𝐴 𝑋𝑑" 𝐹𝑎𝑢𝑙𝑡 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 = 𝐹𝑎𝑢𝑙𝑡 𝑉𝐴 √3 ∙ 𝑉 Page 46 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 Raymond Kilgariff – 30759032 Page 47 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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’. Raymond Kilgariff – 30759032 Page 48 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 49 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 • • • • • • 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. Raymond Kilgariff – 30759032 Page 50 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 51 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 52 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 53 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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) Raymond Kilgariff – 30759032 Page 54 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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). Raymond Kilgariff – 30759032 Page 55 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 56 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 57 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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) Raymond Kilgariff – 30759032 Page 58 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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) Raymond Kilgariff – 30759032 Page 59 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 60 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 61 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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) Raymond Kilgariff – 30759032 Page 62 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 63 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Figure 46 - Table 4.0.2 Schneider Product Catalogue Figure 47–Clipsal (Left) vs. Merlin Gerin (Right) - Circuit Breaker Time-Current Curves Raymond Kilgariff – 30759032 Page 64 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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; Raymond Kilgariff – 30759032 Page 65 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 “(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) Raymond Kilgariff – 30759032 Page 66 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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: Raymond Kilgariff – 30759032 Page 67 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 • • • • Raymond Kilgariff – 30759032 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. Page 68 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 69 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 70 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 71 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 72 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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). Raymond Kilgariff – 30759032 Page 73 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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 Raymond Kilgariff – 30759032 Page 74 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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) Raymond Kilgariff – 30759032 Page 75 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 76 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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). Raymond Kilgariff – 30759032 Page 77 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 78 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 79 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. Raymond Kilgariff – 30759032 Page 80 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 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. 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Raymond Kilgariff – 30759032 Page 89 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix A.1 – Initial Gantt Chart Draft Raymond Kilgariff – 30759032 Page 90 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix A.2 – Final Gantt Chart Raymond Kilgariff – 30759032 Page 91 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix B – Energy Metering Options – Product Assessment Matrix Raymond Kilgariff – 30759032 Page 92 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix C – UPS Options – Product Assessment Matrix Raymond Kilgariff – 30759032 Page 93 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix D – MTX UPS System – Specifications Raymond Kilgariff – 30759032 Page 94 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix E – Generator Specifications Raymond Kilgariff – 30759032 Page 95 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix F – PowerPac® Software Cable Sizing Solution Raymond Kilgariff – 30759032 Page 96 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Raymond Kilgariff – 30759032 Page 97 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Raymond Kilgariff – 30759032 Page 98 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix G.1 – Battery Charger – Product Assessment Matrix Raymond Kilgariff – 30759032 Page 99 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix G.2 – Project IC-800-24 Specifications Raymond Kilgariff – 30759032 Page 100 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix H – Ceramic Quoting – Product Assessment Matrix and Costing Estimate Raymond Kilgariff – 30759032 Page 101 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix I – UPS Distribution Diagram Raymond Kilgariff – 30759032 Page 102 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix J – Monitoring & Control Diagram Raymond Kilgariff – 30759032 Page 103 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Appendix K – PDC Web Interface Screen Shots Raymond Kilgariff – 30759032 Page 104 ENG450 – ENGINEERING INTERNSHIP – FINAL REPORT– 2011 Raymond Kilgariff – 30759032 Page 105