PowerHour webinar series for consulting engineers

Experts you trust. Excellence you count on.

Paralleling Topologies and Uptime

Institute Tier Ratings

Thursday July 28, 2016 11:00 PDT / 2:00 EDT

(1PDH issued by Cummins)
Welcome!

PowerHour is designed to help our engineer partners to…

 Keep up to date on products, technology, and codes and standards development
 Interact with Cummins experts and gain access to ongoing technical support
 Participate at your convenience, live or on-demand
 Earn PDH
Technical tips:
 Audio is available through teleconference, or your computer (don’t forget to unmute)
 You are in “listen only” mode throughout the event
 Use the WebEx Q&A Panel to submit questions, comments, and feedback
throughout the event. We will provide sufficient Q&A time after presentation
 If you lose audio, get disconnected, or experience a poor connection, please
disconnect and reconnect
 Report technical issues using the WebEx Q&A Panel, or email
powergenchannel@cummins.com

PowerHour Experts you trust. Excellence you count on.

Meet your panelists
Cummins presenters:
Mike Sanford Cody Albertus
Group Leader, North America and Product Management Leader,
Caribbean Application Engineering Mission Critical Segment

Cummins facilitator:
Tom Bakritzes, Global Sales Training Manager

Your local Cummins contacts:

 AZ, ID, NM, NV: Carl Knapp, Cummins Sales and Service, Rocky Mountain Region
 CO, MT, ND, UT, WY: Joe Pekarek, Cummins Sales and Service, Rocky Mountain Region
 IL, MN, WI: John Kilinskis, Cummins Sales and Service, Central Region
 TX: Scott Thomas, Cummins Sales and Service, Gulf Region
 FL, GA, NC: Robert Kelly, Cummins Sales and Service, South Region
 IN, KY, OH, TN, WV: Tom Stadulis, Cummins Sales and Service, East Region 3
PowerHour Experts you trust. Excellence you count on.
Course Objectives

Participants will be able to:

 Identify common paralleling topologies, plus their advantages and
disadvantages, so they can make informed choices in paralleling system
design.
 Recognize effects of system topology on maintainability and scalability so
they can consider these factors in system design.
 Describe Uptime Institute Tier Ratings and their implications on generator
sets and power distribution systems.

PowerHour Experts you trust. Excellence you count on.

Overview

 Common Paralleling Topologies

 Uptime Institute Tier Ratings
 Generator Set Features for Data Centers

PowerHour Experts you trust. Excellence you count on.

Common Paralleling Topologies

PowerHour Experts you trust. Excellence you count on.

Common Topologies

 Isolated Bus
 Isolated Bus with Gen main
 Common Bus
 Transfer Pair
 Main Tie Main
 Multiple Transfer Pair
 System Design Strategies
PowerHour Experts you trust. Excellence you count on.
Isolated Bus 12470 V

480 V
G G G

1200
4000 (TYP 3)

G G G

XXX XXX XXX

ATS
LOADS

LOAD 1

 Simplest, most common topology

 No connection with utility ATS

 Power Interruptions on re-transfer LOAD 2

 Load control required to make sure that sufficient capacity is on line before
connecting loads
 Each generator set must be large enough to carry emergency loads
– Need to be on line in 10 seconds (NFPA 110)
PowerHour Experts you trust. Excellence you count on.
Isolated Bus with Gen Main
 Minimum generator sets online
G G G
before connecting critical load
 Common topology for prime
power XXX XXX XXX

PowerHour Experts you trust. Excellence you count on.

Common Bus
 Low cost
G G G
 Can do open & ramping closed
transition transfer 12470 V
2000
(TYP 3)
 Can’t guarantee 100msec max 480 V

parallel time
 Service Problem: 4000

– Bus maintenance causes interruption in

service to loads
– Loads can not be isolated from gen bus

PowerHour Experts you trust. Excellence you count on.

Transfer Pair
 Allows for bumpless retransfer and
test with load functions G G G

 Good for maintenance as generator 12470 V

2000
source can be isolated from loads 480 V
(TYP 3)

and tested
4000
4000

PowerHour Experts you trust. Excellence you count on.

Main Tie Main
U1 U2

12470 V 12470 V

480 V 480 V
G G G G

3000 3000
1600
(TYP 3)

NO

 Tie is normally open

 Similar to two Common Bus designs
– Similar serviceability issues

PowerHour Experts you trust. Excellence you count on.

Multiple Transfer Pair
G G G

12470 V 12470 V
1600
(TYP 3)
480 V 480 V

3000 3000
3000 3000

 Has better serviceability than Main Tie Main

 System operates like two transfer pairs
 Gens can parallel with either utility but not both
– On closed transition transfer gens sync with one utility at a time

PowerHour Experts you trust. Excellence you count on.

Modular Design - Scalability
G G G G G G G G G G G G

Manual ties for

catastrophic failures

Example:
 Three modules on site, installed in 2008, 2010, 2012
– Long term plan is to add a fourth module
 Each module is sized for 25 MW
– Running at about ½ capacity
PowerHour Experts you trust. Excellence you count on.
Maintenance Bypass
G G G G

12.74 kV/4160 Vac Bypass section allows

maintenance without
interruption

Can load bank

4160/480 Vac 4160/480 Vac 4160/480 Vac

generator sets
Maintenance Bypass and
Load Bank without interruption

Load
Bank
PowerHour Experts you trust. Excellence you count on.
Swing Bus

PowerHour Experts you trust. Excellence you count on.

Uptime Institute Tier Ratings

PowerHour Experts you trust. Excellence you count on.

Tier Level Ratings
 The tier rating system is the industry standard
for benchmarking data center reliability.
 Four tiers, each building on requirement to the
one below (ex. Tier II requires all of Tier I
capability, plus the added requirements).
 Power Generation and distribution is one of 16
subsystems evaluated.
 No fractional tier ratings.
 Tiers do not specify certain equipment, but
rather a level of redundancy and security to
maximize run time.
 To be an enterprise class data center, UPS
and generator sets are required equipment.
 Significant costs associated with higher tier
rating.

PowerHour Experts you trust. Excellence you count on.

Uptime Institute Tier Ratings

Tier I Tier II Tier III Tier IV

Description Basic Redundant Capacity Concurrently Maintainable Fault Tolerant
Capacity N N +1 N +1 2N (N after any failure)
Distribution Paths 1 1 1 Active, 1 Alternate 2 Simultaneously Active
Fault Tolerant No No No Yes
Typical Topology Standby Genset Isolated Bus Dual Transfer Pair Dual Transfer Pair

PowerHour Experts you trust. Excellence you count on.

Tier I - Basic
DG

ATS
Life Safety
Equipment
Tier I *Emergency lighting, and
other emergency functions
Capacity N UPS Input required by local code may
specify an additional ATS
Switchgear
Distribution Paths 1
Concurrently Maintainable No
UPS
Fault Tolerant No

UPS Output Computer

PDU
Switchgear Equipment

PowerHour Experts you trust. Excellence you count on.

Tier II – Redundant Capacity

DG DG
+1

PTC

Etc. Mech. UPS

Tier II ATS ATSATS

Capacity N+1
Distribution Paths 1 UPS Input
Switchgear
Life Safety
Equipment
Concurrently Maintainable No
*Emergency lighting, and
other emergency functions
Fault Tolerant No UPS
UPS required by local code may
specify an additional ATS
+1

UPS Output Computer

PDU
Switchgear Equipment

PowerHour Experts you trust. Excellence you count on.

Tier III: Concurrent Maintainability

 Adds redundancy to network distribution paths as well as

capacity established in Tier II systems.
 Every distribution component can be removed or replaced during
a planned event without loss of service.
– Allows for a more proactive maintenance program
– Enables site to be upgraded as technology, capacity and infrastructure
requirements change
 An unplanned event can still lead to disruption.

PowerHour Experts you trust. Excellence you count on.

 Tier III - Concurrently Maintainable
Gen Gen
N +1

PTC PTC

Etc. . Etc

UPS Input
Switchgear

Mechanical Mechanical

UPS UPS Mechanical

+1 Component

Mechanical
Component
UPS Output Output
Critical MCC Critical MCC
Switchgear Switchgear
Critical Fan
or Pump

Critical Fan
or Pump

Computer
PDU PDU
Equipment

Tier III
Capacity N+1
Distribution Paths 1 Active, 1 Alternate
Concurrently Maintainable Yes
Fault Tolerant No

PowerHour Experts you trust. Excellence you count on.

Case Study: Tier III Data Center Design

 4 Megawatts at 480 VAC

 N + 1 design on the generators
 Redundant paralleling buses
 System is concurrently maintainable
 Tier 3 certified by the Uptime Institute

PowerHour Experts you trust. Excellence you count on.

Case Study: Tier III Data Center Design

PowerHour Experts you trust. Excellence you count on.

Case Study: Tier III Data Center Design

PowerHour Experts you trust. Excellence you count on.

Case Study: Tier III Data Center Design

PowerHour Experts you trust. Excellence you count on.

 Tier IV – Fault Tolerant
Gen Gen Gen Gen
N +1 N +1

PTC PTC

Etc. Etc.

UPS Input UPS Input

Switchgear Switchgear

Mechanical Mechanical

UPS UPS Mechanical UPS UPS

+1 Component +1

Mechanical
Component
UPS Output UPSOutput
Output
Critical MCC Critical MCC
Switchgear Switchgear
Switchgear
Critical Fan
or Pump

Critical Fan
or Pump

Computer
PDU PDU
Equipment

Tier IV
Capacity N after any failure
Distribution Paths 2 Simultaneously Active
Concurrently Maintainable Yes
Fault Tolerant Yes

PowerHour Experts you trust. Excellence you count on.

Case Study: Segmented Paralleling Bus

PowerHour Experts you trust. Excellence you count on.

Generator Set Features for Data
Centers

PowerHour Experts you trust. Excellence you count on.

Generator Sets for Tier III or Tier IV Systems

 “Disruptions to the utility power are not considered a failure but an

operational condition for which the site must be prepared”
 “A Tier III or Tier IV engine-generator system, along with its power paths
and other supporting elements shall meet … performance confirmation tests
while they are carrying the site on engine-generator power”
 “Engine-generators for Tier III and Tier IV sites shall not have a limitation on
consecutive hours of operation when loaded to ‘N’ demand”

PowerHour Experts you trust. Excellence you count on.

ISO Ratings (8528-1 Section 13)

 Emergency Standby Power (ESP)

– For supplying emergency power for the duration of a utility power failure
– Not to exceed 200 hrs/yr
– Average load factor of 70% of the standby rating over 24 hour period
 Limited Time Prime Power (LTP)
– Limited number of hours 500 hr/year
– Non-Variable load
– Applications not to exceed 100% of the Limited Time Prime Power rating
 Unlimited Time Prime Power (PRP)
– Unlimited number of hours per year (8760 hr/yr less service)
– Variable load
– Not to exceed 70% average of the Unlimited Time Prime Power rating during any operating period of 24 hours
 Continuous Operating Power (COP)
– Unlimited number of hours per year (8760 hr/yr less service)
– Non-Variable load
– Applications not to exceed 100% of the Continuous Operating Power rating

PowerHour Experts you trust. Excellence you count on.

Data Center Continuous Ratings
 Data Center Continuous (DCC) Ratings
meet the Uptime Institute Tier III and Tier
IV requirements
 Data Center Continuous (DCC) Rating is
defined as:
The maximum power which the generator is capable
of delivering continuously to a constant or varying
electrical load for unlimited hours in a data center
application.

PowerHour Experts you trust. Excellence you count on.

Redundant Options
Redundant Starters Redundant Fuel Filters

Starter 1 & 2

Left Side of Engine

Starter 3 & 4
 Redundant Fuel Filters w/Selector Valve
on Primary Stage of Fuel Filtration

Right Side of Engine

 Allows for fuel filter change without
interruption to generator set operation
PowerHour Experts you trust. Excellence you count on.
Coolant Heating

 Coolant Heater Installation

 Heater Element
 Circulation Pump
 Coolant Circulation Benefits
 Consistent Heat Throughout Block

PowerHour Experts you trust. Excellence you count on.

DC Load Management

 Pre-Wired, factory-tested and validated common DC distribution box

streamlines service and installation
– Single point of DC distribution
– Allows for isolation of batteries of individual starters
– Improves ability to safely service and trouble shoot
– Enables breaker to be reset, rather than removing battery

PowerHour Experts you trust. Excellence you count on.

Minimized AC Connections

 Set-mounted AC distribution box accounts for all of the generator

set’s single-phase AC accessories
– Single point of connection to the
generator set’s powered accessories
– Simplifies design and facilitates
installation
– Improves ability to safely service
and troubleshoot
– Contributes to clean/neat design
of generator set

PowerHour Experts you trust. Excellence you count on.

Integrated Monitoring Sensors

Sensors that are integrated and connected to the generator

set control are critical to providing advanced notification of a
maintenance or service need.

Examples
 Air cleaner restriction indicators
 Exhaust port temperature
 Alternator bearing and RTD

PowerHour Experts you trust. Excellence you count on.

Cooling System

 Factory designed, validated and supplied cooling systems capable

of 40C and 50C ambient temperatures are critical when it comes to
providing the performance and reliability that data center customers
demand.

39
PowerHour Experts you trust. Excellence you count on.
Summary

 Using standard system topologies makes the system

more reliable and serviceable.
 Consider ease of maintenance and future expansion
when designing system topology.
 The Uptime Institute Tier Rating system serves as a
good framework for evaluating redundancy,
maintainability and scalability in a system design.

PowerHour Experts you trust. Excellence you count on.

Q&A

 Type your questions, comments, feedback in the WebEx

Q&A box. We will get to as many questions as we can
 We will publish consolidated FAQ along with
presentation and webinar recording on
powersuite.cummins.com
More questions or support needed? Here are your local Cummins contacts:
 AZ, ID, NM, NV: Carl Knapp (carl.knapp@cummins.com), Rocky Mountain Region
 CO, MT, ND, UT, WY: Joe Pekarek (joe.a.pekarek@cummins.com), Rocky Mountain Region
 IL, MN, WI: John Kilinskis (john.a.kilinskis@cummins.com), Central Region
 TX: Scott Thomas (m.scott.thomas@cummins.com), Gulf Region
 FL, GA, NC: Robert Kelly (robert.kelly@cummins.com), South Region
 IN, KY, OH, TN, WV: Tom Stadulis (thomas.stadulis@cummins.com), East Region
 For other states and territories, email pow ergenchannel@cummins.com or visit http://pow er.cummins.com/sales-service-locator

PowerHour Experts you trust. Excellence you count on.

Closing
 Watch out for a follow-up email including
– A Link to webinar recording
– A PDH Certificate
– A 2-minute survey link. Tell us how we did and how we can improve

 Visit powersuite.cummins.com for

– PowerHour webinar recording, presentation and FAQ archive
– Other Cummins Continuing Education programs
– Sizing and spec development tool

 September webinar: NEC Update

PowerHour Experts you trust. Excellence you count on.