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Increasing the Efficiency of UPS Systems – And Proving It!

Increasing the Efficiency of UPS Systems – And Proving It!. Richard L. Sawyer Director, Critical Facilities Assurance EYP Mission Critical Facilities www.eypmcf.com. The Problem. 60% of US Energy bill is in buildings.

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Increasing the Efficiency of UPS Systems – And Proving It!

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  1. Increasing the Efficiency of UPS Systems – And Proving It! Richard L. Sawyer Director, Critical Facilities Assurance EYP Mission Critical Facilities www.eypmcf.com

  2. The Problem • 60% of US Energy bill is in buildings. • Energy consumed by data centers more than doubled between 2000 and 2005 – J. Koomey, Stanford University. • U.S. Data center electrical bills totaled $2.7 Billion in 2005. • A single, moderate size server in a data center has the same carbon foot print as a SUV that gets 15 MPG (R.Muirhead, Data Center Journal). • A single rack with 6 Blade Server units consumes as much power as 3 kitchen electric ranges (24-30Kw)!

  3. Relative Power Densities

  4. 21st Century Computing – Blade Servers Power = Up to 6 kW per Blade chassis or 30 kW per rack

  5. Where does the power go? UPS = 18% Actual IT Load is 30% of Power Consumed APC-MGE: Neil Rasmussen

  6. Lightning Strikes Faulty Switchgear Storms High Winds Falling Trees Traffic Accidents OUTAGE INPUT POWER FROM UTILITY/GENERATOR Faulty Switchgear Heavy Loads Poor Distribution SAG SWELL Poor Distribution UPS OUTPUT POWER Switching Operations Poor Filters Faulty Load Eq. Static Electricity RF Interference SPIKE DISTORTION Harmonics/ Electronic Loads Poor Distribution PURPOSES OF UNINTERRUPTIBLE POWER SUPPLY 1.Maintain clean, uninterrupted power during utility events 2.Power Conditioning 3.Isolation from other electrical loads 4.Separately Derived Source of Power FREQUENCY Major Utility Problems Faulty Generator

  7. Strategy to Improve UPS Efficiency • Technology: Make the units more efficient. • Selection: Size the units more closely to the load. • Application: Use redundancy only where it is needed. IBM Blue Gene 1.2 Megawatt

  8. Understanding UPS Inefficiency Factors No-Load Losses Proportional Losses Square-Law Losses Paying the price to process power!

  9. EPRI Efficiency Curves for UPS Products

  10. Typical UPS efficiency curve Below 30% loadefficiency drops rapidly Nominal 92% efficiency only applies when UPS load is over 70% 100% 90% 80% 70% 60% UPSEfficiency 50% 40% 30% 20% 10% 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% UPS Load% of full power rating

  11. 13.5 KV 13.5 KV 2(N+1) System 480 480 Each side must have capacity to support both critical loads but maintain redundancy. Total load cannot exceed capacity of 2 UPS Modules. EFFECTIVE DESIGN LOAD = 33% of total capacity, maximum. Primary Bus A Primary Bus B UPS UPS UPS UPS UPS UPS Bypass A Bypass B Load Bank Load Bank UPS Output 2A UPS Output 2B Subsystem Bus A Subsystem Bus B Critical Load Bus A Critical Load Bus B Static Switch Static Switch PDU PDU Critical Load

  12. EFFICIENCY UPS internal power consumption (loss) 93.4% 93.4% Proportional and square losses 93.3% } 93.3% } Power delivered to load 93.1% 93.1% 92.8% 92.8% No-load portion of loss stays constant from full load all the way down to zero load 92.4% 92.4% 91.8% 91.8% Many data centers 90.7% 90.7% operate in this range operate in this range 88.9% 88.9% 85.5% 85.5% 76.4% 76.4% No-load loss is present even at no load 0% 0% { 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% UPS load % of full power rating Aggregate UPS Power Losses

  13. No Load Losses • Definition: The power consumed by the UPS at 0% load just to keep the UPS operating. • Sources – Transformers, capacitors, logic systems, fans, communications cards. • Sometimes referred to as “tare”, “constant”, “fixed”, “shunt” and “parallel” losses. • Most significant inefficiency: Accounts for up to 40% of UPS losses.

  14. Proportional Losses • Definition: The power needed to process more power through the UPS. • Sources – Switching losses, capacitor and inductor impedance, internal resistance • Proportional losses increase as the output load the UPS support increases. • Proportional losses are directly related to the topology (internal design) of the UPS.

  15. Square - Law Losses • Definition: Losses related to the amount of current flowing through the UPS. • Power is the result of voltage times the current. • Current does the work, and power is lost as the amount of current flowing increases, by a square factor, hence “square – law losses”. • Power loss is in the form of heat. • Square-Law losses are 1% to 4% at higher load levels.

  16. SQUARE-LAW loss TOTAL LOSS Electrical Loss in kW (Waste due to inefficiency) PROPORTIONALloss NO-LOAD loss No Load Full Load 10% 30% 50% 70% 90% Equipment Loading Power Loss Component Graph

  17. Two devices with same nameplate efficiency can have significantly different losses in actual operating range, due to the particular characteristics of their PROPORTIONAL and NO-LOAD losses Same nameplate efficiency (full-load loss) Example: Two different 100kW UPSs with 92% nameplate (full-load) efficiency 10kW Loading where most data centers operate Electrical Loss (Waste due to inefficiency) UPS A TOTAL LOSS UPS B has higher proportional loss (steeper line) but lower no-load loss UPS B TOTAL LOSS UPS A No-load loss UPS B No-load loss But different performance at actual operating load 0kW No Load Full Load 10% 30% 50% 70% 90% Equipment Loading

  18. One device can even have WORSE nameplate efficiency than another, yet have lower loss in actual operating range, if it has a low NO-LOAD loss Example: Two 100kW UPSs with same 92% nameplate (full-load) efficiency UPS A has better nameplate efficiency (lower full-load loss) 10kW Loading where most data centers operate B A Electrical Loss (Waste due to inefficiency) UPS A TOTAL LOSS UPS B has higher proportional loss (steeper line) but lower no-load loss UPS B TOTAL LOSS UPS A No-load loss UPS B No-load loss But UPS B performs better at actual operating load 0kW No Load Full Load 10% 30% 50% 70% 90% Equipment Loading

  19. Improving Efficiency Technology Selection Application

  20. Improving Efficiency – Fixing No-Load Loss Effect of lowering NO-LOAD LOSS Example: 100kW UPS with 92% full-load efficiency 10kW Nameplateefficiency goes from 92% to94.5% Same improvement in nameplate efficiency Loading where most data centers operate Total loss before improvement Electrical Loss (Waste due to inefficiency) Total loss after improvement Electric bill savings OriginalNo-load loss But waste is roughly cut in half in actual operating range Lowered No-load loss 0kW No Load Full Load 10% 30% 50% 70% 90% Equipment Loading

  21. Improving Efficiency – Fixing Proportional Loss Effect of lowering PROPORTIONAL LOSS Example: 100kW UPS with 92% full-load efficiency 10kW Nameplateefficiency goes from 92% to94.5% Loading where most data centers operate Total loss before improvement Electrical Loss (Waste due to inefficiency) Total loss after improvement Electric bill savings (UnchangedNo-load loss) Waste is reduced by 10-20% in actual operating range 0kW No Load Full Load 10% 30% 50% 70% 90% Equipment Loading

  22. Rack Based UPS Systems as needed for 2N redundancy M HEAT REJECT S E C U R UPS UPS UPS UPS F I R E Cold Aisle Hot Aisle Cold Aisle Hot Aisle Cold Aisle CRAC CRAC CRAC CRAC EPO pdu pdu pdu pdu HEAT REJECT Central UPS for one “N” side, scalable, modular system M UPS CRAC Site Availability – 99.995% SYSTEM MONITOR Battery $2,000+ per square foot WEBLINK Application Efficiency – Zoned Redundancy

  23. Commissioning UPS Systems Availability The Cost of Downtime The Value of Commssioning

  24. Data Center Tier Ratings * The Uptime Institute

  25. Maximizing Availability Total Time - Downtime Availability = Total Time • The only variable is Downtime • Downtime sources: Equipment Failures, Human Error, External Causes, Maintenance Cost of Downtime drives the Value of CFA!

  26. What does Downtime Cost?

  27. The Reliability Curve for equipment (IEEE) Infant Mortality Period End-of- Life Period High Probability of Downtime Failure Rate Time (Data Center Life Span) “The Bathtub Curve”

  28. The Value of Commissioning Infant Mortality Period End-of- Life Period Minimize Failures Time

  29. Commissioning UPS Systems • Verify the full load performance of each module using load banks – typical burn in is 4 hours at rated KW load (hint: infrared inspections of all connections). • Measure and verify the efficiency in the full operating range at 5%, 10%, 15%, 20%, 25%.......... • Verify system redundancy under design load levels. • Verify failure modes (under-voltage transfers, bypass transfers, over load shutdown). • Verify isolation modes for concurrent maintenance. Assuring you get the reliability and efficiency you pay for!

  30. Questions? Richard L. Sawyer 518-337-2049 rsawyer@eypmcf.com

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