How To Design The Power Supply For Data Centres and Airports

1/24/23, 4:44 PM How to design the power supply for data centres and airports while megawatts of loads
le megawatts of loads rise fast | EEP
How to design the power supply for data centres and

airports while megawatts of loads rise fast
electrical-engineering-portal.com/design-power-supply-data-centres-airports-megawatts-loads-rise-fast
By Edvard December 26, 2022
Traditional LV vs MV Distribution
The first choice for service and distribution voltage is almost always 480 volts. Why is
that? Well, it’s because it’s traditional, it has a safe design and specifications are already
written around 480 V. UPS and backup aggregate equipment are readily available at 480
V. It seems that everything fits. But it’s not. Let’s take a closer look at why this does not
work well for all facilities.
How to design the power supply in data centers and airports while megawatts of loads rise fast (on
photo: Integrated diesel rotary UPS (DRUPS); credit: Rahimafrooz Energy Services Limited)
Despite the economic slowdown worldwide, one area of business investment that
continues to post strong growth, year in and year out, is mission-critical applications, such
as data centres and hospitals – which inevitably increases the infrastructure’s size.
As energy prices continue to rise, harnessing power-related costs has never been more
essential. Now is the time for companies to take a closer look at those tools specifically
engineered to ensure such facilities maximize their power needs.
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Think about the typical everyday data consumption of businesses and people: Nowadays,
everyone expects their Netflix to start streaming instantly, their Amazon buy to go
smoothly, real-time education software, education courses, video chats with Grandpa,
and regular email with attachments. This data needs to be created, handled, and kept.
The modern user wants their information now, but they don’t necessarily comprehend or
appreciate the massive infrastructure required to keep it all or send it around the
world.
Any supporting power infrastructure must have the backup required to minimize damage.
An effective uninterruptible power supply (UPS) system and backup generator are the
foundation of the system.
A device called a UPS, sometimes known as “battery backup“, allows data centres to
continue operating while switching to a generator or another dependable power source.
Table of Contents:
1. Typical Commercial Design of Power Supply

Typical commercial design of facility power supply compromises a utility service
(commonly medium voltage), pad-mounted or distribution step-down transformer with LV
underground secondary feeder, main switchboard with service-main breaker and optional
backup diesel engine generator and transfer devices.
Some facilities optionally might have a UPS system to carry critical loads through
switching transfers.
Figure 1 – Typical commercial design of a facility power system
Figure 1 – Typical commercial design of

a facility power system
Standard power supply systems are not the subject of this technical article. EEP covered
these topics a dozen times in the past. Here you can find related information (articles,
guides).
Go back to the Contents Table ↑
2. Medium Voltage UPS Technology

The trend in the internet and IT industry toward big data centres necessitates an increase
in the need for high dependability electricity at single locations. Large, crucial industrial
processes are becoming more and more dependent on a degree of power quality that is
not available from the public grid.
Because a low voltage distribution with its high current levels is technically and
financially impractical, the electrical power distribution within those installations is
carried out using medium voltage technology.
Figure 2 outlines how large systems allow transformer consolidation and lower costs due
to the different configuration.
Figure 2 – Comparison of power supply designs
Figure 2 – Comparison of power supply designs
Similar to the medium voltage UPS, a centralized high power uninterruptible power
supply (UPS) system is a practical technological option, especially if it is built with an
integrated diesel rotary UPS (DRUPS).
Due to the fewer required transformers, medium voltage UPS technology decreases
space requirements and distribution losses downstream of the UPS. Using a high
grade UPS system keeps short circuit currents to a tolerable level while maintaining a
high level of power distribution dependability.
By paralleling two or more high power UPS or DRUPS systems on a single common
output bus in a N+x configuration, the MV distribution eliminates the need for a sizable
number of low voltage switching devices to provide redundancy.
The grid-to-load interface of a line interactive UPS can be switched from low voltage to
medium voltage components using its modular design, but the UPS’s core components
and storage remain the same. This maintains the positive and comfortable experience
with the operation and upkeep of a trustworthy LV UPS.
Aspects of space and electrical loss are described, along with designs that have been
implemented in the actual world for a data center, an airport, and a semiconductor
factory.
Suggested Video – Largest Rotary UPS System in the Southern Hemisphere: 20MVA
Watch Video At: https://youtu.be/_OyrDZKWjl8
3. Power Demand & Distribution in Today’s High Power

Applications
Over the past ten years, the enormously expanding E-commerce industry has increased
the amount of physical space and electrical power needed to run data centres. Then,
when the power density in kilowatts per m2 increases, consequently, cooling power
becomes a pressing concern. Customers and operators of those data centres demand
an uninterruptible power supply (UPS) system to provide a safe and dependable power
supply.
Because of the possibility of thermal runaway, UPS frequently provides all required
electrical power. One to three megawatts were needed for a typical data center in the
early 90s, but currently, ten to fifty megawatts per installation are quite common.
Additionally, businesses in the chemical, food, and semiconductor industries need a safe
power supply more frequently because they cannot accept significant production
losses brought on by mains interruptions.
The need for a secure power supply of up to 40 MVA has increased as single locations
have gotten bigger. Additionally, the manufacturing area is frequently spread out,
necessitating the distribution of a large amount of electrical power across the space.
Long distances in the power distribution also have to be overcome in applications like
airport runway lighting system.
Figure 3 – Comparison of electricity consumption among countries and datacenters
Figure 3 – Comparison of electricity consumption among countries and

datacenters
4. Limits of LV Distribution in High Power Applications
What would be the solution?

At low voltage system levels of 400 or 480 volts, the common bus quickly reaches its
maximum capacity of about 5 MVA. The capacity of busbars and breakers, which is
around 6000 A on one side, and the switchboards, which normally have a short circuit
capability of 100 kA on the other, are what limit the power to 5 MVA.
Higher ratings for both will cause the switchgear’s costs and dimensions to soar, and the
market’s supply of the parts will be severely constrained.
High currents also result in relatively high resistive losses and high copper cross sections,
both of which raise the cost of power transmission.
Moving to a medium voltage (MV) system level is one technique to decrease the
currents and allow for an additional boost in power. The maximum system power
increases up to 27 MVA using a regular medium voltage breaker size of 1200 A and up to
57 MVA using a breaker size of 2500 A at a typical MV level of 13.2 kV (relatively
common in the US). A system power rating of up to 70 MVA is possible at medium

voltage levels of up to 34.5 kV.
The same electrical principles apply when distributing power using UPSs: Paralleling
UPS modules at a low voltage level on a common bus is subject to the same restrictions.
Figure 4 illustrates a possible situation. Let’s analyze the elements of the concept
presented below.
Figure 4 – The concept of paralleling UPS modules in a high power distribution
Figure 4 – The concept of paralleling UPS modules in a high power

distribution
Several paralleled UPS modules are displayed on the left. An overload of the supply
transformer’s secondary winding and the upstream bus work comes from the addition of
a fourth module (indicated in red).
The UPS group has been relocated to the MV side of the transformer in the middle,
which has resolved the overload issue at the bus work connected to the UPS
modules. However, if you simply use one MV transformer, the LV bus will continue to
operate despite the secondary winding being overloaded.
In order to supply the load, three different transformers are utilized on the right side,
where some of the distribution has also been relocated to the medium voltage side. The
overload scenario for the transformer and LV bus operations is eliminated by dividing the
low voltage distribution into three distinct pathways.
5. Integration of UPS Systems in the MV Distribution

The addition of a transformer to both the input and output side of an MV distribution is a
straightforward solution to integrate one or more common low voltage UPS modules. The
overall number of components, the amount of space needed, and the efficiency of the
entire power supply system all rise as a result of the additional step-up and step-
down transformers.
By using an integrated medium voltage UPS, both transformers can be omitted.
As shown in Figure 5 further components can be saved if a high power UPS replaces four
or five standard dual conversion LV UPS modules. While operating more efficiently, this
arrangement offers space savings around the power supply system.
Figure 5 – Medium voltage UPS technology reduces the total number of components
Figure 5 – Medium voltage UPS technology reduces the total number of components
The line interactive UPS gives the finest option for integration into an MV system out of
the several UPS configurations available on the market.
Figure 3 provides an overview:
1. The MV breakers and coupling choke, which act as a connection between the
mains and the load, can be installed in the MV switchboard in place of the
comparable LV components.
2. The medium-voltage transformer is an additional part and represents the interface
to the remaining standard low-voltage UPS components.
These common low voltage UPS parts include a frequency converter that connects the
energy storage, a synchronous motor-generator that supplies steady and uninterrupted
power for the load, and an optional Diesel engine that is connected via a mechanical
clutch.
Chemical batteries or space-saving flywheels can be used as energy storage to bridge
brief mains disruptions until the diesel engine has taken over the load.
Suggested Video – NASA 360 Flywheel Energy Storage
Watch Video At: https://youtu.be/mz_7UF4KQpk
The fact that all low voltage components, including the complete control electronic and
the operation software, are derived from common and thoroughly tested LV units is a
significant advantage of such a configuration.
The Figure 6 below shows the electrical (single-line diagram) and the physical (grey
boxes) arrangement of the systems components.
Figure 6 – Design of an integrated MV Diesel Rotary UPS (DRUPS)
Figure 6 – Design of an integrated MV Diesel Rotary UPS (DRUPS), showing the electrical
(single line diagram) and the physical (grey boxes) arrangement of the systems components
6. Redundancy Concepts
A high-quality power source for mission-critical applications is predicated on the idea of
redundancy. There are several well-known and tested solutions for LV systems, including
the N+1 parallel redundant concept and the N+N system redundant arrangement
with two redundant A and B feeders that can link dual corded loads.
A redundancy concept is a MUST for a high-quality power supply for mission-critical

applications. There are some well-established and tested solutions for LV systems, such
as the N+1 parallel redundant concept or the N+N system redundant arrangement with
two redundant A and B feeders where dual corded loads can be connected.
These concepts and arrangements can be simply applied to a medium voltage

configuration without any difficulty. They represent straightforward installations that are
easy for operators and maintenance staff to operate.
Figure 7 shows single-line diagrams of such redundant systems. Again, the power
distribution from the UPS location to the load transformers is done in medium voltage.
Figure 7 – Medium Voltage UPS modules in redundant system configurations
Figure 7 – Medium voltage UPS modules in redundant system configurations
The Isolated Parallel System (IP System) is a brand-new, cutting-edge technology that
aims to achieve redundancy while reducing the short circuit power. The loads are
each individually fed by different UPS modules that are partially loaded. When a UPS
module fails, the assigned load will be fed via a shared IP bus that each UPS module
contributes to via an IP Choke.
The fundamental design of a Medium Voltage IP System is shown in Figure 8, which

enables the development of a highly dependable power supply system that has some
advantages over the previous two systems.
Figure 8 – Medium voltage UPS modules integrated in an IP System
Figure 8 – Medium voltage UPS modules integrated in an IP System
7. Floor Space and Losses In Large Systems

In a production facilities or data cenres, floor space is one of the key cost concerns.
Reducing the space needed for infrastructural equipment like power supply frees up more
room for manufacturing or information technology equipment. The area for the UPS
system is frequently restricted and constrained, especially in older buildings, yet the
amount of power needed is rising.
Modern high power UPS modules with kinetic energy storage in LV or MV technology are
very well suited to overcome this challenge.
In Table 1, you can compare the occupied space between various LV and MV redundant
concepts.
In order to do these comparisons, a total load requirement of 10 MVA and a feeding

voltage level of 13.2 kV were used. Typical values for the foot print for static and rotary
UPS modules, 5 minute batteries and switchgear cabinets are taken from manufacturer
brochures. MV transformer and choke are of cast resin dry type with foot prints taken
from real projects.
The complete system is made up of 7 groups, each of which has a 1670 kVA capacity,
and is achieved using either 3 parallel static UPS units or 1 rotational unit for each group.
The rotary unit has flywheel storage, while each static unit has a 5-minute battery. The
7th group adds redundancy, making the configuration 6+1.
Table 1 – Comparison of space required of a 10 MVA, 13.2 kV, N+1 redundant UPS
system in different design concepts
Distrib. UPS Groups Space

voltage Required
Type Voltage Power Energy UPS No. of
Store per groups
group
LV Static LV 600 Battery 3 7 692 m2

kVA
MV Static LV 600 Battery 3 7 921 m2

kVA
MV Rotary LV 1670 Kinetic 1 7 151 m2

kVA
MV Rotary MV 1670 Kinetic 1 7 154 m2

kVA
When comparing the first and second lines in Table 1, it can be seen that placing the
static LV UPS units between a step-up and step-down transformer increases the system’s
overall area need by around 25%. As seen in lines 3 and 4, using a rotary UPS in both
LV and MV results in a significant decrease in space.
Electrical losses should also be taken into consideration in addition to the environmental
footprint. Distribution losses become a problem, especially at long distribution
distances to reach huge industrial sites or dispersed airport regions. Figure 9 compares
the aforementioned arrangements with a 100-meter cable between the UPS and load.
The typical losses for UPSs and transformers are taken from catalogues or brochures.
The losses for the cable have been calculated by using an adequate type of cable
suitable for the current.
In this example, the LV cable produces 1.5% losses (line 1) while the MV cable only
creates 0.1% losses. This is not the best approach because the transformers (line 2)
must endure an additional 2.4% losses due to the step-up step-down method. Losses
are 0.5% lower with the high power one module rotary UPS (line 3), but they are
significantly lower when the step-up step-down transformers are removed (line 4).
The difference between the previous two figures, when losses per year are added
together, is greater than 1 million kilowatt-hours, or almost $100,000 US.
The influence of the cable will increase with longer distribution lengths, improving the
outcome for MV distribution once again.
Figure 9 – Comparison of losses of a 10 MVA, 13.2 kV UPS distribution in different

design concepts
Figure 9 – Comparison of losses of a 10 MVA, 13.2 kV UPS distribution in different design

concepts
However, transmission cabling and distribution must be balanced against MV UPS and
MV switchgear in terms of investment expenses. MV switchgear and UPS modules
obviously cost more than LV components. Less copper can be used for the distribution,
especially in lengthy and complex distribution networks, to offset some of these
higher costs.
If a medium voltage solution is required for technical reasons, the usage of real MV UPS
modules is more cost effective and more efficient than any integration of standard LV
UPS modules in a MV distribution.
Suggested Reading – Civil engineering in installation of substation buildings and

switchboard rooms
8. Examples:
8.1 Medium Voltage UPS In Airport Field Lighting

High reliability power supplies have traditionally been used in safety-related installations
at airports such as radar systems, control towers, and airfield lighting. These vital loads
are dispersed widely around the airfield, therefore medium voltage electrical distribution is
frequently used.
Figure 10 is an example of a medium voltage supply system that uses four 1670 kVA
Diesel UPS modules in a parallel redundant arrangement to provide power to a total
load of 3.8 MW at a voltage level of 20 kV. The MV network is 56 kilometers long
overall. The UPS is added to the current network in series.
Two groups of two paralleled units each make up the arrangement of the four DRUPS.
The switchgear offers operation as n+1 or system-system redundancy depending on the
load needs.
Figure 10 – DRUPS configuration for an airport runway lighting supply
Figure 10 – DRUPS configuration for an airport runway lighting supply
Suggested Video – Diesel Rotary UPS System Hitec 625kVA
Watch Video At: https://youtu.be/rmkyZbzu4JE
8.2 Power Supply of a 35 MW Semiconductor Factory

The second example shows the power supply system of a semiconductor fabrication
plant which includes a cogeneration plant of nine generator sets with natural gas
engines, 3.9 MW each. The distance between the energy plant and the production
facility is several hundred meters for both the transportation of heat and electricity.
The overall voltage level is 20 kV. The UPS system’s job is to interface between the raw
utility bus and the high-quality supply bus in order to offer backup from the utility while
preventing any grid-related problems.
As a second important task the UPS with its flywheel storage provides stabilization power
for a constant voltage and frequency level during transient conditions.
Figure 11 – A flywheel-based energy storage system Kinetic Power Booster in SKODA

car factory
Figure 11 – A flywheel-based energy storage system Kinetic Power Booster in SKODA car factory
In contrast to other UPS systems, the flywheel storage’s special mode of operation
enables distribution and absorption of all available power. Bi-directional power flow
makes it possible to adjust frequency effectively, especially in transient situations and
within strict bounds for the entire system.
A single line diagram of the principal layout is shown in Figure 12.
Figure 12 – Combining cogeneration and grid backup to a high quality power supply for a
semiconductor fabrication
Figure 12 – Combining cogeneration and grid backup to a high quality power supply for a
semiconductor fabrication
8.3 Redundant MV UPS at a High Rise Data Centre
The last example, to be seen in Figure 13, explains the power supply of a large data
centre. The total load, which is made up of a 10.8 MVA short break load and a 28.8
MVA no break load, is close to 40 MVA. At a voltage level of 11 kV, the supply system is
set up as an isolated redundant system.
In addition to one redundant group of four modules to provide backup power in the event
that one of the six primary groups fails, the UPS units are organized into six primary
groups of three modules each. Therefore, there are a total of 22 UPS units, each of
which is configured as an MV Diesel UPS and offers 1600 kVA of continuous power
and 600 kVA of intermittent power.
The further down stream distribution is performed in medium voltage to the individual
floors of the data centre and ends in supply transformers complemented by static transfer
switches close to the IT equipment.
Figure 13 – Single line diagram of a redundant 40 MVA high quality power supply system
for an internet data centre
Figure 13 – Single line diagram of a redundant 40 MVA high quality power supply system for an
internet data centre
The isolated redundant back up line is implemented using two different power supply
routes to the loads: the first on the MV level with automatic transfer switches (ATS) in
front of the supply transformers, and the second on the LV level feeding directly to the
static transfer switches (STS) connected to the loads.
9. Conclusion and What’s Next

Increasing power density and increasing total power demand at single sites combined
with rising requirement for high reliability power in IT business and production facilities
are today’s trends. The power supply system has to respond with suitable UPS and
distribution designs.
The transition to medium voltage level is an appropriate technological solution because,

on the one hand, high power low voltage systems cause current limitations in the
distribution and, on the other hand, long distances must frequently be bridged. MV
systems boost distribution network efficiency by reducing cable size and losses.
Additionally, the utilization of integrated high power MV UPS modules reduces the
number of components to a minimum. Basic parts of those modules are taken from
standard and proven low voltage equipment, including control hardware and software.
The MV UPS enable a clearly laid out high power system configuration, keeping its
complexity within manageable limits.
Suggested Video – Installing DRIPS on data center site: How it looks like
Watch Video At: https://youtu.be/-Zd8vPyE2ds
Savings in actual costs are one clear advantage of switching to a medium voltage
system. A 480 V power distribution system, for instance, necessitates the use of more
distribution-related materials, including copper conductors. Given the exponential growth
in copper prices, this is very irritating.
Smaller and fewer conductors are needed for medium voltage systems, which saves on
the high cost of copper.
The DRUPS method avoids “traditional” constraints and permits the construction of
the facility’s infrastructure at medium voltage levels, followed by distribution using
the much smaller copper cables at the same medium voltage levels. Additionally, it gives
users of this power the flexibility to adjust the voltage level to best suit the cooling
infrastructure and the various tenant applications within a data hall.
For instance, using 4160 V motors for facility cooling may be more effective than using
415 V/240 V servers for one tenant’s operating system or 480 V/208 V servers for
another tenant’s. Distribute the medium voltage to the area that will be using it, then step
down as necessary.
Although static UPS is frequently the simplest option, it is not necessarily the
best. Look into rotary-based UPS systems right now, particularly those
powered by diesel.
Recommended Reading – Automatic transfer switch between three power sources
Sources:
1. Medium Voltage UPS Solutions: When and Why? by Piller

2. Optimizing the Medium Voltage Data Center How to attain infrastructure reliability
and reduce energy usage by HITEC Power Protection
3. Medium Voltage Electrical Systems For Data Centres by Facilities Integration
Incorporated

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1/24/23, 4:44 PM How to design the power supply for data centres and airports while megawatts of loads

le megawatts of loads rise fast | EEP

How to design the power supply for data centres and

By Edvard December 26, 2022

1. Typical Commercial Design of Power Supply

Figure 1 – Typical commercial design of a facility power system

Figure 1 – Typical commercial design of

Go back to the Contents Table ↑

2. Medium Voltage UPS Technology

Figure 2 – Comparison of power supply designs

Figure 2 – Comparison of power supply designs

Watch Video At: https://youtu.be/_OyrDZKWjl8

Go back to the Contents Table ↑

3. Power Demand & Distribution in Today’s High Power

Figure 3 – Comparison of electricity consumption among countries and datacenters

Figure 3 – Comparison of electricity consumption among countries and

Go back to the Contents Table ↑

4. Limits of LV Distribution in High Power Applications

What would be the solution?

common in the US). A system power rating of up to 70 MVA is possible at medium

Figure 4 – The concept of paralleling UPS modules in a high power distribution

Figure 4 – The concept of paralleling UPS modules in a high power

Go back to the Contents Table ↑

5. Integration of UPS Systems in the MV Distribution

By using an integrated medium voltage UPS, both transformers can be omitted.

Figure 3 provides an overview:

Suggested Video – NASA 360 Flywheel Energy Storage

Watch Video At: https://youtu.be/mz_7UF4KQpk

Figure 6 – Design of an integrated MV Diesel Rotary UPS (DRUPS)

Go back to the Contents Table ↑

A redundancy concept is a MUST for a high-quality power supply for mission-critical

These concepts and arrangements can be simply applied to a medium voltage

Figure 7 – Medium Voltage UPS modules in redundant system configurations

Figure 7 – Medium voltage UPS modules in redundant system configurations

The fundamental design of a Medium Voltage IP System is shown in Figure 8, which

Figure 8 – Medium voltage UPS modules integrated in an IP System

Figure 8 – Medium voltage UPS modules integrated in an IP System

Go back to the Contents Table ↑

7. Floor Space and Losses In Large Systems

In order to do these comparisons, a total load requirement of 10 MVA and a feeding

Distrib. UPS Groups Space

LV Static LV 600 Battery 3 7 692 m2

MV Static LV 600 Battery 3 7 921 m2

MV Rotary LV 1670 Kinetic 1 7 151 m2

MV Rotary MV 1670 Kinetic 1 7 154 m2

Figure 9 – Comparison of losses of a 10 MVA, 13.2 kV UPS distribution in different

Figure 9 – Comparison of losses of a 10 MVA, 13.2 kV UPS distribution in different design

Suggested Reading – Civil engineering in installation of substation buildings and

Go back to the Contents Table ↑

8.1 Medium Voltage UPS In Airport Field Lighting

Figure 10 – DRUPS configuration for an airport runway lighting supply

Figure 10 – DRUPS configuration for an airport runway lighting supply

Suggested Video – Diesel Rotary UPS System Hitec 625kVA

Watch Video At: https://youtu.be/rmkyZbzu4JE

Go back to the Contents Table ↑

8.2 Power Supply of a 35 MW Semiconductor Factory

Figure 11 – A flywheel-based energy storage system Kinetic Power Booster in SKODA

A single line diagram of the principal layout is shown in Figure 12.

Go back to the Contents Table ↑

8.3 Redundant MV UPS at a High Rise Data Centre

Go back to the Contents Table ↑

9. Conclusion and What’s Next

The transition to medium voltage level is an appropriate technological solution because,