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Uninterruptible Power Supplies Ltd
UPS Design – A Case Study
Mike Elms
Technical Manager
Uninterruptible Power Supplies Ltd
www.upspower.co.uk
Modularity in UPS Design –What does it Mean, What are the Pro’s and Con’s?
1995 20162002 2007 2014
From Inefficient, Large-Footprint Transformer UPS…
…To Efficient, Small-Footprint Transformerless UPS
Standalone UPS Technology Innovation
Modular UPS Technology Innovation
UPS Systems Topologies
“N” System
UPS Capacity = Load
N = 200 kW
=
“N + 1” System
A
N+1 = 200kW + 200kW
Standalone Modular
B
Redundant
Capacity
N 1+
200kW
N+1 = 200kW + 100kW
Load = 200kW
= =100 kW
Redundant
Capacity
100 kW
Redundant
Capacity
Load =
200kW
200kW
200kW
Redundant
Capacity
100 kW
Redundant
Capacity
A = B = 200 kW
UPS Systems Topologies
“N + N” or “2N” SystemUPS Capacity = LoadUPS Capacity = Load
2N = 2 x 200kW
=
Standalone Modular
=A B
Lo
ad
=
200kW
2N = 2 x 200kW
A
N N
A = B = 200 kW
Redundant
CapacityRedundant
Capacity
100 kW
Redundant
Capacity
100 kW
Redundant
Capacity
UPS Systems Topologies
“2(N+1)” SystemUPS Capacity = Load
2(N+1) = 2(200kW + 200kW)
Standalone Modular
2(N+1) = 2(200kW + 100kW)
= =
Lo
ad
=
200kW
RedundantCapacity
RedundantCapacity
RedundantCapacity
RedundantCapacity
+N 1 +N 1
Lo
ad
=
200kW
150 kW
Redundant
Capacity
150 kW
Redundant
Capacity
150 kW
Redundant
Capacity
150 kW
Redundant
Capacity
200 kW 200 kW 200 kW 200 kW
200 kWRedundant
Capacity
100kW
200 kWRedundant
Capacity
100kW
Lo
ad
=
200kW
BA BA
A = B = 200 kW
UPS Systems Topologies
UPS System
Configuring a UPS System
Configuring a UPS System:-
A Quick Guide
UPS System
Design Criteria
Static UPS System:
200kVA
N+1
Battery Autonomy:
15 mins
UPS System
Battery range
Battery System
Tip!
Fewer number of Battery Strings of larger blocks
= Commercially advantageous
≠Resilience
Selecting a UPS
“N + 1” System
A BRedundantCapacity
200kW
100 kWRedundant
Capacity
100 kWRedundant
Capacity
100 kWRedundant
Capacity
33 kWRedundant
Capacity
33 kWRedundant
Capacity
33 kWRedundant
Capacity
Redundant
Capacity
200KVA N+1 Standalone
Topology (2 x 200kVA)
A B
Redundant
Capacity
Load =
200kVA
Redundant
Capacity
A = B = 200 kVA
200KVA N+1 Standalone
Switchgear (2 x 200kVA)
Bypass Switch
UPS 1
UPS 2
200KVA N+1 Standalone
Separate Battery Options
15 minute
Battery System per
200kVA UPS frame,
Single string
Note:- 400kVA of
Batteries
Weight 4,900Kgs
1 x 50 x
SWL4250
200KVA N+1 Standalone
Separate Battery Options
15 minute
Battery System per
200kVA UPS frame,
Multiple strings,
Limited redundancy
Note:- 400kVA of
Batteries
One string =
3.5 minutes
Weight 5,600Kgs
2 x (2 x 50) x
SWL2300
200KVA N+1 Standalone
Separate Battery Options
15 minute
Battery System per
200kVA UPS frame,
Multiple strings,
With redundancy
2 x (2 x 50) x
SWL4250
Note:- 800kVA of
Batteries
Weight 9,800Kgs
200KVA N+1 Standalone
Separate Battery Options
15 minute
Battery System per
200kVA UPS frame,
Multiple strings,
With redundancy
Note:- 600kVA of
Batteries,
Two strings
= 15 mins
Weight 8,400Kgs
2 x (3 x 50) x
SWL2300
200KVA N+1 Standalone
Common Battery Options
15 minute Common
Battery System between
Each 200kVA UPS frame
Note:- 200kVA of
Batteries
Weight 2,450Kgs
1 x 50 x
SWL4250
200KVA N+1 Standalone
Common Battery Options
15 minute Common
Battery System between
Each 200kVA UPS frame,
Multiple strings,
Limited redundancy
Note:- 200kVA of
Batteries
One string =
3.5 minutes
Weight 2,800Kgs
2 x 50 x
SWL2300
200KVA N+1 Standalone
Common Battery Options
15 minute Common
Battery System between
Each 200kVA UPS frame,
Multiple strings,
With redundancy
2 x 50 x
SWL4250
Note:- 400kVA of
Batteries
One string =
15 minutes
Weight 4,900Kgs
200KVA N+1 Standalone
Common Battery Options
15 minute Common
Battery System between
Each 200kVA UPS frame,
Multiple strings, with
One string redundancy
Note:- 300kVA of
Batteries
Two strings =
15 minutes
Weight 4,200
3 x 50 x
SWL2300
Selecting a UPS
“N + 1” System
A BRedundantCapacity
200kW
100 kWRedundant
Capacity
100 kWRedundant
Capacity
100 kWRedundant
Capacity
33 kWRedundant
Capacity
33 kWRedundant
Capacity
33 kWRedundant
Capacity
Redundant
Capacity
200KVA N+1 Standalone
Topology (3 x 100kVA)
A B
Redundant
Capacity
Load =
200kVA
Redundant
Capacity
A = B = C = 100 kVA
C
Redundant
Capacity
200KVA N+1 Standalone
Switchgear (3 x 200kVA)
Bypass Switch
UPS 1
UPS 2
UPS 3
200KVA N+1 Standalone
Separate Battery Options
15 minute
Battery System per
100kVA UPS frame,
Single string
Note:- 300kVA of
Batteries
Weight 4,200Kgs
1 x 50 x
SWL2250
200KVA N+1 Standalone
Separate Battery Options
15 minute
Battery System per
100kVA UPS frame,
Multiple strings,
Limited redundancy
Note:- 300kVA of
Batteries
One string =
3.5 minutes
Weight 4,350Kgs
3 x (2 x 50) x
SWL1100
200KVA N+1 Standalone
Separate Battery Options
15 minute
Battery System per
100kVA UPS frame,
Multiple strings,
With redundancy
Note:- 600kVA of
Batteries
Weight 8,400Kgs
3 x (2 x 50) x
SWL2250
200KVA N+1 Standalone
Separate Battery Options
15 minute
Battery System per
100kVA UPS frame,
Multiple strings,
With redundancy
Note:- 450kVA of
Batteries,
Two strings
= 15 mins
Weight 6,525
3 x (3 x 50) x
SWL1100
200KVA N+1 Standalone
Common Battery Options
15 minute Common
Battery System between
Each 100kVA UPS frame
Note:- 200kVA of
Batteries
Weight 2,450Kgs
1 x 50 x
SWL4250
200KVA N+1 Standalone
Common Battery Options
15 minute Common
Battery System between
Each 100kVA UPS frame,
Multiple strings,
Limited redundancy
Note:- 200kVA of
Batteries
One string =
3.5 minutes
Weight 2,800Kgs
2 x 50 x
SWL2300
200KVA N+1 Standalone
Common Battery Options
15 minute Common
Battery System between
Each 100kVA UPS frame,
Multiple strings,
With redundancy
Note:- 400kVA of
Batteries
One string =
15 minutes
Weight 4,900Kgs
2 x 50 x
SWL4250
200KVA N+1 Standalone
Common Battery Options
15 minute Common
Battery System between
Each 100kVA UPS frame,
Multiple strings, with
One string redundancy
Note:- 300kVA of
Batteries
Two strings =
15 minutes
Weight 4,200Kgs
3 x 50 x
SWL2300
Selecting a UPS
“N + 1” System
A BRedundantCapacity
200kW
100 kWRedundant
Capacity
100 kWRedundant
Capacity
100 kWRedundant
Capacity
33 kWRedundant
Capacity
33 kWRedundant
Capacity
33 kWRedundant
Capacity
Redundant
Capacity
200KVA N+1 Modular
Topology (5 x 50kVA)
Load =
200kVA
5 X 50kVA = 200 kVA N+1
200KVA N+1 Standalone
Topology (5 x 50kVA)
Bypass Switch
MODULAR
UPS 1
50kVA
50kVA
50kVA
50kVA
50kVA
200KVA N+1 Standalone
Separate Battery Options
1 x 50 x
SWL1100
Note:- 250kVA of
Batteries
Weight 5800Kgs
200KVA N+1 Standalone
Common Battery Options
Note:- 200kVA of
Batteries
Weight 2,450Kgs1 x 50 x
SWL4250
15 minute
Battery System per
UPS frame,
Single string
200KVA N+1 Standalone
Common Battery Options
15 minute
Battery System per
UPS frame,
Multiple strings,
Limited redundancy
Note:- 200kVA of
Batteries
One string =
3.5 minutes
Weight 2,800Kgs2 x 50 x
SWL2300
200KVA N+1 Standalone
Common Battery Options
15 minute
Battery System per
UPS frame,
Multiple strings,
With redundancy
Note:- 400kVA of
Batteries
One string =
15 minutes
Weight 4,900Kgs2 x 50 x
SWL4250
Selecting a UPS
“N + 1” System
A BRedundantCapacity
200kW
100 kWRedundant
Capacity
100 kWRedundant
Capacity
100 kWRedundant
Capacity
33 kWRedundant
Capacity
33 kWRedundant
Capacity
33 kWRedundant
Capacity
Redundant
Capacity
200KVA N+1 Modular
Topology (5 x 50kVA)
Load = 200kVA
3 X 100kVA = 200 kVA N+1
200KVA N+1 Standalone
Topology (5 x 50kVA)
Bypass Switch
MODULAR
UPS 1
Spare
100kVA
100kVA
100kVA
Spare
200KVA N+1 Standalone
Separate Battery Options
Note:- 300kVA of
Batteries
Weight 4,200Kgs1 x 50 x
SWL2250
200KVA N+1 Standalone
Common Battery Options
Note:- 200kVA of
Batteries
Price £8,750
Weight 2,450Kgs
1 x 50 x
SWL4250
15 minute
Battery System
Per UPS frame,
Single string
200KVA N+1 Standalone
Common Battery Options
15 minute
Battery System per
UPS frame,
Multiple strings,
Limited redundancy
Note:- 200kVA of
Batteries
One string =
3.5 minutes
Weight 2,800
2 x 50 x
SWL2300
200KVA N+1 Standalone
Common Battery Options
15 minute
Battery System
Per UPS frame,
Multiple strings,
With redundancy
Note:- 400kVA of
Batteries
One string =
15 minutes
Weight 4,900Kgs
2 x 50 x
SWL4250
Calculating battery systems is a process of iteration…
Battery Systems
Calculating a Battery System - Variables
Pre-requisite
Load kVA + p.f
Autonomy
Variables
End of discharge voltage
Temperature
UPS efficiency
Manufacturing tolerance
Battery Systems
Calculating a Battery System
Watts per Cell Chart @ 20Deg C
Constant Power Discharge Table for SWL2500
EODV (W/Cell)
Discharge Time (min)
VPC 2 3 4 5 6 7 8 9 10 15
1.5 768 758 748 703 625 568 543 520 502 378
1.6 763 751 717 649 583 553 532 513 490 373
1.65 757 733 668 605 562 542 522 505 477 370
1.7 737 680 613 568 545 526 508 488 453 363
1.75 673 605 565 542 522 503 483 452 430 347
1.8 547 530 517 507 495 463 435 417 400 320
1.85 515 502 488 452 432 412 397 382 368 290
1.9 390 382 377 372 367 363 360 353 340 268
Battery Systems
Calculating a Battery System
Effect of Temperature
Constant Power Discharge Table For The SWL2500
EODV (W/Cell)
Discharge Time (min)
VPC 2 3 4 5 6 7 8 9 10 15
1.5 738 656 596 570 546 527 397
1.6 753 682 612 581 558 539 515 392
1.65 769 702 635 590 569 548 530 501 389
1.67 747 679 620 583 562 542 523 491 386
1.7 714 644 597 572 552 534 513 476 381
1.75 707 635 593 569 548 528 507 474 452 364
1.8 574 557 543 532 520 486 457 438 420 336
1.85 541 527 513 474 453 432 417 401 387 305
1.9 410 401 396 390 385 381 378 371 357 282
Watts per Cell Chart @ 25Deg C
Battery Systems
UPS Efficiency
Overall UPS Efficiency 96.1%
Inverter Efficiency 1%
Calculating a Battery System
200kVA @ 0.8 p.f. @ 97.1% UPS efficiency = 164,778W
164,778W /50 Battery Blocks/6 Cells per Block = 549 WPC
Watts per cell table @ 25Deg C EODV @ 1.67
Constant Power Discharge Table For The SWL2500
EODV (W/Cell)
Discharge Time (min)
VPC 2 3 4 5 6 7 8 9 10 15
1.5 738 656 596 570 546 527 397
1.6 753 682 612 581 558 539 515 392
1.65 769 702 635 590 569 548 530 501 389
1.67 747 679 620 583 562 542 523 491 386
1.7 714 644 597 572 552 534 513 476 381
1.75 707 635 593 569 548 528 507 474 452 364
1.8 574 557 543 532 520 486 457 438 420 336
1.85 541 527 513 474 453 432 417 401 387 305
1.9 410 401 396 390 385 381 378 371 357 282
Battery Systems
Battery Systems
Calculating a Battery System
200kVA @ 0.8 p.f. @ 92.5% UPS efficiency = 172,973
172,973W /50 Battery Blocks/6 Cells per Block = 577 WPC
Watts per cell table @ 20Deg C EODV @ 1.75
Constant Power Discharge Table For The SWL2500
EODV (W/Cell)
Discharge Time (min)
VPC 2 3 4 5 6 7 8 9 10 15
1.5 738 656 596 570 546 527 397
1.6 753 682 612 581 558 539 515 392
1.65 769 702 635 590 569 548 530 501 389
1.67 747 679 620 583 562 542 523 491 386
1.7 714 644 597 572 552 534 513 476 381
1.75 707 635 593 569 548 528 507 474 452 364
1.8 574 557 543 532 520 486 457 438 420 336
1.85 541 527 513 474 453 432 417 401 387 305
1.9 410 401 396 390 385 381 378 371 357 282
Battery Systems
Calculating a Battery System
Battery System One = 1 String of 50 x SWL4250
= 2 Strings of 50 x SWL2300
Battery System Two = 1 String No Configuration
= 2 Strings of 40 x SWL2500
Note:-Excludes additional costs for DC Isolation,
Battery Assembly, Larger Rack, Transport
Battery Systems
Calculating a Battery System
OPEX -
Transformerless Design UPS = flexible battery arrangements
30 – 50
Blocks!
Configure for autonomy
Configure for cost-effectiveness
Battery Systems
End of Life?
• Standards define EOL for a battery as 80% capacity
• Eg: Start at 100AH, after 10 years 80AH
• For 100AH at 10 years oversize by 25%
• Drop off in capacity is towards end of life
Battery Systems
Battery Containment
Battery Systems
Battery Containment
1. What model of UPS system is proposed?
2. Standalone system - which UPS frame is proposed?
3. Standalone system- what configuration of frames?
4. Modular system - which UPS frame is proposed?
5. Modular System - How many UPS modules, of what rating?
Configuring a UPS System
Checklist - UPS
Configuring a UPS System
Checklist – Battery System
1. Battery autonomy @ what load?
2. Separate or Common battery system
3. Number of battery strings
4. Number of battery blocks per string
5. Manufacturer and model number of battery block
6. 5 or 10 year batteries
7. Battery containment system
8. Method of battery string dc isolation- per string and UPS
9. Dimensions of battery containment system and weight
10. Battery autonomy calculations:-
• what efficiency has been used for the UPS unit
• final end of discharge voltage (EODV) value per battery cell
• temperature at which autonomy has been calculated
1. What UPS System Resilience is required?
2. What UPS System – Standalone v Modular
3. Battery System Topologies – Common, Separate, Resilience
4. Batetry System – Calculation v Actual Performance
5. UPS system design – a balance of cost v resilience
6. UPS system design – technical submittals evaluation
Key Points to Take Away
Thank you for your time, any questions?
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