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An uninterruptible power supply (UPS) system, also called continuous power supply or battery backup, provides power from a separate source when utility power is not available. Unlike a standby generator or auxiliary power supply, a UPS system maintains a continuous supply of electric power without interruption. Although used to protect all kinds of equipment and businesses—particularly where unexpected power loss could cause critical disruption, data loss, or even personal injury—the most common applications are data centers and commercial, industrial, and medical facilities. 

Jim Davis, three-phase UPS business unit manager for Eaton Corp. in Raleigh, NC, lists examples of some typical users of UPS systems: “IT [information technology], communications, credit cards, Wall Street, Internet providers, payroll, pharmaceutical, medical imaging, and emergency rooms—wherever there are critical operations where continued protected operation is required.”

Robert J. Walker, director of application engineering for JT Packard—a Power Plus company in Verona, WI-estimates that 25–30% of his clients, with 12,000–13,000 UPS systems currently under contract, are Fortune 500 companies: “hospitals, data centers—anything that needs mission critical power or has a harsh manufacturing environment,” he says.

Reiterating Davis and Walker, Martin Olsen, vice president of business development with Active Power Inc., in Austin, TX, elaborates on UPS customers, noting that “hospitals are required by law to have 10-second backup generators.” Other mission critical industries he lists include the aviation industry—airports, runway lighting, and such—telecommunications, and the petrochemical industry.

It’s easy to understand why UPS systems have become essential equipment for many businesses.

Building a Better Mousetrap Means a More Efficient, Reliable System
“Four years ago, we launched the first UPS platform,” reminisces Davis. “It was cutting edge technology.”

Since then, Eaton has continued to take the lead, and now, as product manager Pedro Robredo puts it, Eaton has “made a natural progression from a lower to a higher power range.”

Eaton recently introduced a new and extended power rating for its industry-leading Powerware 9395 UPS, with 825 kVA. Davis says customers wanted more powerful systems to support their critical business processes. The 9395 not only provides more power with 94% efficiency, but it also offers cost-saving scalability across a wide load range. Furthermore, it’s designed to be field upgradable by adding modules to achieve N+1 redundancy or to provide additional capacity.

Because a single large UPS unit can also be a single point of failure causing continued disruption of other systems, many businesses prefer multiple smaller integrated modules for equal but redundant power protection. A N+1 system is designed to supply more power than is required, so that one module can be down for service in the case of a failure without interruption, explains Robredo.

“You used to have separate modules for bypass, reducing the chance of failure of multiple items,” elaborates Davis. “With our modular system, you have redundant power modules set up to be removed if catastrophe strikes. You don’t have to remove the whole box. That speeds up repair and recovery time [when you have to reset all the servers], which is even more critical than downtime. When the power goes out, this gives you time to secure the system and the data; you have time to fix the problem. There’s no such thing as load sharing or load dumping; even onsite generation can fail.”

Another advantage of the N+1 system is that it readily accommodates expansion to increase capacity by combining additional units. Although it wasn’t always possible to combine the output voltage of two separate UPS units because the output waveform of one invariably led or lagged behind the other, causing damaging power fluctuations, Eaton’s patented Hot Sync technology alleviates that potential problem.

Hot Sync technology allows UPSs with different power ratings to be paralleled together to provide “clean, continuous power,” states Davis. Eaton’s patented wireless paralleling technology eliminates the need for centralized controllers and complicated control wiring. A special synchronization signal is shared by the modules to insure they’re in synchrony, without leading or lagging waveforms.

Multiple redundancy provides an additional layer of protection. Rather than connect individual power supplies into a single UPS, each is connected to its own UPS, ensuring continued operation in the event of the failure of an individual unit. Because there’s no master/slave arrangement in Eaton’s system, Davis says the scalable architecture is easily expandable for greater flexibility.

“You simply reprogram the UPS to operate in parallel mode,” he says. Introduced 15 years ago in all three-phase and single-phase units, the modular system allows for unplanned growth, because “it’s hard to forecast growth needs,” adds Davis.

But some companies have to plan for expansion, he acknowledges. That requires a lot of equipment and capital. “The cost of materials and construction is going up,” he says. “If you’re putting in a traditional UPS, it’s going to be expensive in terms of materials, installation, and floor space. A raised floor is the most expensive real estate in a data center.” The 9395, on the other hand, is 30–50% smaller.

Physical footprint isn’t the only concern expressed by today’s corporate world. Davis mentions one CIO of a major Wall Street trading firm who considers reducing his company’s carbon footprint a major issue.

Robredo explains the impact to the environment engendered by the 9395’s technology. Thanks to its size, it sees a reduction of raw materials in its fabrication: fewer chemicals. Its transformer-less design results in lower weight and smaller footprint. It is smaller and lighter to ship and set up—and with factories around the world, transportation costs are further reduced.

In addition, Eaton’s transformer-less position allows the manufacturer to provide high-energy usage that works with any energy source available. “UPS at the right level eliminates the transformer—and costs,” says Robredo. “The system is more efficient. That’s why there’s a race to get to the server with less steps.”

“UPS is all about being an insurance policy,” notes Davis. “Reliability is why they buy it. Systems are so critical-one is not enough security, so most put in two. In the top tier, reliability is a given, but other priorities vary with the customer-space, etc. But invariably, the number one concern is efficiency.”

As Robredo confirms, customers used to face a tradeoff of reliability or efficiency. But because companies like Eaton changed the way they do power conversion, it saves customers thousands of dollars in operating costs every year.

Economics go hand-in-hand with efficiency. “Efficiency is a big lever in savings. It ties to the whole green movement and to economics,” says Davis.

As he explains, with a redundant system where duplicate units are running at the same time (to avoid transfer time in critical failure), “by nature, neither side can be more than 50% loaded.” The 9395’s efficiency rate is 4–6% higher anywhere across the load.

“All the talk in the industry is alternative data center voltages to save power,” adds Davis. “Europe uses distributed voltage to take out the pdu [power distributor unit], run the server at 230 volts, and eliminate the cost of the pdu and wasted energy.”

He also points out that the 9395 works with most energy sources—fuel cells, ultra capacitors, flywheels—and all battery manufacturers. Eaton builds only one unit for the whole world; its global UPS platform is another efficient, cost-saving measure.

Flywheel Solutions
Because Eaton’s UPS systems are compatible with most energy sources, the company has worked with Active Power, a manufacturer of flywheel-based UPS systems. “We’re more than just a UPS flywheel provider,” observes Olsen. “We’re a critical power solution provider.”

The technology is still new, he concedes, adding that over the last 2–3 years, he has witnessed a rapid adoption rate. However, he distinguishes Active Power from the rest. “We have a patent on integrating UPS with the flywheel,” says Olsen.

Active Power’s turnkey UPS systems are based on green technology, precision engineered to be up to 98% efficient at high load (still up to 96% efficient at partial load) and designed to be seven times less likely to fail (for reduced downtime), while achieving a 75% reduction in carbon footprint because it consumes 25% less energy than battery-based systems.

The “green” aspects of the system are important. Constructed of 66% recycled steel, it features no lead and no toxic batteries. Carbon dioxide (CO₂) emissions are reduced, Olsen claims, through higher energy efficiency and less consumption from the grid. He points out that some states now issue carbon credits to utility companies, and mentions one customer, Timberland Company, who is “very green.”

“They use solar panels and state their carbon footprint in their annual report,” he adds.

The “green” effect is important for more reasons than just the feel-good-about-the-environment one. Electronic Power Research Institute research suggests the average load factor of UPS systems in the field is 37.8%, which results in efficiencies as low as 81%. In contrast, an integrated flywheel UPS system is 98% efficient at 100% load and 94% efficient at a partial 40% load.

Other economic advantages include spatial ones. “You get two times the power in half the space, and you don’t need space for batteries,” summarizes Olsen. This fully modular, compact system has the smallest system footprint.

“That’s a huge issue in Europe and Asia and it’s getting bigger here,” he adds.

Energy consumption and facility space are areas of concern for data centers. Finding a green solution to help companies reduce their energy consumption and space without adding high capital or operating expenses is a tall order.

Active Power’s PowerHouse containerized power and cooling infrastructure system, manufactured and assembled off site, combines all sources in a 40-foot container: backup generator, switch gear, plug-and-play power-in/power-out, flywheel, and CleanSource UPS. The efficient, pre-packaged system provides a 20–25% savings on capital expenses, installation, maintenance, and cost of operation, according to Olsen. In fact, he adds, first-year savings can reach as high as 86% for a 10-MW system, based on efficiency. And because they can be deployed in modular fashion as part of Active Power’s “right-sizing” strategy, not all capital costs must be incurred up front.

Active Power studies indicate an accumulated savings of more than $3.2 million over 10 years on efficiency improvements, when right-sizing using containerized and modular power infrastructure is incorporated. Right-sizing the infrastructure to the load also impacts electrical consumption. The pre-fabricated containerized units have limited customization options from combinations of standard components, including the type and size of the engine, the kilovolt module, and dual- or single-input switchgear. However, Olsen considers installment easier because it’s all together in one box, and service requirements are similar to battery-based systems, but without time spent monitoring a battery.

One medium-spin flywheel design features a 32-inch-diameter flywheel that spins constantly, with a top speed of 600 miles per hour, which is maintained by a trickle charge. It stores energy as motion and, in a power outage, becomes a motor generator. The kinetic energy turns into power, with each flywheel providing 250 kW for 15 seconds. Additional wheels can be paralleled for more capacity-up to a maximum in one system of 8,400 kVA.

Of its many benefits, Olsen lists redundant cooling, control, and engine starting systems; redundant power supplies; and, of course, its reliability.

“The more a battery is used, the less performance you get from it,” he says. “But a steel rotor spins at the same speed all the time-12 years is the longest running flywheel. There are still some ‘battery huggers’ who haven’t heard of the flywheel concept, but it’s compact; has repeatability, automation, and speed; and is interchangeable with different manufacturers.”

Although it carries a slightly higher initial cost, Olsen promises significant savings over time, with a payback of roughly 12–18 months. Sun Microsystems believes in it and considers the PowerHouse all-in-one configuration suitable for its Modular Data Center S20.

That’s not the only company turning to Active Power’s flywheel technology. Tesco PLC, one of Europe’s largest grocery and general merchandising retailers, ordered two PowerHouse systems to replace two 800-kVA conventional battery-based UPS systems currently in place at their mission critical data center north of London, England. Each container consists of one CleanSource UPS 1500iC system, switchgear, a 1,900-kVA diesel generator, and fuel tanks.

Because the container systems use only about a quarter of the footprint as conventional systems, they’re well suited to Tesco’s parameters, which include spatial limitations, as well as the needs to guard against power fluctuations and outages, and to increase power capacity onsite. In addition, Tesco wanted to reduce its energy consumption to half its 2000 energy usage by 2010. The two UPS systems should save the company enough energy to power 196 households and displace as much as 1,586 tons of CO₂ emissions yearly.

Active Power’s single largest order came from one of the world’s largest Internet search engine providers in Fall 2008. Twelve 1200-kVA CleanSource UPS systems utilizing 48 flywheels will protect mission critical IT equipment from power outages. Active Power figures estimate that this multi-million-dollar order that will produce 12 MW of power could save up to $1 million annually in electrical and operational costs when compared with conventional UPS systems, and displace 7,500 tons of CO₂ emissions each year.

Multi-tasking From More Manufacturers
As the nation’s largest independent service provider for mission critical power equipment, JT Packard, in Verona, WI, sees a lot of large orders. Walker describes the company as “more like a distributor, a value-added reseller that stocks factory new products and equipment.”

They stock several different brands of equipment. “We want to remain brand-agnostic,” he says. “That allows us to look at the best solution for each customer.”

To assist in that search, JT Packard recently forged a partnership with Mitsubishi’s UPS Division. As a national distributor, JT Packard will carry a full line of Mitsubishi UPS systems from 6 kVA to 750 kVA, including multi-module applications. “Mitsubishi has strong three-phase UPS products,” observes Walker.

In fact, he adds, Mitsubishi has been “far ahead of the curve for a long time,” when it comes to building a generator-friendly UPS system that efficiently operates as a cogen emergency generator. “They achieve a one-to-one generator friendliness ratio,” says Walker. “It’s even safe for a one-to-1.5 ratio.”

Walker considers it a valuable product that has filled gaps. “Without upsizing the generator, you get more power,” he says.

In addition, he adds that it’s extremely reliable. The only drawback is that the selection is limited. “This is the box: build your own infrastructure,” he states.

Walker cautions against marrying infrastructure to the UPS, because if one becomes obsolete, both are obsolete. If, on the other hand, the UPS is integrated, “they match, they line up,” he says. “But if one is obsolete, it’s difficult to remove just the UPS.”

He considers it an important philosophy: How versatile is the solution? Are the assets easy to move around as needs change?

Mitsubishi has ideologies, engineering standards, and practices that offer a distinct difference, states Walker. Its systems are very lightweight, with small footprints. They’re also extremely efficient at low levels.

“Historically, below 50% [load], products dropped off,” he adds. “They run better at higher levels. But because they’re designed for redundancy, they never run at peak; they’re energy hogs. For every one kilowatt of usable power, it costs two kilowatts out of your wallet.”

Mitsubishi’s 900 series, however, is 95% efficient at lower loads—as low as 20% loads. Additionally, it’s scalable, allowing flexibility through paralleling, and hits peak efficiency at 40% loads, Walker claims. With a typical payback period of 2–5 years and a lifetime of 15–20 years with routine maintenance, he estimates the total cost of ownership is very affordable, especially when considering many older systems operate at only 50–60% efficiency.

The Mitsubishi 9900 has an even smaller footprint. It’s “double the density per square foot,” says Walker. It runs more efficiently and requires less coolant, so it saves on power bills. There’s also less hardware to buy for it.

“The push for green efficiency is a focus due to rolling blackouts and not enough generators,” he says. “The more efficient, the less fuel cost. We’re seeing a big push in that direction. Customers want to cut energy consumption and save money.”

Nevertheless, Mitsubishi has a reputation as an expensive, albeit long-lasting, brand. “Our customers’ goal is to get the most for their budget,” recognizes Walker.

He says JT Packard is in a “sweet spot,” focusing on building alliances with different manufacturers and even offering refurbished equipment. Walker considers GE better “on a certain range of units” regarding size, model, application, and needs.

“GE is a good vendor, with a wide variety of three-phase options,” he adds. “They also have more to offer in single-phase.”

Furthermore, Walker says GE provides superior engineering support with better access to input and output switch gears. “GE has more resources, because it’s a large company that’s been in this country a long time.”

GE and Mitsubishi both feature the capability for paralleling with standalone units. Walker notes that, previously, only parallel modules could be configured in tandem, but now units can be used individually, or a parallel card can be added for capacity or redundancy. It’s an important feature for flexibility and cost efficiency.

To illustrate the importance of flexibility in paralleling, Walker refers to a customer who needed two 750-kVA UPS. “They wanted N+1 redundancy in case of failure,” he says. “We looked at the building; they don’t own it, it’s very old, and space is limited, so we could only put a UPS in the basement—and even then, we’d have to raise it 18 inches. They’d have to design a raised floor to support the weight of a monster system.

“What they really needed was a system small enough to fit in the data center and still leave room for the HVAC, ” adds Walker. “We suggested four 225-kilovolt-amp units in parallel [35 inches wide] versus one 750 kilovolt-amp at 130 inches wide, because the total footprint is smaller. Footprint is a big thing-real estate is expensive. We put two in; they’ll build up to the other two.”

JT Packard’s solutions cut the customer’s battery cost and footprint in half. “It was a big savings, four battery cabinets versus eight,” recounts Walker. “The smaller units weigh less and cost less in shipping, installation, wiring, and breakers. Because it operates at 95% efficiency [versus 85–90% with other systems], it will save money in power expenses.”

Not only is the total cost less, Walker adds, but the scalable plan can be augmented within budget increments. US companies spend as much as 10% of their total IT budget on power and cooling. Walker uses as an example, how hospitals work on tight budgets.

“If you reduce the demand on the UPS, there’s more money for other equipment,” he says. “The less power taken from an onsite power generator, the more there is available for other things.”

Available power is useless unless it’s reliable and efficient. Of the 61 billion kWh consumed in 2006, 11 billion kWh can be attributed to UPS losses as a result of underutilized or inefficient UPS systems. According to The Green Grid, UPS losses represent 18% of overall consumption. Many of these losses can be reduced by up to 86%.

Walker knows reliability is another important factor in the purchase decision. “Infrastructure and design are now robust,” he says. “What [system] can it handle? More redundancy is built in, even for small customers. Years ago, that wasn’t the case. A single standalone unit was the norm; now, it’s always two power plants or Tier 4 with two substations with the ability to close switches and breakers to run everything from the generator or other utility. The new standard for mission critical is redundancy from the power plant down.”

Another Combination
Last October, APC upped the ante with the launch of its second-generation modular UPS, the Symmetra MW II. With data centers in mind, the Symmetra MW II is designed to solve the constant problems of rising costs and increasing system footprints. In an attempt to mitigate downtime costs resulting from human error and other unforeseen power interruptions, APC focused on a modular deign that can be easily accessed and quickly replaced for maintenance or repair.

Mindful of the concerns of UPS customers, APC includes a service agreement package with a 24-hour, seven-days-a-week service for the system. APC hopes this added benefit will allow users to plan for future expenses and predict the total costs of installing and running the unit. The Symmetra MWII also comes with the company’s InfraStruXure Central that allows for “monitor metering and alarms from the Symmetra MW II itself, directly through the network.” The system includes a self-diagnosing power module, for what the company calls “predictive failure notification.” According to APC, the Symmetra MWII should deliver at least 94% efficiency at a 25% load, or 97% at full-load capacity.