Portfolio

UPS System Upgrade, Battery Refresh, and CRAH Replacement - Enterprise Data Center

Client: Confidential Health Care Sector Client

Summary: This UPS System Upgrade, Battery Refresh, and CRAH Replacement project significantly bolsters and increases available critical production capacity while optimizing the electrical and cooling system and improving system reliability of this Enterprise Data Center’s Critical Infrastructure.

Dependability and reliability of mission critical facilities requires good design, best operating practices, rigorous preventative maintenance, and proactive end-of-life equipment and systems replacement.

This confidential Fortune 50 health care sector client selected SIGMA7 to replace their aging UPS system. As part of our team's due diligence and systems review, it was discovered that the CRAHs dedicated to the UPS rooms were due for replacement within the year and the UPS systems were encumbered with critical mechanical loads, reducing production capacity.

SIGMA7 suggested that the CRAH units be replaced as part of this initiative, rather than as a separate project, which would introduce additional risk to the facility. The client agreed that the CRAHs should be replaced while the UPS systems were down. They also agreed that the mechanical UPS loads should be isolated from the critical production equipment, as the data center's critical load was approaching 90% utilization.

Our team SIGMA7 designed and implemented new smaller dedicated redundant and concurrently maintainable 'mechanical' UPS systems to accommodate the critical mechanical loads which were ultimately removed from the main data center UPS systems.

The installation of the new and efficient UPS systems coupled with the introduction of the new mechanical UPS systems, along with modifications to the UPS battery recharge protocols resulted in the Client appreciating an increase of more than 325kW of available UPS system capacity. The additional capacity significantly reduced the percentage (%) of critical load on the system while providing adequate overhead and growth capacity for short term planned initiatives.

SIGMA7's in depth review and forward-thinking approach resulted in the deferral of the design and implementation of very costly improvements to their facilities infrastructure at a time when material costs are at a premium and lead times have grown to unreasonable durations due to COVID and related supply chain issues and impacts.

Our design included the installation of trailer mounted temporary UPS systems that were connected to the existing switchgear for the duration of the project. The redundant and concurrently maintainable temporary systems ensured "business-as-usual" operation for this critical facility throughout the entire duration of the project.

• Project Overview:
  • The project involves upgrading the UPS system, refreshing batteries, and replacing CRAHs (Computer Room Air Handlers).
  • The goal is to enhance critical production capacity, optimize electrical and cooling systems, and improve overall system reliability in an Enterprise Data Center.
• Challenges and Discoveries:
  • The existing UPS system was aging, and the CRAHs needed replacement, all approaching end-of-service life.
  • Critical mechanical loads were affecting UPS production capacity.
• Integrated Approach:
  • Rather than separate projects, the team proposed replacing the CRAHs during the UPS system upgrade.
  • Isolating mechanical UPS loads from critical production equipment was essential to provide necessary data center capacity.
• Mechanical UPS Systems:
  • New, redundant, and concurrently maintainable dedicated mechanical UPS systems were designed and implemented.
  • These systems handled critical mechanical loads, freeing up the main data center UPS systems for production equipment loads only.
• Results: Installing efficient UPS systems and modifying battery recharge protocols led to:
  • A 325kW increase in available UPS capacity.
  • Reduction of critical load on the UPS system
  • Provided adequate overhead and growth capacity for immediate and short-term initiatives.

This comprehensive project addressed critical infrastructure needs while improved reliability and optimizing the data center’s performance.

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