As demand for cloud services, large-scale data processing, and artificial intelligence continues to grow, hyperscale data centers have expanded dramatically in size. It is now typical for a single campus to encompass multiple large buildings and support tens or even hundreds of thousands of servers, along with extensive distributed storage infrastructure and high-capacity networking.
When aggregated across an entire hyperscale campus, the total power demand typically ranges from 100 to 400 MW. In the case of newer mega-data centers, clusters can reach totals exceeding one Gigawatt.
Like other bulk users of power, data centers often integrate directly with utility infrastructure. This requires a carefully engineered electrical system design that includes medium-voltage switchgear and associated power distribution systems to manage the flow of electricity, isolate faults, coordinate protective functions, and maintain operational continuity during disturbances.
Even as campuses expand on-site generation through cogeneration, renewables, nuclear, or microgrids, they must remain tightly integrated with systems capable of managing synchronization, load sharing, and seamless transitions between power sources and the associated grid.
At the same time, hyperscale environments demand redundancy at every level, ensuring that no single failure can compromise uptime. In many cases, this means specifying electrical equipment and system designs that exceed conventional ratings or typical class capabilities.
To meet the stringent requirements for availability and uptime, the electrical infrastructure must be built to exceptionally robust standards. In practice, this often means exceeding the requirements set by industry Standards organizations, with added layers of redundancy, hardened equipment, and conservative design margins specified by the utility.
Based in Middlebury, Connecticut, National Breaker Services specializes in the development, engineering, design, and manufacture of medium-voltage circuit breakers and switchgear used specifically in electric utility substations and generating facility applications. The company’s flagship product line, The Citadel™, reflects its commitment to robust, utility-grade construction.
According to Bruce Hack, Managing Member of National Breaker Services, these systems are engineered, KEMA tested, and commissioned to ensure they perform reliably under the most adverse conditions, minimizing the risk of disruption in data centers.
“Only this kind of approach can ensure that the electrical power supply can consistently deliver the level of reliability and high availability large data centers require,” says Hack.
In many cases, meeting these requirements calls for substantially greater mechanical strength and more carefully engineered designs than conventional equipment. As a result, Citadel switchgear is intentionally up-rated to ensure reliability.
“Rather than sizing components strictly to the nameplate rating, we build in additional capacity across all major current-carrying elements,” says Hack.
The Utility’s Requirements
Data centers that want to tie into a utility’s power pool are often required to satisfy standards that exceed the recommended guidelines established by oversight organizations such as IEEE/ANSI and NEMA.
At one leading utility, the requirements for medium-voltage switchgear on their 27kV portion of the system is that of 38 kV Class, to ensure excellent safety margins throughout. Furthermore, the close-and-latch and short-circuit fault ratings had to be verified through certified independent high-power laboratory testing.
The utility imposed an additional requirement. Based on its internal study, review, and equipment rating practices, it specified a symmetrical fault current rating of 44 kAIC at 38 kV. By comparison, most switchgear is typically designed with interrupting ratings ranging from 20 to 40 kA.
National Breaker Services was able to independently certify these requirements. To demonstrate the equipment could achieve the specified close-and-latch and short-circuit fault ratings, National Breaker Services validated the Citadel platform through independent testing conducted at two highly respected international high-power test lab facilities, KEMA Arnhem, the Netherlands, and KERI Laboratories in Korea.
Read the full article here as published in POWER Magazine: https://www.powermag.com/rugged-switchgear-a-reliable-data-centers-bedrock/
For more information call (475) 316-3471, email jduggan@nationalbreaker.com, or visit www.nationalbreakerservices.com.