Data Center Client: Digital Realty
LOCATION: California
CONTRACT AMOUNT: $143,265.00
SQUARE FOOTAGE: 80,000 (Phase 1)
80,000 (Phase 2 & 3)
At the request of DPR Construction Inc., Genelco performed an extensive series of testing and commissioning services at the Digital Realty Trust Data Center in California. The project started with conference calls, site visits and drawing and submittal reviews. This full-site testing and commissioning effort focused on all of the critical and essential electrical and mechanical systems which supported the data center facility.
Custom step-by-step procedures were produced, reviewed and utilized during these tests. Digital Realty Trust is the world’s largest host of rented data center space and due to the complexity of the site configuration, several infrared reports were created. An Issues and Resolutions Log was also created, starting with day one of the overall testing and commissioning process.
With regard to actual procedures performed, the UPS modules and the generators were subjected to incremental loading, four hour 100% load burn-ins, followed by large step loading, UPS battery discharge tests (also referred to as battery run down tests), were performed on each of the individual UPS modules and each PDU was exercised through a burn-in cycle per the included procedures. Additionally, the mechanical systems, (chillers, pumps, CRAH’s, AHU’s, and other associated hardware and control systems) were commissioned and responded appropriately to numerous full and partial utility failure scenarios.
After the individual components were proven, Genelco conducted a multi-scenario Integrated Systems Test.
Over the course of the project, components and systems commissioned included:
- (1) 12KV distribution section
- (3) 12KV to 277/480vac transformers
- (3) 2,250KW Cummins/Onan generators
- (2) Main distribution boards
- (1) Swing generator/utility board
- (2) Mechanical boards
- (4) UPS output distribution boards
- (8) 625KVA UPS modules with batteries
- (4) Parallel control system switchgear
- (1) 40KVA UPS modules, with battery system
- (14) Automatic transfer switches
- (12) Air handler units computer room and equipment room
- (3) Air handler units for office space
- (2) Make-up air units
- Lot exhaust fans
- BMS Controls System for monitoring electrical and monitoring and controlling HVAC systems
- (1) Fire alarm and detection system
- (2) Risers pre-action double interlock sprinkler system
- (3) EPO systems
Data Center Client: Entergy Mississippi, Inc.
LOCATION: Jackson, Mississippi
CONTRACT AMOUNT: $272,126.00
SQUARE FOOTAGE: 30,000
As requested by Cushman and Wakefield, testing and commissioning services were performed on the critical systems infrastructure for the Entergy Data Center project. System commissioning was conducted by Genelco Inc. All components were first individually “Sub-System Tested” and then commissioned collectively in a process known as “Integrated Testing”.
The project started with conference calls, site visits and drawing/submittal reviews. Full site Testing & Commissioning efforts focused on all of the critical/essential electrical and mechanical systems which support the Data Center. Commissioning was based on custom-scripted procedures per project specifications and equipment manufactures’ guidelines. These step-by-step procedures were produced in house by Genelco’s Documentation Department and utilized for all aspects of testing. All line items within each procedure were executed, all data was recorded as required and any discrepancies were noted. Due to the extensiveness of this site configuration, several Infrared Reports were created. An “Issues & Resolutions Log” was also created, starting with day one of the overall Testing & Commissioning process.
UPS modules and Generators were subjected to incremental loading, 4 hour 100% load burn-ins, followed by large step loading, UPS Battery Discharge Tests (aka “Battery Run Down” tests), were performed on each of the individual UPS modules and each PDU was exercised through a burn-in cycle. Additionally, the mechanical systems, (Chillers, Pumps, CRAH’s, AHU’s, and other associated hardware and control systems) were commissioned and responded appropriately to numerous full and partial Utility failure scenarios.
After the individual components were proven, Genelco conducted a multi-scenario Integrated Systems Test.
Over the course of the project, components and systems commissioned included:
- (1) 12KV distribution section
- (3) 12KV to 277/480vac transformers
- (3) 2,250KW Cummins/Onan generators
- (2) Main distribution boards
- (1) Swing generator/utility board
- (2) Mechanical boards
- (4) UPS output distribution boards
- (8) 625KVA UPS modules with batteries
- (4) Parallel control system switchgear
- (1) 40KVA UPS modules, with battery system
- (14) Automatic transfer switches
- (2) Exhaust fans
- (12) Fan coil units
- (4) VAV box units, floors 2, 3, 4 & 5
- (3) Generators
- (6) Automatic transfer switches
- (5) Manual transfer switches
- (1) Static transfer switch
- (10) Distribution boards
- (1) System control cabinet
- (5) Uninterruptible power supplies with battery
- (1) Load breaker board
Data Center Client: Iron Mountain
LOCATION: Pennsylvania
CONTRACT AMOUNT: $117,900.00
SQUARE FOOTAGE: 25,000
Iron Mountain is an underground facility in Pennsylvania. Genelco was engaged for a concentrated Commissioning of a new data center and associated nuances of the specific site and support equipment. The new data center housed several work stations, servers and other facilities.
The scope of work included testing and commissioning new data center support infrastructure following installation and successful vendor startup of all major subsystems. Participants included installing contractors and vendor technicians for major equipment such as switchgear, HVAC, BMS, Generator systems, etc. Subsystem performance was tested to specifications and the integrated system was tested to design intent. The entire process was managed by Genelco and validated all items prior to acceptance by CDC and their Client.
Genelco was also responsible for a review of construction documents, shop drawings, organizing and participating in commissioning meetings, preparation of test scripts, functional and integrated testing, equipment, rental and testing technicians, results analysis and report preparation and a final wrap up and training meeting.
As part of a Site Assessment, Genelco provided a third party independent review of all infrastructure systems that comprised the electrical and mechanical systems supporting the data center operations. All electrical and mechanical drawings were reviewed to determine the fault tolerance and robustness of the design as well as system concurrent maintainability and redundancy. The two day on-site survey of infrastructure systems included inspecting existing installations and a review of current system operations with site personnel. Following this assessment, Genelco provided a detailed report explaining findings and suggestions where system reliability, maintainability and redundancy can be improved.
Over the course of the project, components and systems commissioned included:
- (2) Switchboards with fixed circuit breakers (D48A, D48B) IR and HiPot Testing
- UPS input, output, and system bypass boards
- (2) 1000kVA UPS modules with Battery Systems and disconnects
- UPS Output distribution switchboard
- (2) 750kVA Critical Power Transformers
- (18) 400A Remote Power Panels (RPP)
- (4) 225A Remote Power Panels (RPP)
- (1) 400A ASCO Transfer Switch with Bypass Isolation
- (1) Chiller Plant (750 ton capacity with 2 Chillers), associated Pumps and controls
- EPO System
- (4) Chilled Water AHU Units
- Leak Detection
Data Center Client: Toyota Motor Corporation
LOCATION: California
The objective of this unique project was to introduce a third UPS system into an operating Tier 3 data center that had exceeded the ability of the original UPS systems to maintain redundancy.
Ironically, UPS-3 had sat idle for several years because integration without an outage had been deemed impossible. When Toyota approached Genelco in search of a solution, we devised a temporary configuration involving two large mobile Generator/UPS packages outside with switchgear and PDUs inside as well as cabling to connect all elements. The entire system was designed and installed by Genelco.
Preparations were completed over a period of several months in close cooperation with the Toyota IT and facilities staffs. Scheduling was complicated by the fact the entire project could be executed only during Christmas week. But with the help of our vendors, Genelco overcame all of the technical and logistical obstacles.
Our electricians installed the temporary system and our technicians certified that every element, existing and new, was thoroughly commissioned. We were ready to perform what amounted to a “heart by-pass” operation on a data center. The critical load was carefully and methodically rolled to external an UPS. Once that was done, we went to work to bringing UPS-3 on- line, using two existing but dissimilar static switches. after commissioning the newly expanded permanent system, we rolled the data center back onto permanent power.
An operation, once thought impossible, had been completed with no interruption to Toyota’s operation and UPS-3 was finally able to give the other two UPS systems the redundant support the original designers intended.
Data Center Client: Capgemini
LOCATION: Arizona & Massachusetts
Capgemini could see that space and infrastructure capacity were running out and its management turned to Genelco to help solve the problem. As with all existing data centers, the first order of business was to devise a strategy that ensured uninterrupted operation while raised floor, security, cooling, fire suppression, generator and UPS systems were expanded.
Working closely with Capgemini facility managers, the Genelco team developed and then executed the design. The tasks included the removal of existing equipment and installation not only of new HVAC units, power distribution and controls, but a temporary generator to protect the load while the original machine was removed, the equipment yard expanded and the new unit installed. The UPS room remodel was especially demanding, since it involved. Responding to an extremely tight budget, Genelco was able to procure refurbished equipment for several major components.
Additionally, Genelco has had an ongoing relationship with this company as critical facility maintenance provider for multiple locations. These contracts provide for and/or oversee maintenance and ensure the mission critical components remain operational 24/7.
When completed, the key data center had been improved by the following:
- 6,000 additional square feet of Class A white space
- 800 kW additional UPS capacity (two multi-module systems)
- 750 kW additional generator capacity
- 200 tons of data floor and UPS room cooling
- New Rack Assembly/Test Lab
- Expansion of BMS, security, VESDA and sprinkler systems