An In-Depth Case Study on Advanced Electrical Design and Implementation for a 58-Acre State-of-the-Art Data Center Campus
Introduction
As the world is picking up the pace in digital transformation, data centers have become the backbone of modern businesses, the IT industry, cloud computing and digital infrastructure, which require connectivity and electrical infrastructure that is adaptable and robust. Various factors such as availability of power, efficiency and reliability are important components for data processing, data storage and real time application in a data center, which also result in high power consumption. Due to which large data centers require electrical infrastructure that can assure steady supply of power, regulatory compliance and flexibility in response to varying energy demand.
This case study talks about the design of electrical distribution infrastructure of a 58 Acres campus housing various Data Centers buildings including evacuation of power from the grid and design of a 220 kV substation. The 58-acre data center campus represents great engineering excellence to support 12 data center buildings, each with a power demand of 36MW. With a total load demand of more than 400 MW, the project presented multiple challenges, including optimization of space, regulatory compliance and redundancy. This case study provides strategies employed to mitigate various challenges through ingenious electrical design by creation of an underground utility corridor, implementation of a dual power source distribution network and integration of a 220 kV GIS substation. Along with design of the distribution network, the project involved design and execution of a 220 kV GIS substation and a cable terminal tower. An optimized electrical infrastructure required to meet rigorous requirement of the data center industry was designed and implemented through ERO Power’s expertise in electrical design, gird connectivity and distribution planning.
Work Scope
The 58 Acre Data Center campus had about 12 data center buildings each with a power requirement of 36 MW. The primary work scope included planning of the distribution network in such a way that each building has redundant power sources and each power source is from a different route. Also, the 220kV substation design along with the design of cable termination tower to evacuate power from the grid was the part of the scope. The work scope of the 58-acre data center campus was to design an electrical infrastructure to ensure high availability, scalability and fault tolerance. It involved precise engineering and design of the electrical distribution network, design and commissioning of a 220kV GIS substation, and the execution of power evacuation from the grid.
Challenges
The 58 Acre Data Center campus presented various challenges during execution of its electrical infrastructure which required critical thinking and innovative engineering solution. Multiple challenges considering the stringent data center requirements were as below.
- Availability of space.
- Co-ordination of all required services.
- Ensuring compliance with statutory guidelines.
- Allowing flexibility in load pattern and sizing equipment accordingly.
Laying high-voltage power cables from dual power sources across a vast data center campus presented several critical challenges, requiring precise coordination and meticulous planning. One major challenge was managing adverse weather conditions, including extreme heat, heavy rainfall, and fluctuating humidity levels. Monsoon seasons caused water accumulation in trenches, delaying excavation and increasing the risk of insulation damage, while temperature variations led to expansion and contraction issues in underground cables, potentially compromising their long-term reliability.
Another challenge was routing cables from two independent power sources to twelve data center buildings while ensuring redundancy, safety, and fault tolerance. The need for separate underground routes for each power source made cable alignment complex, requiring careful planning to avoid overlapping pathways or short-circuit risks. Fault conditions required strategic relay protection schemes to isolate affected sections without disrupting the overall power supply. Additionally, integrating high-voltage cables, optical fiber networks, water pipelines, fire system and drainage systems within a shared underground tunnel system introduced further difficulties. Preventing interference between services, ensuring proper clearance, and maintaining accessibility for maintenance while complying with fire safety and ventilation regulations required extensive coordination across multiple engineering disciplines.
Various constrains such as limited availability of space for high-capacity electrical equipment, including transformers, switchgear panels, and bus ducts. Given the high-power density of the data center campus, ensuring an optimized equipment layout that conformed to fire safety and maintenance accessibility regulations along with coordination of multiple technical services within the same infrastructure corridor was a significant challenge. The data center campus required seamless integration of electrical, mechanical, HVAC, and networking services, necessitating a highly structured approach to service routing and management. Ensuring compliance with statutory guidelines and obtaining necessary approvals from the regional power distribution authorities posed additional challenges, given the critical nature of grid connectivity and voltage transformation requirements. Additionally, the power distribution network needed to accommodate fluctuating load patterns and future scalability considerations. Data center power demand can vary significantly based on computational workload variations, requiring a design approach that allows for modular expansion while maintaining power quality and stability.
Solutions
Equipment was selected with ratings and with appropriate technology to ensure that space usage was optimized. Multiple options of equipment orientation and routes were considered to finalize the space requirements to a minimum and optimum ensuring space for future growth. To resolve the issue of services coordination, it was decided to use a utility tunnel to carry all electrical and other services to various buildings and campus utilities.
This tunnel was placed underground and was designed in a way to ensure easy flow of all services from their entry point to the destination ensuring that:
- Proper clearances are maintained.
- Free space is available for maintenance and addition of future services.
- Entry and exit points of services are spaced appropriately to ensure smooth working.
- Tunnel was well ventilated and all safety systems were installed in the same.
ERO Power was part of the and designing for the electrical distribution was in ERO scope. ERO Power designed the 220kV substation and the entire electrical distribution in the campus for all the buildings which amounts to designing evacuation of more than 400 MW of power in small area while ensuring safety as well as reliability.
To overcome the challenges associated with laying high-voltage cables from dual power sources, a meticulously planned electrical distribution system was implemented, ensuring redundancy, reliability, and operational efficiency. Each data center building was connected to two independent power sources through dedicated underground cables, creating a robust dual topology that eliminated single points of failure. This approach was critical in maintaining uninterrupted power supply, a non-negotiable requirement for mission-critical data center operations. The complexity of the design was further heightened by the need to integrate other essential services, such as optical fiber networks, water pipelines, and fire safety systems, within a shared underground utility tunnel. To address this, the cable layout was carefully optimized, with individual cables housed in sidewall trays that were strategically separated to prevent electromagnetic interference, overheating, and fire risks. This design not only ensured the safety and integrity of the power distribution network but also allowed for quick isolation in the event of a fault or fire, minimizing the impact on overall operations. Environmental factors such as humidity, temperature fluctuations, and seasonal weather variations were also taken into account, with specialized insulation and heat-resistant coatings applied to enhance the longevity and durability of the cable network.
Space constraints posed a significant challenge in housing high-capacity electrical equipment, particularly in a high-power-density data center campus. To address this, compact gas-insulated switchgear (GIS) technology was employed, significantly reducing the spatial footprint of the substation while enhancing operational reliability. Transformers were strategically positioned to optimize conductor routing and minimize losses, ensuring efficient energy distribution across the campus. Advanced load flow analysis was conducted to determine the most effective cable sizing strategy, which not only minimized losses but also maintained an optimal power factor, further enhancing the system’s efficiency. The underground utility tunnel, a cornerstone of the project, was meticulously designed to accommodate electrical and auxiliary services while maintaining adequate clearances for future expansions and maintenance operations. Equipped with advanced ventilation systems, fire suppression mechanisms, and emergency access points, the tunnel adhered to stringent safety and regulatory requirements, ensuring a secure and compliant infrastructure.
This design ensured that any disruption in one section of the network would not compromise the overall power supply, thereby enhancing the system’s resilience and reliability. To further streamline operations and improve system performance, a advance monitoring and automation system was integrated into the substation control architecture. This system enabled real-time voltage regulation, load balancing, and rapid fault detection, allowing for proactive maintenance and minimizing downtime. The intelligent automation capabilities of the automation system also ensured that power demand fluctuations, inherent in data center environments, were effectively managed, supporting the scalability needs of the campus. The structured approach to service integration within the underground utility tunnel played a pivotal role in the project’s success. By preventing congestion and maintaining accessibility, the design safeguarded against operational conflicts between different utilities, ensuring smooth and efficient coordination. This comprehensive solution not only enhanced the reliability and efficiency of the power distribution system but also created a future-proof infrastructure capable of meeting the evolving demands of a high-power-density data center environment. The integration of advanced technologies, meticulous planning, and innovative engineering solutions underscored the project’s commitment to delivering a world-class electrical infrastructure that set new benchmarks for the industry.
Results
The above solutions worked favourably to ensure that all the services got streamlined and good early planning led to designing an execution strategy that would allow for ease in addition to services. This meant that the services could be built up in a phase wise manner. Also, having this kind of tunnel underground led to a better aesthetic and mobility in the overall premises. For electrical distribution the route of the cables for main and redundant were different which ensured that client need was satisfied. Along with this, the cable laying plan was shared much in advance to ensure that cable laying was easy when cables needed to be added for addition of buildings.
A highly optimised electrical distribution system which insured uninterrupted power supply along with high operational efficiency was achieved due to the implementation of these solutions. The risk of single point failure assuring maximum uptime for operations of data centers was achieved through integration of dual power source. Efficient routing of electrical and auxiliary services along with maintaining high degree option of scalability for expansion in future was achieved through the design and implementation of underground utility tunnel.The innovative design and integration of 220 kV GIS substation successfully enabled uninterrupted power from the grid thus reducing transmission losses and increasing power stability. The planning and integration of advanced automation systems in design significantly improved real-time load management and fault diagnostics which resulted in enhanced system reliability and reduced maintenance downtime.
Key Learnings
This project was a good learning experience to learn the power of team-work to solve challenging issues. It took multiple iterations to arrive at a solution that worked short term and long term. The client requirements which kept changing and required flexibility and modularity to be in built in the design was specifically challenging to incorporate but, in the end, this was ensured.
This project highlights the importance of diligent electrical planning and advance electrical engineering in large data center infrastructure. The use of underground utility tunnels demonstrated a highly effective strategy for optimizing space utilization while maintaining service accessibility. The successful execution of this project serves as a benchmark for future data center electrical infrastructure developments, emphasizing the need for innovative engineering solutions that prioritize scalability, reliability, and efficiency. The project’s success underscores the importance of collaboration, innovation, and forward-thinking in delivering infrastructure that meets the demands of the digital age.
About ERO POWER LLP
ERO Power is founded by young, energetic, highly skilled and visionary professionals. ERO Power has already established their footprints in power distribution. Power generation and transmission is in foray.
Our professionals are attributed to conceptualising India’s first private IT/ITeS SEZ deemed distribution licensee and also played a key role in India’s first power distribution franchisee. We have captured a major share of the Data Centre industry with respect to Power.
We are committed to deliver with quality and within time. We exhibit a strong will to win every aspect of our business. We are personally accountable for delivering our commitments. We value our people, encourage their development and reward their performance. We develop relationships that make a positive difference in our customer lives.
