Location: Santa Clara, California
Profile: Multinational technology corporation with multiple data centers that store and process mission-critical data
Challenge: Replace and retrofit existing diesel particulate filters on one MTU Tier 2, 2-megawatt diesel genset and 24 HITEC DRUPS systems equipped with MTU S4000 Tier 1 engines
Solution: Installed 25 Rypos active diesel particulate filters to the existing MTU S4000 (3000 HP) engines to comply with current regulatory standards
Results: Increased emissions reduction, decreased maintenance workload and met the regulatory goal for the mission-critical facility
In recent years, emissions regulations have increased across North America with California leading the charge. The California Air Resources Board (CARB) requires particulate matter (PM) emission levels to be 0.2 g/bhp-hr or less when used on diesel engines certified to Tier 1, Tier 2 or Tier 3.
Background
A technology corporation chose to proactively install after-treatment filtration to its existing HITEC Diesel Reciprocating UPS (DRUPS) systems at a recently renovated data center in Santa Clara. The HITECS were installed in 2000, which preceded the recent more-stringent CARB regulations for PM reduction on diesel gensets. The retrofit included one newer (model year 2010) genset unit equipped with a passive PM filter. The passive filter was functional but required excessive labor and run time with sufficient load to regenerate (clean) the unit.
For the next installation, ownership wanted diesel particulate filters (DPFs) that would be efficient, reliable, meet the current regulatory requirements, and reduce operational costs. The Rypos active, self-cleaning filters, were specified as they regenerate independent of exhaust temperature, do not require excessive run times for cleaning, and eliminate the need for facility personnel to track the number of cold starts between service intervals. Rypos active DPFs meet CARB regulations to reduce PM emissions at 85% and often reach 96% reduction.
Pacific Power Group (PPG), headquartered in Ridgefield, Wash., an authorized MTU Onsite Energy distributor and service provider for all generator brands, was brought into the selection process. The customer’s facility management weighed all replacement and retrofit options for the generator project, ultimately selecting PPG to oversee the retrofit of the existing 25 standby genset/HITECs with Rypos active DPFs.
PPG collaborated with the emissions control experts at Rypos to size and specify the correct filters for this mission-critical project. With its unique construction and flexibility, the Rypos active DPFs are ideal for retrofit installations.
Installation
During the course of six months, PPG installed 25 DPFs on the S4000 engines at the data center site. The installation required structural steel framework/footing, exhaust rework and additional custom modifications. The CARB-verified Rypos DPFs are integrated with diesel oxidation catalysts that effectively reduce other harmful emissions such as CO, NO2 and hydrocarbons.
“Rypos’ support throughout the project was consistently strong and timely,” said Rick Elder Sr., Pacific Power Group Technical Sales & Project Manager. “The team developed and executed engineered solutions to any challenges that arose.”
Rypos active DPFs self-clean during normal engine operation, which ensures maximum flexibility in how facility operators choose to run their generators. Operating independently of exhaust temperatures means that the data center does not have to install costly generator load banks or run the generator sets for extended time periods to enable filter cleaning.
Following installation, the filters were commissioned by Rypos field service technicians, who inspected all mechanical and electrical connections and witnessed the filters run through a complete regeneration cycle.
“The site commissioning support team was very knowledgeable and essentially assimilated into PPG’s technician group to successfully complete this vital part of the project,” added Elder.