1Taylor Engineering, LLC HVAC System Design Mark Hydeman, P.E., FASHRAE Taylor Engineering, LLC

2Taylor Engineering, LLC it takes 2,000 to 3,000 times the volume of air to cool what you can with water! How do you effectively fight a fire? With air, or…with water?

3Taylor Engineering, LLC State of the present: with air

4Taylor Engineering, LLC Air system design overview Data center layout Airflow configurations  Distribution: overhead or underfloor  Control: constant or variable volume Airflow issues Economizers Humidity control issues

5Taylor Engineering, LLC Server airflow front to back or front to back and top are recommended © 2004, American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. ( Reprinted by permission from ASHRAE Thermal Guidelines for Data Processing Environments. This material may not be copied nor distributed in either paper or digital form without ASHRAE’s permission. Data center layout Cold Aisle Hot Aisle

6Taylor Engineering, LLC Data center layout © 2004, American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. ( Reprinted by permission from ASHRAE Thermal Guidelines for Data Processing Environments. This material may not be copied nor distributed in either paper or digital form without ASHRAE’s permission. Underfloor Supply Cold Aisle Hot Aisle Only 1 pressure zone for UF!

7Taylor Engineering, LLC Data center layout © 2004, American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. ( Reprinted by permission from ASHRAE Thermal Guidelines for Data Processing Environments. This material may not be copied nor distributed in either paper or digital form without ASHRAE’s permission. Overhead Supply Cold Aisle Hot Aisle You can incorporate VAV on each branch

8Taylor Engineering, LLC Elevation at a cold aisle looking at racks Typical temperature profile with UF supply Too hot Just right Too cold There are numerous references in ASHRAE. See for example V. Sorell et al; “Comparison of Overhead and Underfloor Air Delivery Systems in a Data Center Environment Using CFD Modeling”; ASHRAE Symposium Paper DE ; 2005

9Taylor Engineering, LLC Elevation at a cold aisle looking at racks Too warm Just right Typical temperature profile with OH supply

10Taylor Engineering, LLC Aisle capping © 2004, American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. ( Reprinted by permission from ASHRAE Thermal Guidelines for Data Processing Environments. This material may not be copied nor distributed in either paper or digital form without ASHRAE’s permission. Cold Aisle Caps End cap Hot aisle lid © APC reprinted with permission Cold Aisle Hot Aisle

11Taylor Engineering, LLC Aisle capping © 2004, American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. ( Reprinted by permission from ASHRAE Thermal Guidelines for Data Processing Environments. This material may not be copied nor distributed in either paper or digital form without ASHRAE’s permission. Cold Aisle Caps LBNL has recently performed research on aisle capping Cold Aisle Hot Aisle

12Taylor Engineering, LLC Overhead (OH) vs. Underfloor (UF)

13Taylor Engineering, LLC Airflow design disjoint IT departments select servers and racks Engineers size the fans and cooling capacity What’s missing in this picture?

14Taylor Engineering, LLC Airflow with constant volume systems Hot spots Higher hot aisle temperature Possible equipment failure or degradation

15Taylor Engineering, LLC Least hot spots Higher air velocities Higher fan energy Reduced economizer effectiveness (due to lower return temperatures) Airflow with constant volume systems

16Taylor Engineering, LLC Note most of these observations apply to overhead and underfloor distribution With constant volume fans on the servers you can only be right at one condition of server loading! The solution is to employ variable speed server and distribution fans… Airflow with constant volume systems

17Taylor Engineering, LLC Partial flow condition Best energy performance but difficult to control Airflow with variable volume systems

18Taylor Engineering, LLC How Do You Balance Airflow? Spreadsheet CFD Monitoring/Site Measurements Image from TileFlow Used with permission from Innovative Research, Inc.

19Taylor Engineering, LLC Thermal report From ASHRAE’s Thermal Guidelines for Data Processing Environments

20Taylor Engineering, LLC What’s the server airflow?

21Taylor Engineering, LLC Best air delivery practices Arrange racks in hot aisle/cold aisle configuration Try to match or exceed server airflow by aisle  Get thermal report data from IT if possible  Plan for worst case Get variable speed or two speed fans on servers if possible Provide variable airflow fans for AC unit supply  Also consider using air handlers rather than CRACs for improved performance (to be elaborated on later) Use overhead supply where possible Provide aisle capping (preferably cold aisles, refer to LBNL presentation for more details) Plug floor leaks and provide blank off plates in racks Draw return from as high as possible Use CFD to inform design and operation

22Taylor Engineering, LLC Air-side economizer

23Taylor Engineering, LLC Air-Side Economizer issues Hygroscopic dust  LBNL is doing some research on this Design humidity conditions  See following slides

24Taylor Engineering, LLC Design conditions at the zone © 2005, American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. ( Reprinted by permission from ASHRAE Design Considerations for Data and Communications Equipment Centers. This material may not be copied nor distributed in either paper or digital form without ASHRAE’s permission.

25Taylor Engineering, LLC San Francisco X Design Target Upper Allowed Humidity Limit Lower Allowed Humidity Limit (20%RH) Negligible time of possible concern for humidification

26Taylor Engineering, LLC Los Angeles X Design Target Upper Allowed Humidity Limit Lower Allowed Humidity Limit (20%RH) Only a few hours of possible concern for humidification

27Taylor Engineering, LLC Sacramento X Design Target Upper Allowed Humidity Limit Lower Allowed Humidity Limit (20%RH) Negligible time of possible concern for humidification

28Taylor Engineering, LLC Lower humidity limit Mitigate electrostatic discharge (ESD)  Recommended procedures Personnel grounding Cable grounding  Recommended equipment Grounding wrist straps on racks Grounded plate for cables Grounded flooring Servers rated for ESD resistance  Industry practices Telecom industry has no lower limit The Electrostatic Discharge Association has removed humidity control as a primary ESD control measure in their ESD/ANSI S20.20 standard  Humidity controls are a point of failure and are hard to maintain  Many data centers operate without humidification  This needs more research And for some physical media (tape storage, printing and bursting)  Old technology not found in most data centers  It is best to segregate these items rather than humidify the entire data center

29Taylor Engineering, LLC ESD control: floor grounding Image from Panduit, reprinted with permission

Water-Side Economizer Integrated Heat Exchanger in series with chillers on CHW side

31Taylor Engineering, LLC Economizer Summary Air-Side Economizers Provides free cooling when dry-bulb temperatures are below 78°F-80°F. May increase particulates (LBNL research indicates this is of little concern). Should be integrated to be most effective. Improves plant redundancy! Can work in conjunction with water-side economizers on data centers! Need to incorporate relief. Water-Side Economizers Provides low energy cooling when wet-bulb temperatures are below 55°F-60°F. Avoids increased particulates (and low humidity if that concerns you). Should be integrated to be most effective (see previous slide). Improves plant redundancy! Can work in conjunction with air-side economizers on data centers! Both are proven technologies on data centers!

32Taylor Engineering, LLC A case study of two designs Collocation facility in the Bay Area Side by side designs in same facility over two phases Motivation for the second design was to reduce cost Case study was developed by Lawrence Berkeley National Laboratory (LBNL)  Data Centers 8.1 and 8.2 Both sections at ~30% build-out during monitoring

33Taylor Engineering, LLC A tale of two designs: overview Phase 1 Data Center (8.1)  26,200 ft2  27 W/ft2 design  Traditional under-floor design with CRAC units  Air-cooled DX  Humidity controls (45%-55%) Phase 2 Data Center (8.2)  73,000 ft2  50 W/ft2 design  Under-floor supply from central AHUs with CHW coils  Water-cooled plant  Air-side economizers  No humidity controls

34Taylor Engineering, LLC A tale of two designs: a closer look Normalized efficiency metric: Data normalized to computer loads ~1/4 of the normalized energy Phase 1 Data Center (8.1) Phase 2 Data Center (8.2)

35Taylor Engineering, LLC A tale of two designs: results Phase 1 Data Center (8.1)  Around 2x the HVAC installed cost ($/ft2)  Around 4x the energy bills (when normalized to server load)  Acoustical problems  Higher maintenance costs  Lost floor space in data center due to CRACs Phase 2 Data Center (8.2)  Preferred by the facility operators and data center personnel

36Taylor Engineering, LLC Two data centers: summary What made the difference?  Airside economizers  No humidity controls  Water-cooled chilled water system  AHUs instead of CRAC units

37Taylor Engineering, LLC Custom CRAH Unit (Large)

38Taylor Engineering, LLC Example CRAH Unit Comparison

39Taylor Engineering, LLC 34% less water flow 13% less fan energy  More if you consider the supply air temperature and airflow issues Excess fan capacity on new units 36% higher cost for units, but  Fewer piping connections  Fewer electrical connections  Fewer control panels  No need for control gateway  Can use the existing distribution piping and pumps (case study)  Can use high quality sensors and place them where they make sense Possibly less turbulence at discharge? Example CRAH Unit Comparison

40Taylor Engineering, LLC Air cooling issues Limitations on the data densities served (~200w/sf)  Air delivery limitations  Real estate Working conditions  Hot aisles are approaching OSHA limits Costly infrastructure High energy costs Management over time Reliability  Loss of power recovery  Particulates

41Taylor Engineering, LLC Take Aways Use air- or water-side economizers where possible Consider personal grounding in lieu of humidification Consider AHUs as an alternative to CRACs Consider VSDs on fans, pumps, chillers and towers Refer to ASHRAE, LBNL and Uptime Institute for more recommendations

42Taylor Engineering, LLC State of the future: cooling with liquid