3.1 GENERAL CONSIDERATIONS
Spatial and Envelope
Considerations
A datacom facility can be a dedicated building, or be part of a general purpose building that
houses other business functions or tenants. Regardless of the type of building in which it is
housed, or its location within a building structure, a datacom facility is comprised of a number
of spaces having different but interrelated functions (see Figure 1).
The main computing area is identified by different names: data hall, ITE equipment room, computer
room, machine room, raised floor area, or white space. This chapter uses the term datacom room to differentiate it from the other areas that support it,
and which comprise the complete datacom facility.
Determining the appropriate size of a datacom room is more challenging than it has ever been.
There are three major reasons: the ever-increasing demand for computing services; the
consolidation, virtualization, and increasing density of datacom equipment; and the transition
of many computing services to the cloud, leased colocation facilities, or computing as a service
(CAS) facilitators.
It is all too common to underestimate the amount of electrical/mechanical space required to
support a datacom facility. The need for reliability in these critical facilities dictates a
requirement not just for systems that are often redundant, but also for adequate maintenance
space. Overcrowding, even if minimum legal or manufacturer-dictated service clearances are
maintained, can lead to inadvertent interruption of one system while servicing another. A rule
of thumb, to be used as a starting point only, is to base minimum electrical/mechanical support
space requirements on a percentage of the datacom room area:
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At least 50% for non-redundant facilities
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From 75 to 100% for N + 1 redundant facilities
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From 100 to 150% for 2N redundant facilities
See the section on Redundancy, Reliability, and Concurrent Maintainability for definitions of
N + 1 and 2N).
Every increase in reliability requirements also increases the need for additional pieces of
redundant equipment, which in turn requires even more support space. Further, highly redundant
facilities require physical compartmentalization of duplicate or parallel systems by fire-rated
walls, further increasing support space requirements.
The structure enclosing a datacom room should provide good thermal separation from the
surrounding areas, whether those are exterior or interior spaces. In addition to thermal
insulation, a major concern with the overhead structure is that it not be a source of
particulate contamination or water leakage.
The overhead structure must be cleanly finished and sealed to avoid concrete or insulation
flake-off. If it is a roof structure, extra precautions must be taken to preclude leakage. In
highly critical spaces, a double roof structure is often used for added ensurance. Gaps and
joints should be caulked.
Suspended ceiling tiles must be either metal pan or plastic encapsulated on both sides to prevent
particulate flake-off. This is particularly important when the above-ceiling plenum is used to
convey return air. Cut edges must be sealed with spray paint or similar. It is best to suspend
overhead infrastructure (lights, cable trays, power busway, air containment panels, etc.) from a
structural ceiling grid designed for use in datacom room suspended ceiling installations. This
not only provides virtually infinite flexibility in adjusting suspended equipment locations, but
also avoids penetrating the ceiling tiles with threaded suspension rods and drilling into
overhead concrete to make future changes. Any suspension rods that do penetrate the tiles should
be sealed at the penetrations. Metals used above a return air plenum ceiling should be either
hot-dip galvanized or of a type that will not grow zinc whiskers.
Walls surrounding a datacom room should be well insulated to avoid both cooling loss and heat
infiltration. All cracks should be sealed, which is mandatory if the room is also protected by a
gas-based fire protection system.
Although most datacom equipment can accept a broad range of allowable humidity levels, consider
installing vapor barriers for datacom spaces. Avoiding condensation anywhere in the room is very
important.
Windows should generally be avoided in a datacom room, but if they exist or are somehow
necessary, they should be double-glazed and sealed. If covering the windows is allowed, but
replacement is only possible from the inside, it will be necessary to make the coverings
removable and to avoid blocking access. This may require locating large pieces of
mechanical/electrical equipment to the sides of, or well in front of, the windows, which can
prevent placing cooling units in ideal locations or waste large amounts of perimeter floor
space.
Although raised access floors are still used in many datacom rooms, they are no longer a standard
requirement. It is not only possible, but now relatively common, to put the entire power,
cooling, and network infrastructure overhead, particularly when close-coupled cooling is used.
In these designs, the raised floor is not necessary to convey air.
However, with the amount of piping often used to service liquid-cooling systems (in-row,
rear-door, and direct liquid cooling), raised floors are often used anyway to avoid concerns
about overhead water, as well as to minimize congestion above cabinets. When power, cable tray,
and lighting are all run overhead, the vertical space can become congested and difficult to
coordinate. Three-dimensional modeling of the space is highly recommended when overhead
infrastructure is used, to avoid both installation conflicts and long-term operational
difficulties.
There are several advantages and disadvantages to using raised access floors, regardless of their
purpose. The two most common uses are to convey under-floor air to the ITE, and to provide a
space for permanent infrastructure such as power, piping, and cabling. An additional advantage
can be to level slab variations too large to be leveled with patching and unrealistic for
self-leveling cement. Once it is determined that a there is a preference for a raised access
floor, several factors should be considered in its selection and design.
When used for cooling air delivery, CRAC/CRAH units, which are generally located around the room
perimeter, blow cold air under the raised floor, pressurizing the floor plenum. Openings in the
floor (airflow tiles) allow the air to be pushed upward in front of cabinets by the under-floor
pressure and delivered to the server air intakes. The amount of air delivered through each
opening can be regulated by the choice of airflow tiles, which may have different opening
percentages (generally 25 or 63%), adjustable air dampers, or both. The supply of air is not
infinite and its static pressure is not entirely uniform throughout the under-floor plenum, so
delivering more air through one tile can reduce the air delivered through others. Air balancing
is therefore important to maintaining good cooling throughout the space. More information is
provided in the section on Air Cooling.
A raised access floor also adds total mass to the structure. The floor must also be
maintained, which includes re-leveling every few years, particularly if technicians do not take
care in replacing tiles where they were removed, or open too many tiles in a row at the same
time and destabilize the floor. If not well managed, the plenum space can become a tangle of
wire and cable if care is not used in installing new cable and removing old. When the floor is
used to convey air, masses of unmanaged cable can reduce or totally block airflow. When cables
are located in a raised floor plenum that is also used to convey cooling air, best practice is
to run cables parallel to airflow, and to provide overhead cable pathways for ad hoc cable
installation to minimize the need to work under the floor. It is even better to not locate
cables in an air-plenum floor space at all.
The height of a raised access floor is determined by its purpose. If it is used to convey cooling
air, it must be high enough to deliver the required air quantity while maintaining the necessary
static pressure as evenly as possible throughout the floor plenum,
Piping, power systems, or cable tray that will also occupy the space must be taken into
consideration in determining the floor plenum height and its effect on air flow. It is generally
accepted today that a raised access floor used to convey cooling air needs to be at least
600 to 760 mm high to be effective, and that even higher is better.
After height, the biggest consideration is floor structural strength. Raised floors for datacom
rooms should use bolted stringer substructures to increase load capacity and to make it easy to
remove and replace tiles without destabilizing the floor.
Newer computing equipment cabinets are usually rated for 1100 to 1360 kg, which is
significantly higher than most legacy cabinets. Even if they are not full of the heaviest
available equipment, floor loading must be planned as if they will be to address potential
maximum loading in the future.
However, cabinets with these load ratings also tend to be larger than legacy 600 by 600
mm cabinets, so the load is spread over more than one floor tile. It is not
unrealistic to specify raised-floor systems designed for 700 kPa or 1360
kg rated tile capacity. Any abnormally heavy equipment can be supported with
supplemental floor pedestals under the tiles, so long as the slab structural strength is
sufficient for both the total and point loads.
In selecting floor strengths, it is particularly important to examine the rolling load
characteristics along with the static structural ratings, because equipment must often be moved
into position on small integral wheels. The rolling load tests are generally performed for 10
passes and 10 000 passes with mass on test wheels of particular
sizes in accordance with testing methods established by the Ceilings & Interior Systems
Construction Association (CISCA) (CISCA 2007). However, not all tests are performed with the
same wheel sizes, and the results can be misleading.
It is always safest to put thick hardboard or plywood over the floor when moving particularly
heavy loads. This is especially important when rolling equipment through cold aisles with
perforated airflow tiles, many of which do not have a rolling load specification at all and are
easily deformed.
The most common surface material for raised access floor panels is high-pressure laminate (HPL).
This material holds up well to heavy rolling loads without deforming or cracking, has good
static dissipative characteristics when properly bonded to a grounded surface, is available in
light colors to maximize lighting effectiveness, and is easy to maintain with damp mopping.
Heavy scrubbing, buffing, or waxing should never occur in a datacom
room. This precludes the use of vinyl composite tile (VCT), pure vinyl tile (which can also be
easily deformed under rolling loads), or linoleum (which is also too easily damaged). Carpeting,
of course, should never be used in a datacom room, even if it is antistatic, because it both
accumulates and generates particulate contaminants. (Note: it is
generally accepted that the ground resistance of an installed raised-floor panel, when properly
connected to a robust grounding system, should be in the range of 104 to
106 Ω to minimize any potential for static generation.)
One of the most challenging decisions in selecting materials for air plenum raised access floors
is the airflow panels. As noted previously, a range of types is available, including legacy
perforated tiles (25% open), grate-style cast aluminum tiles (56 to 63% open), and tiles
incorporating directional vanes, air boost fans, and automatic air flow control. (See further
discussion of airflow tiles in the section on Underfloor Air Delivery).
All air plenum raised floors leak air. Because cool air is expensive to produce and requires
considerable fan energy to distribute through the plenum, this wastes energy. A good-quality
raised-floor installation should be tight enough to leak no more than 2% air. This requires not
only expert installation, but through-sealing of all cuts around equipment and penetrations, and
completely around the floor perimeter.
For datacom rooms designed without a raised access floor, the primary concern is that all power,
cooling, and network infrastructure must be routed overhead. Depending mainly on the cooling
method used, this can create a congested overhead space that requires careful design
coordination and exacting installation. As previously noted, 3D modeling techniques are highly
recommended when designing complex overhead systems. It should also be recognized that the cost
of overhead infrastructure, particularly if extensive ductwork is necessary, can be very similar
to the cost of a raised access floor.
Support and Ancillary Spaces
Space must be allocated within a datacom facility for storing components and material, support
equipment, and operating and servicing the datacom equipment. Some ancillary spaces may require
environmental conditions comparable to those of the datacom equipment, whereas others may have
less stringent requirements. Continuous operation of some support spaces is often vital to the
facility’s proper functioning.
If tape storage is located outside the datacom white space, its requirements are more stringent
than for most ITE equipment, especially for temperature and humidity rate-of-change. Temperature
range for tape is usually between 15 and 32°C, relative humidity between 20 and
80%, and maximum dew point of 22°C. Typically, the maximum allowable rate of
temperature change is 5 K in a 1 h period. The maximum humidity rate of change is
5% per hour with no condensation. Appendix K of ASHRAE (2021) provides a more detailed
discussion, with several examples of both compliant and noncompliant rate-of-change conditions.
Electrical power distribution equipment can typically tolerate more variation and a wider range
of temperature and humidity conditions than datacom hardware. Equipment in this category
includes incoming service/distribution switchgear, switchboards, automatic transfer switches,
panel boards, transformers, and standby generators. Manufacturers’ data should be checked
to determine the amount of heat release and design conditions for satisfactory operation.
Further information and guidance can be found in IEEE Standards 446
and 1100. (Note: Both standards are currently inactive and will be
superseded by the 3005 and 3003 series in the future.)
Air-Cooled Chillers. Air-cooled chillers used for
datacenter applications are selected to operate at elevated chilled-water supply and return
temperatures to help building owners achieve energy savings during system operation. In central
chiller plants, the chilled-water supply temperatures can be as high as 20°C
and the chilled-water return temperature can be 30°C. With these water
temperature ranges, the supply air temperature to the data hall from precision air-handling
units could be in the range of 25 to 26°C.
Chillers used for datacenter applications must be provided with a quick restart feature. Once
power is restored after a failure (either utility or generator), chillers must be able to
rapidly resume pre-failure operating capacity. The quick restart time varies by manufacturer,
and must be selected to meet the project’s specific requirements. The air-cooled chillers
used for datacenter applications must be selected for ambient temperatures of n = 20 years based on ASHRAE weather data or project-specific
requirements. Generally, air-cooled chillers are located at the terrace level of a datacenter
building or on the roof, mounted on an elevated structural beam grid system. The chiller
platform is elevated approximately 3.5 to 4 m from the terrace slab or roof. The
space below is used to route the main chilled-water headers and other services, including pumps.
The elevated platform must be provided with handrails and MS plates of sufficient thickness for
service personnel to safely move around the chillers. Chiller compressor and condenser fans
should be provided with variable-speed features to minimize energy use during part load
operation. Chillers and their controls must have the same design redundancy as has been
established for the datacom room cooling units.
Uninterruptible Power Supplies (UPSs). These units
come in various configurations, including flywheel and diesel rotary UPS (DRUPS), but most use
batteries as the energy storage medium. Regardless of type, UPS systems are usually configured
to provide redundancy for the central power buses in mission-critical systems, and typically
operate continuously at less than full-load capacity.
UPS power monitoring and conditioning (rectifier and inverter) equipment is usually the primary
source of heat release. This equipment usually has self-contained cooling fans that draw intake
air from floor level or the equipment face, and discharge heated air at the top or back of the
equipment. Air-distribution system design should take into account the position of the UPS air
intakes and discharges.
Installation of secondary battery plants as temporary back-up power sources should be in
accordance with all applicable codes and standards. If ITE is to operate continuously throughout
an emergency or accident (business continuity), then the UPS must be air-conditioned with
sufficient redundancy and diversity to provide an operable system. Battery durations of more
than 30 to 60 min are usually ineffective unless generators are available to maintain cooling,
because UPS systems will overheat and shut down within that time period or less. If generators
are used, battery durations of only a few minutes are often sufficient: good generators will
generally start and stabilize in less than a minute.
Several types of batteries are used with UPS systems. Flooded
lead-acid (wet cells) are generally considered the longest lasting, but
also present the highest initial cost due to facilities. They require special rooms with, among
other things, containment for possible acid spills, deluge shower and eye wash stations, as well
as hydrogen gas detection and exhaust fans. It is important to locate the battery room close to
the UPS room to minimize loop current losses in the large DC conductors. More commonly used
today are valve-regulated lead-acid (VRLA) batteries,
also known as sealed cells or maintenance-free batteries. These can be colocated with
the UPS system, which may be in the datacom room (IEEE Standard
1187). However, if the ambient temperature in the datacom room is not appropriate for the
batteries, battery life may be adversely affected. VRLA batteries are available in different
qualities, but those usually supplied with a UPS system may have a service life of only three to
five years before replacement is required, depending on usage conditions.
The newest battery used with UPS systems is the lithium-ion (Li-ion)), commercially introduced to
datacom facility service around 2016. Li-ions are still new to UPS usage but are expected to
have longer lifespans than VRLAs, although limited usage data is yet actually available. Other
advantages are smaller footprint, lower mass, and lower total cost of ownership
despite higher initial cost.
Temperature in a battery area is crucial to the life expectancy and operation of the batteries.
The optimum space temperature for lead-calcium batteries is 25°C. If higher
temperatures are maintained, it will reduce lead-acid battery life; if lower temperatures are
maintained, it may reduce the batteries’ ability to hold a charge. Recommended ambient
temperatures for Li-ion battery types are higher than lead-acid, but should be verified with the
battery manufacturers.
Engine-driven generators used for primary or standby power typically have air-cooled radiators
that require large volumes of outdoor air when running. It is best to locate them in a room
within the building structure, but if that is not possible, they should be in a high-quality
enclosure designed specifically for generators. Generators will incorporate heaters to ensure
reliable starting in cold weather, and the enclosure should also be maintained at a temperature
that enables servicing in cold weather. Designs should ensure that engine exhaust air does not
recirculate back to any building ventilation air intakes. Commonly, up to 72 h of fuel oil
storage is required, so fuel oil storage tanks and distribution systems need to be integrated
into the overall facility design and planning. The governing codes often mandate specific
requirements for containment, location of fuel oil storage, fire resistance ratings, etc.
However, as has been unfortunately demonstrated in several weather disasters, local codes may
impose requirements that can negate the benefits of generators unless all potential conditions
are taken into account in the designs. Fuel tanks are heavy when full, but will start to float
in a flooded basement as fuel is used, breaking the pipes. Both fill and pressure relief pipes
must be located high enough above ground to remain both accessible and impervious to flood
waters. Generators themselves must also be carefully located and protected from potential
problems.
Not all generators are diesel. Natural gas and propane are also used, and bi-fuel generators are
also available that combine the high energy delivery of diesel with the generally lower cost of
natural gas. Diesel fuel maintenance is also critical to ensuring reliable backup.
Something rarely considered is fuel delivery. Have at least two sources for emergencies, and make
certain suppliers have their own generators so they can pump the fuel that must be delivered.
Other Systems and Considerations
Fire Protection. Datacom fire protection involves a
combination of strategies starting with prevention and continuing through detection,
suppression, and response to a fire event. The National Fire Protection Association (NFPA) has
several standards addressing design, installation, maintenance, and operation of fire protection
systems in datacom facilities listed in the Bibliography. Municipalities may have their own
codes, and worldwide other fire protection standards will apply as well. Consult local
government regulations.
There are several options for providing fire suppression in datacom rooms, but only two
classifications: water and gas. Conventional wisdom, invoked by many code authorities, is that
gas protects equipment but sprinklers protect people and structures. However, many older (and
even some newer) datacom facilities use a code exemption to allow gas only without any water
system at all. Often, however, datacom facilities are equipped with both a sprinkler and gaseous
suppression systems for a combination of life, structure, asset, and service protection.
Water-based systems in datacom rooms should be dual-interlocked pre-action to minimize the
chance of an inadvertent discharge or damage from a leak. Fog mist systems have also been
approved in some jurisdictions.
Gas-based systems are of two generic types: inert gas
consisting mainly of nitrogen and argon that reduce the oxygen mixture below levels required to
sustain flame; and clean agent systems that use
chemicals to remove heat and extinguish the fire. There are even systems that combine inert gas
with fog mist, or that maintain a hypoxic environment to prevent combustion altogether. Any
system must be approved by local code authorities. The primary reason for gas-based systems is
to avoid damage to electronic computing equipment. The primary concern is environmental. All are
safe for humans, with certain restrictions differing among products, and all have low ozone
depletion (ODP) and global warming potential (GWP), albeit to different degrees. Depending on
the specifics of the gas-based system, it may be necessary to also provide a ventilation fan to
remove the gas after discharge.
Early warning, aspirating smoke detection systems have
also become common in datacom facilities with the goal of detecting and suppressing small fires
with portable extinguishers before any kind of full system discharge occurs. It is important to
coordinate the locations of aspirating sensing tubes with air-conditioner discharge streams,
because high air velocities can negate the ability of the aspirating system to draw in air and
detect smoke.
Air containment, either hot aisle or cool aisle, has
become a common method of improving cooling performance and reducing energy usage. However, when
containment systems are retrofit or designed into a new facility, effects on the required
detection, suppression, release system, materials of construction, and prevention of fire must
be considered. These important considerations are addressed in detail in the NFPA standards. The
added obstructions often necessitate modifications to the suppression systems (sprinklers and/or
gaseous agent nozzles) to ensure proper suppression release and dispersion. An alternative to
suppression system changes can sometimes be partial
containment, which has been shown to be as much as 80% as effective in
improving air control as full containment, but does
not block existing sprinkler or gas discharge heads. (See the section on Containment.)
Water Concerns. Water damage is always a concern in a
datacom facility, which is why conventional sprinklers are to be avoided. However, it is also
best to locate the facility, including its central power and cooling systems, above grade if
possible. Where this is not practical, significant attention should be given to mitigating water
infiltration.
There are other sources of water leakage as well: designs must consider the possibility of leaks
from overhead. Datacom rooms and supporting electrical equipment should not be located below
bathrooms, pantries, laboratories, or the like. If unavoidable, the space above should have
waterproof membrane floors. Liquid piping should also be routed around the datacom room, but if
this is not possible, it should be provided with drip pans and leak detectors. Leak detectors
should also be provided anywhere water can infiltrate, particularly if it could affect
electrical infrastructure. A common problem in buildings that have not been specifically
designed for high-availability datacom facilities is the location of primary power switchgear
and bus duct terminations in the lowest level of the building, where they are subject to
flooding. These conditions cannot likely be changed in existing buildings, but should be avoided
in purpose-built facilities.
Acoustics. The rapid increase in datacom equipment
density and power draw has brought with it commensurate increases in required cooling. Air
cooling requires substantial volumes of air movement, which generates high noise levels that can
have deleterious effects on worker communication, concentration, and health. Extremely high
sound pressure levels cause by fire suppression systems (as noted previously) or by elevated
datacom system fan speeds, may also lead to reduced hard disk drive (HDD) performance, and even
to permanent damage, due to acoustically driven vibrations.
Sound level exposure limits in datacom rooms and their associated mechanical/electrical plant
facilities are evaluated in terms of exposure levels and duration through a time-weighted
average. In the United States, workplace noise emission is governed by the Occupational Safety
and Health Administration (OSHA [Annual]) in Code of Federal Regulations (CFR) 1910.95. Other
organizations, such as the National Institute for Occupational Safety and Health (NIOSH 1998)
and the American Conference of Governmental Industrial Hygienists (ACGIH), promote even stricter
limits. Similar regulations with various thresholds exist in other countries. Acoustical
declarations pertinent to the system configuration, operation, and environment can be used to
forecast exposure in advance of datacom equipment purchases. Additional noise mitigation
measures may include engineering controls, administrative controls, and requiring a hearing
protection program.
Sound emissions from heat rejection equipment (cooling towers and/or air-cooled chillers) as well
as emergency and/or prime power-generating equipment for the datacom facility’s
mechanical/electrical plant must also be considered. Noise generated outside the building,
typically from rooftop chillers, cooling towers, and generators, must also be mitigated so that
sound levels in the building are conducive to conducting normal business activities.
Community sound levels, mostly from exterior heat rejection and power-generating equipment, must
typically comply with state, regional, or local noise codes, ordinances, guidelines, and/or
regulations. Community sound level limits are typically cited at property lines and/or anywhere
on the property of a potential complainant.
Sound levels of exterior equipment during normal, emergency, and test operation should allow for
relatively easy communication among service personnel, as well as auditory awareness of vehicle
and general service activities in the area. A sound level at or below 70 dBA in service areas
and equipment yards, with all equipment operating, is an ideal goal.
Vibration. Vibration levels in datacom facilities must
be considered as well. Primary sources of vibration that may adversely affect normal operations
of datacom equipment are usually roof-mounted support equipment such as air handlers, cooling
towers, chillers, and generators. Similar equipment mounted inside the building may also lead to
undesirable vibration levels. However, sources of vibration are not limited to external
equipment. Vibration may be induced by the datacom equipment itself (e.g., by rack cooling
fans). This form of induced vibration may also pose issues for high-density disk drives. The
ASHRAE TC 9.9 datacom book series, especially ASHRAE (2008a), provides valuable resources and
guidance on vibration-related matters.
Vibration specifications for all datacom equipment should be obtained from the manufacturers.
Subsequently, compliance with the specifications must be demonstrated with respect to ambient
conditions, including structural dynamic characteristics of the facility’s supporting
floor. This may require field measurements to establish realistic vibration demands on datacom
equipment and its content. Typical datacom equipment can withstand a vibration range of
0.07g without functional degradation. In fact, most datacom
equipment is capable of withstanding higher operational shock and vibration amplitudes.
Many geographical locations around the world are considered seismic zones where special design
considerations are stated by national and regional codes and guidelines. It is expected that
datacom equipment will experience the highest force and deformation demands when subjected to
earthquake-induced vibration. Accordingly, special bracing and safety restraints for much of the
infrastructure may be required. Use of structural supports and restraints, such as fastening
cabinets to the floor, is generally recommended, even at locations where seismic regulations are
minimal or do not exist. These requirements are intended to ensure continuous operation of
mission critical facilities such as datacom facilities, during and after both major and minor
seismic events.
As described in ASHRAE (2008a), it is important for both the owner and the designer to understand
all potential hazards of the region where the data facility is located, including seismic, wind,
fire, flood, etc. Clear operational criteria should be established and used for the design of
systems. These may include recommendations for structural restraints and bracing beyond what is
required by law. Local code requirements must be identified and understood, as well as the
requirements set forth in ASCE Standard 7, which provides further
information and direction.
Lighting. In datacom rooms, lighting should usually be
centered in the aisles, using narrow fixtures with wide horizontal dispersion patterns similar
to lighting of library book stacks. Fixtures should be located above equipment cabinets or cable
trays where much of the light energy would be wasted. Fixtures are best suspended 2.44 to
2.75 m above the floor so as to deliver maximum illumination over the heads of
technicians and into cabinets. This also enables placing fixtures where there is minimal
conflict with overhead air diffusers and airflow. Higher mountings may be necessary to clear
other overhead infrastructure, but this disperses more wasteful light energy over the tops of
cabinets and other obstructions. An illumination level of 325 lx on the vertical
surfaces of cabinets is generally sufficient. Although lighting is a small part of datacom room
energy consumption, and LED has become the light of choice, proximity sensors should be still
used to ensure they are not left on when there is no activity.
Emergency lighting in datacom rooms must consider contained aisles as separate rooms for
emergency egress purposes. UL 924-listed battery packs can be added to any PoE lighting fixture
to make it into an emergency fixture. This is an advantage over conventional lighting, which
requires selected fixtures to be designated and provided as emergency luminaires. Whichever
emergency system is decided on, it must meet local requirements for illumination and run time in
the event of loss of normal power.
Redundancy, Reliability, and
Concurrent Maintainability
It is axiomatic that redundant systems should improve the reliability of a facility, but how much
redundancy is justified is always a question. Redundancy decisions must consider business and
operational needs and energy efficiency, as well as economic justifications. Unfortunately,
redundancy alone does not guarantee increased reliability.
It is not uncommon for large investments to be made in duplicate power and cooling systems that
have been configured or installed in ways that defeat or greatly compromise their purposes.
Consequently, a careful analysis of all possible failure modes should be an integral part of the
design phase of any datacom facility.
The primary goal of any datacom facility should be to align the level of redundancy with the
organization’s applications criticality, available CAPEX and OPEX budget, and risk
tolerance. The combination of these three characteristics is not necessarily the same for
datacom facility operators within the same industry. Each operator will weigh these three
characteristics in their own unique ways.
The most common level of redundancy incorporated into a datacom facility is to provide for concurrent maintainability. This requires a design that
allows any element in the power and cooling infrastructure to be shut down and removed from
service for maintenance without compromising the computing systems that depend on that
infrastructure. This level of redundancy requires two independent facility infrastructure paths
supporting the datacom equipment, with no single points of failure, and redundant components or
systems to ensure concurrent maintainability.
The term N+1 is often used
in the industry to describe a level of redundancy. However, this term alone does not provide
sufficient detail to fully understand the level of redundancy provided, or to ensure that the
resulting facility is actually concurrently maintainable. N+1 can
refer to component redundancy or systems redundancy; it can consist of a single path with
redundant components, or multiple paths with system redundancy.
Higher levels of redundancy require some degree of duplicate systems, such as two identical and
fully load-sharing chiller plants with duplicate piping systems or two full-capacity UPS
systems. This is known as 2N redundancy. (Note that a smaller
installation requiring two units to provide N+1 redundancy is
automatically 2N in nature, but will not function as a true 2N system unless the rest of the infrastructure is designed
accordingly.) An even more stringent design would have duplicate systems, but with additional
redundant components in each. Depending on how the additional redundancy is configured, the
systems may be known as 2N+1, in which an additional unit (e.g., a
chiller module) is made available to either of the duplicate systems, or 2(N+1) in which both redundant systems each have their own redundant
modules. Several methods have been developed to classify levels of redundancy and their
resulting reliabilities and uptimes (e.g., ANSI/TIA Standard 942-B).
It is standard practice to power datacom equipment from an uninterruptable power supply (UPS).
UPSs have two main purposes: to isolate the datacom equipment from power line disturbances; and
to maintain ride-through power to the datacom equipment until back-up generators start, or
alternatively, long enough to accomplish an orderly shutdown if generation is not available or
fails. Most modern ITE is dual-corded, meaning it has
two full-capacity power supplies and two power cords. To maximize the effectiveness of the
dual-corded investment, it has become common to run duplicate branch circuits to each cabinet.
This often causes owners to also elect to use duplicate UPS systems, resulting in a 2N electrical design that may not be matched by the cooling systems or
even by the rest of the electrical infrastructure. It is important to recognize the actual
facility vulnerabilities when one element of the infrastructure is more robust than the rest,
and to not assume that a facility is more reliable than it actually is.
With today’s heat densities, datacom systems cannot be maintained for very long on UPS
alone. The usual maximum back-up time is 15 to 20 min, before thermal rise causes a shutdown of
the datacom equipment and/or the UPS. High-performance computers may shut down in minutes or
even seconds if cooling is interrupted. It is therefore necessary to have a means of maintaining
cooling for the most critical systems until either generators start, or systems can be shut down
properly.
It is generally impractical to run large cooling systems on UPSs. If this must be done, the
cooling equipment’s electrical characteristics make it prudent to use separate UPSs.
Further, the substantial power draws and high in-rush currents on compressor start-up and
cycling require large and expensive UPS systems. DRUPS or motor generator (MG) sets are often
used instead of electronic battery systems to support these kinds of loads.
In many datacom rooms it is not necessary or justifiable to provide full business continuity for
an extended period, which would require maintaining full cooling with generators. Even with
generators, cooling often must be maintained to the most critical computing systems until both
generators and full cooling restart. If a chilled-water system with close-coupled liquid-based
cooling has been selected, this can be relatively easy to accomplish. There may be sufficient
residual water in header pipes to cool critical systems for several minutes if small, auxiliary
pumps are provided on UPS. If not, additional water can be stored in tanks.
Long battery life is of no value if the UPS it supports is without cooling. A UPS generates
substantial heat under load, as do the batteries when they take full load after a power failure.
Batteries also emit heat as they recharge once the generators start. This heat generation should
be considered when choosing the location for the UPS, which is too often relegated to a marginal
location. This is sometimes in an electrical or mechanical room that generates additional heat,
in a corner of a parking garage, or even in a roof penthouse that is exposed to high sun loads.
These kinds of locations can dramatically shorten the actual back-up duration of the UPS,
particularly if the batteries are also exposed to continuous heat. The cooling system in the UPS
room should have the same level of redundancy as the cooling for the datacom room.
Commissioning (Cx) of critical facilities, including datacom facilities, follows the process
described in ASHRAE Standard 202-2018 and ASHRAE Guideline 0-2019. Additional information is also available in Chapter 44 of this volume.
Commissioning Process Applied to Datacom Facilities.
The commissioning process for a datacom facility follows the same fundamental processes as
commissioning any building. The difference is the nuances related to critical facilities that
must be addressed. As in the generic commissioning process, commissioning starts with the
programming phase, with the project goals and objectives being defined and captured in the owner’s project requirements (OPR) document.
During the programming phase, expected reliability and availability must be established for
critical ITE loads. This is a very different determination than is normal to typical building
OPR requirements, and also involves building performance and facility management considerations.
Staffing strategies must also be considered as they will influence the design intent. Sites that
do not have continuous staff coverage will require a greater level of automation and remote
monitoring. All these factors affect the infrastructure topologies, such as the need for onsite
storage and spare parts, and the required training program content
The commissioning provider (CxP) ensures those
requirements are addressed and satisfied in the engineering and design team’s basis-of-design (BoD) document, and that they are
further refined and expanded upon in the construction documents
(CDs) by performing iterative design reviews. The CxP must also ensure
that drawings and specifications clearly define the commissioning scope for the CxP, and for the
other entities that must participate in the commissioning process. These include the engineering
and design team, general contractor and respective subcontractors, select suppliers and/or
manufacturers, the owner and facilities management staff, and other entities that may be
required. Specification 01 91 13 should be drafted by the CxP and submitted to the owner for
approval, and then included in the overall construction documents
In the construction phase, the CxP ensures that the physical construction of the facility is
compliant with the design by reviewing submittals, addenda, and bulletins, and performing onsite
progress inspections. The construction-phase verifications culminate in ensuring proper startup
and checkout of the installed equipment and systems, including leak/pressure testing of ducting
and piping systems; clean and flush; test, adjust, and balance (TAB); NETA testing; and initial
energization and checkout by the installing contractors, often with manufacturers’
support. Startup and checkout, also referred to as prefunctional
testing, must include verifying all related monitoring and controls are
completed by performing point-by-point, end-to-end
validation of each monitored or control point. Prefunctional testing and
resolution of identified discrepancies is a prerequisite for proceeding to the acceptance
testing phase.
Acceptance testing typically proceeds from the simple
to the complex, starting with components, then equipment, followed by system-level testing.
Acceptance testing involves executing site-specific functional performance tests on the critical
infrastructure. This is the most critical part of the datacom facility commissioning process,
because any potential point of failure or combination of failure scenarios that is not properly
tested could one day be the reason a facility fails. Since datacom facility outages are
incredibly costly, thorough testing of the completed facility, and particularly of its redundant
systems, is critically important. This can involve testing under low, partial, and design-rated
loads to verify that power and cooling systems remain stable during anomalies, and that the
environment remains with the OPR and design intent parameters.
Load testing of the infrastructure requires the use of artificial, simulated power and heat
loads. Since the vast majority of power sent to the ITE is converted into heat, using resistive
electrical load banks allows for simultaneous testing of the electrical power system and the
heat rejection (HVAC&R) systems. The CxP should develop a load bank plan in collaboration
with the engineer of record and the installing trades to plan and execute load testing. The best
practice is to use true server simulators, which are
resistive load banks of a size similar to typical IT servers that are temporarily installed in
the IT racks. These include fan speed adjustment to simulate actual server airflow, including
respective differential temperature rises from server inlets to exhausts. When hot/cold air
separation is achieved using rack/row hot/cold aisle containment systems, the testing strategies
can become tedious and complex and are beyond the scope of this handbook. Interested readers
should consult the ASHRAE Datacom books (www.ashrae.org/technical-resources/bookstore/datacom-series) for more
information.
Acceptance testing culminates with integrated systems testing
(IST) to confirm that the overall site can respond to expected anomalies
(e.g., power outages) and restore back to normal operations without impact to the critical loads
(typically, computers and other ITE). ISTs are also referred to as pull-the-plug tests. Due to the inherent complexity and
performance requirements for critical facilities, and the specialized technologies and
requirements for redundancies, the level of effort required to perform formal commissioning of
datacom facilities can be significantly greater than what is required for office buildings.
designed and tested to assure very high levels of reliability. CxPs who commission datacom
facilities must be subject matter experts in these specialized technologies and system
topologies.
Critical facilities typically have very robust and comprehensive monitoring and control systems,
which may include mirrored-redundant central plant controllers so the controls do not become
single-points-of-failure. Typical building management systems (BMS) are supplemented with
sophisticated electrical power monitoring systems (EPMS), intelligent switchgear with
mirrored-redundant programmable logic controllers, and include full integration into critical
equipment, resulting in literally hundreds of possible monitoring points for a single system.
Monitoring and control systems are typically the last to be completed, yet still need to be
tested and validated before proceeding with testing the critical infrastructure that they
monitor and control. They must be tested and validated as they would for any other system, but
it must also be verified that their interface with the critical datacom infrastructure is
correct. This requires site-specific prefunctional test scripts with embedded software
verification, field panel programming, head-end graphics, monitoring points, and control
sequences of operations.
Thorough CxP services include transitioning to the operations phase, which includes ensuring the
project is thoroughly documented for posterity in organized system
operations and maintenance manuals (SOMMs). The CxP should also be
responsible for ensuring the facility O&M staff receive thorough site-specific training,
which needs to be substantially greater than for office buildings. Of particular importance is
understanding how to maintain continuous operations while concurrently performing equipment
maintenance, and without causing inadvertent shutdowns.
Air-Cooling System Configurations
Datacom equipment rooms can be conditioned with a wide variety of equipment types and
configurations. These include packaged computer room air-conditioning units and central-station
air-handling systems. Air-handling and refrigeration equipment may be located either inside or
outside the datacom equipment rooms, and should incorporate economization or free cooling to the
greatest extent possible. Some climates and ITE now enable use of free cooling year round. This
section concentrates on cooling systems using some type of refrigeration.
The following systems and configurations are the most commonly used solutions to providing
sufficient cooling to air-cooled datacom equipment.
Computer Room Air-Conditioning (CRAC) and Computer Room Air-Handling
(CRAH) Units. Despite the development of a variety of newer cooling
technologies, CRAC and CRAH units remain the most common datacom cooling solutions. They can be
packaged in different ways, but are specifically designed for datacom equipment room
applications. They should be built and tested in accordance with the requirements of ANSI.ASHRAE
Standard 127 and ANSI/AHRI Standard
1361.
CRAHs are special-purpose chilled-water air handlers designed for datacom applications. CRACs are
compressorized cooling systems and are available in several configurations, including direct
expansion (DX) air-cooled, DX water-cooled, and versions that include a water- or
refrigerant-cooled economizer coil. Dual-fluid systems are available as well, consisting of a
chilled-water circuit plus a DX air-cooled or water-cooled circuit. They are used in
applications where full redundancy is required with limited space for CRACs, where the buildings
central chilled water system is not available 7 × 24 × 365, or where municipal water
may be interrupted and reverting to air cooling is necessary to maintain operations. Both CRAH
and CRAC units are available in either downflow or upflow designs. Downflow units are used
primarily for underfloor air delivery and have top air returns. They can be installed for either
free air return or, for more efficient operation, with a ducted return. Downflow units are
available in at least three different versions: (1) with standard height and fixed, built-in
fans; (2) with standard height and fans that can be lowered into the raised floor on site; and
(3) with extended height, where the separate fan section is located in the raised floor and the
heat exchanger section is placed on the fan section above the raised floor. Upflow units
discharge air overhead, often into ducts, and can have either front, rear or bottom air returns.
CRAC and CRAH units are usually located in the datacom equipment room, but may also be in
mechanical galleries adjacent to the datacom room, or installed remotely and ducted to the
conditioned space. Ducted designs require consideration of the relatively low-static-pressure
designs of CRAC and CRAH units when plug-type fans are used. Long ducted designs may require
conventional forward-curved fans that can work against higher static pressures. Although these
fans do not use EC motors, variable-frequency drives (VFDs) can still be used to control fan
speed and improve energy efficiency.
If CRACs or CRAHs are located in datacom rooms without a raised floor, or in rooms with a raised
floor that is not used for cooling, overhead air delivery is required, which means using upflow
cooling units. The return air grilles on these units are typically at the front, so the units
should be located at the4 ends of the hot aisles and the supply air should be ducted into the
cold aisles using overhead supply and containment (see the following sections on Hot Aisle/Cold
Aisle and Containment).
With either placement, temperature and humidity sensors must be located to properly control air
delivery in order to keep inlet air conditions to the datacom equipment within specified
tolerances.
Centralized Air-Handling Systems. Traditionally, many
telecommunications central office facilities and datacom facilities use overhead or side-wall
air delivery on a non-raised floor with central-station air handlers. Larger, centralized air
handlers, typically either roof mounted or adjacent to the datacom space, have been gaining
popularity as air-side economizer-based solutions have become more common. These air handlers
may include DX cooling coils, chilled-water coils, a combination of both, adiabatic cooling
sections, and/or indirect economizer solutions (such as air/air heat exchangers). Larger air
handlers may use fan arrays consisting of multiple direct-drive plug fans. Side-wall air
conditioners deliver supply air from CRAH/CRAC units through side throw grilles installed on the
mechanical room walls. Generally, this arrangement is used in large datacom facilities with no
raised floor and with hot-aisle containment systems.
Central air-handling systems are also used to serve non-critical areas in a datacom facility,
such as office spaces and meeting rooms.
Control of Variable-Speed Fans. Virtually all
air-conditioner fans are now speed controlled to minimize energy use when cooling demand is low.
Conventional motors can be equipped with variable-frequency drives (VFDs), but they are
expensive and add their own inefficiencies. More common today are direct-driven fans using
electronically commutated (EC) motors that are highly energy efficient and inherently variable
speed using a low voltage control.
There are several ways to sense the cooling environment and send control signals to fans. The
most common are underfloor pressure, cold-aisle containment pressure, differential pressure,
supply air temperature, and return air temperature. The choice of approach can depend on the
air-conditioner design as well as on the room layout and air delivery approach.
Traditionally, telecommunication spaces have had no raised floor, with overhead ducted air
delivery, whereas datacom facilities have used raised-flooring systems as supply air plenums.
Although that is changing in many datacom facilities, underfloor air is still often used. See
the preceding section on Datacom Facilities for more information on raised-floor selection and
installation.
Underfloor Air Delivery. The interstitial space under
the raised floor creates a large-volume air plenum that, if properly configured, can deliver
relatively uniform air pressures across the entire room area. One of the major benefits of this
configuration is that the raised floor represents a common supply air path from multiple cooling
units to multiple server racks. However, because the floor plenum is also often used for piping,
power and cable, there are many potential obstacles to airflow that upset air distribution,
cause significant pressure changes, and can be challenging to mitigate.
Underfloor air is delivered to cold aisles and balanced using a range of airflow tiles. These are
available in 25% open, 56 to 63% open, and fan boosted, both dampered and undampered. Tiles with
variable dampers enable adjustment of airflow to match the requirements in each part of the
floor. Tiles are also available with directional vanes that allow air to be directed toward the
cabinets as needed. However, the addition of a damper to any airflow tile results in reduced
airflow and cooling capacity, even when the damper is 100% open. Even distribution of air
through the airflow panels is primarily a function of the evenness of the underfloor static
pressure. However, pressures are also altered by the very existence of the airflow tiles.
Therefore, though it may be tempting to install high-airflow tiles everywhere in an attempt to
provide sufficient air delivery to all cabinets, the quantities and locations of different tile
types must be balanced in conjunction with the available air volume and static pressures. As
with any fluid, air will take the path of least resistance, so too many high-air flow tiles in
one area can result in air starvation for equipment in other areas.
The static pressure under a raised access floor is not high (generally not over 50
Pa, so it can be difficult for air to be delivered from a floor tile all the way to
the top of a tall cabinet. Per thermodynamics, warm air does not rise, as is commonly stated;
rather, cool air (being more dense) falls, displacing warmer air and forcing it upward. Cooling
with air from below, therefore, is contrary to the laws of physics and, although it has worked
very well for decades, it requires more careful control as cabinet heat densities rise. Tiles
with integrated air-booster fans or tiles with variable dampers, either manually or motor
controlled, can be used in combination with raised-floor pressure-controlled airflow systems to
ensure sufficient cold-air supply at any time and at any place, as well as to push air upward.
However, just as with too many high-airflow tiles, tiles with integrated air-booster fans may
solve a spot cooling problem but impair cooling to other cabinets because fans will take the air
they need.
Computational fluid dynamics (CFD) modeling is
generally recommended to confirm air flow patterns and to adjust cooling designs for maximize
cooling effectiveness. Where redundant cooling systems are used, it is particularly important to
examine raised-floor designs under cooling failure-mode scenarios. Further information on CFD
modeling is provided in the section on Computational Fluid Dynamic (CFD) Analysis.
In short, air balance with underfloor systems can be challenging, and specifications should be
carefully examined when selecting from the wide range of air flow tiles now available.
Leakage between the floor tile joints will also reduce the expected airflow. Likewise, air will
leak and be wasted through unsealed gaps at the raised-floor-to-wall or raised-floor-to-column
junctions, and through any floor cutouts for power, cable, or liquid lines from the raised-floor
plenum that are not correctly sealed. A properly installed and maintained floor should leak no
more than 2% of the delivered air.
Non-Raised Floor Air Delivery Solutions. Datacom rooms
that do not incorporate a raised floor, or that use a raised floor for purposes other than air
delivery, have several options available. Common air delivery solutions include overhead,
above-row, row-based, door-based, and side-wall methods.
These air delivery methods can be used in datacom rooms with or without raised floors. They can
be used in new data center designs, or to increase capacity or add redundancy within existing
data centers. If used to supplement new or legacy data centers with perimeter CRAC/CRAH cooling
units, they can increase cooling capacity in specific areas to address hot spots created by
high-density datacom equipment. They can also be very useful in small computer rooms with only a
few rows of cabinets. Above-row and row-based air delivery systems are available in refrigerant,
condenser water, or chilled water-based solutions.
Overhead Air Delivery. Delivering air overhead can be accomplished in
two ways. The more common approach has been via ducts from upflow CRACs or CRAHs. The CRAC or
CRAH cooling units are typically located around the perimeter of the datacom room or in an
equipment gallery adjacent to the datacom room. The ducts must be large enough to convey the
required air volume to the ITE in each aisle, and at velocities and pressures that enable air
flow to be easily adjusted and balanced in each aisle. It is important that one duct runout
serve only one cold aisle to enable proper adjustment of airflow to the loads in each aisle.
This can make planning ducts for future cold aisles and IT cabinet rows challenging. The large
ducts can also add to a crowded overhead infrastructure when power, cabling, and lighting must
also be coordinated in ways that ensure maintenance access. Irrespective of planning
difficulties, overhead air delivery may still provide more effective airflow management than
conveying air underfloor because the delivered air volume can be controlled by the measured
temperatures in each aisle. This means the system can dynamically increase or decrease airflow
to each cold aisle in response to actual conditions.
Above-Row Air Delivery. Above-row air delivery incorporates
close-coupled cooling methods by placing cooling units above the datacom cabinets. The cooling
units deliver cool air in close proximity to the datacom equipment, and pull hot return air back
into themselves from the hot aisle, resulting in very short air delivery and return paths,
limited opportunity for air bypass or recirculation, and reduced fan energy The cooling units
are similar in depth and width to the datacom equipment cabinets, so an above-row cooler can be
placed above each datacom cabinet or above the datacom row, based on the cooling capacity
required. The above-row cooling units can be attached to and supported by the datacom cabinets,
or can be suspended from the structure above, which enables datacom cabinets to be moved or
replaced without affecting the above-row cooling units. Above-row coolers can use either chilled
water or refrigerant for heat transfer.
Above-row air delivery creates a highly efficient, close-coupled cooling design. Above-row units
are sometimes combined with under-floor air delivery systems to provide supplemental cooling for
high density ITE cabinets, but they can be challenging to integrate with air containment
barriers. They can also complicate the integration of power distribution and network pathways
above the datacom cabinets. Since they deliver only sensible cooling, some form of humidity
control may also be necessary.
Door-Based Cooling. Door-based cooling units incorporate cooling
coils into the doors of datacom equipment cabinets. Cooling doors can be mounted on the front,
as precoolers, or on the rear to cool exhaust air before it is discharged into the room.
Rear-door heat exchangers (RDhX) are the most common, and may be passive, relying on ITC fans to
move air through low-resistance doors, or may have integrated fans to enable higher cooling
capacities. Door cooling units are affixed to individual cabinets, replacing standard doors, and
add several dozen millimetres of depth. It is critical that units on raised floor
systems are coordinated with floor openings, and incorporate air seals if they supplement
under-floor air delivery, so that liquid hoses can move without kinking or damage when doors are
opened and closed.
Since door cooling units are non-redundant and provide only sensible cooling, they must be
integrated with more common cooling systems to maintain cooling when doors are opened or taken
offline for maintenance. It is also critical to maintain the temperatures of liquid coolants to
the door-based coolers above the dew point, which also means maintaining compatible humidity
control within the room.
Although door-based cooling is often supplemental to an overall cooling system, it is possible to
use it as a total cooling solution if heat loads and cooling capacities can be matched, In these
cases there is no actual hot or cold aisle because intake and exhaust are maintained at the same
temperatures, so not only is air containment not required, but it is also necessary to ensure
good air circulation throughout the room. Humidity control must then be addressed another way.
The close coupling of cool supply air to datacom equipment air intakes, and warm exhaust air to
cooling unit returns, can result in an excellent cooling solution, both in cooling and energy
efficiency.
Row-Based Cooling. Row-based cooling is another close-coupled system
that can deliver highly efficient cooling and energy efficiency. Units consist of air delivery
and cooling equipment installed within cooling cabinets that are similar in depth and height to
the datacom equipment cabinets. Cooling cabinet widths vary with cooling unit capacities and
colling type (chilled water, condenser water, or refrigerant), but most are either 300 or
600 mm wide. Row-based cooling is also referred to as in-row cooling (IRC) by some manufacturers.
Cooling unit cabinets are intermixed within the rows of datacom equipment cabinets. The numbers
and locations of cooling units required will vary for each customer application, and must be
verified based on manufacturer recommendations, redundancy requirements, engineering
computations, and CFD analysis. It is sometimes satisfactory to place row-based coolers only at
the ends of rows, but more often it is necessary to intersperse them between groups of datacom
equipment cabinets.
Row-based cooling units supply cold air from their entire frontal surfaces at relative low speed
to flood the cold aisles with supply air. Some units incorporate directional vanes to control
airflow direction, and others blow air sideways across ITE cabinet faces. Regardless of type,
row-based cooling units are most efficient when incorporated into an air delivery containment
system, either cold-aisle or hot-aisle.
When row-based cooling is combined with underfloor air delivery from existing perimeter CRAC/CRAH
cooling units, cold-aisle containment generally provides an advantage over hot-aisle
containment.
Side-Wall Air Delivery. Side-wall air delivery can be used in both
raised-floor and non-raised-floor environments. This design supplies air to the datacom room
above the floor on which the datacom equipment sits. If a raised floor plenum exists, it is not
used for this air delivery system. The goal is to deliver cooling air evenly but at relatively
low velocity, so that it floods the room. Air is delivered perpendicular to the IT aisles
through the large supply area provided by the long side walls. The external units can be either
centralized or modular cooling systems, the latter being positioned adjacent to the datacom room
external wall (e.g., indirect evaporative cooling [IEC] systems). Side-wall air delivery systems
more generally use large fan wall units (FWUs), which
consist of high-capacity cooling coils and plug fan arrays. These units are generally located
inside a mechanical gallery
In a side-wall air delivery design, the hot aisle is usually contained so that the warm ITE
exhaust air can be routed out of the datacom room via a ceiling plenum and returned to the
cooling units. The cooling air from the discrete external cooling units is often delivered into
a large plenum, and then through the side wall grilles, in order to create a more even
distribution of cooling air. The cooling can be double-sided if opposite walls of the datacom
room are both external.
FWUs incorporate control valves to modulate chilled-water flow through the cooling coils to
ensure constant supply air temperature. Proper space planning during the concept design stage is
critical when using large side-wall delivery systems. Sufficient space must be ensured within
the mechanical gallery and corridors to achieve smooth airflow and provide for movement and
service of mechanical equipment. The mass loading details of this equipment must be provided to
the structural engineers during concept design. Care must be also be taken when designing a
side-wall supply system to ensure sufficient width in both side and cold aisles to avoid
developing high air velocities as the air turns into the cold aisles. High air velocities create
separation and low pressure in front of the IT equipment, particularly at the ends of the
aisles, which is especially important to avoid with high-density IT equipment.
Effects of Air Mixing. Air mixing occurs in two ways:
(1) when hot air discharged from computing equipment recirculates back to the air intakes,
thereby increasing the inlet air temperature at the computing equipment; and (2) when cool
supply air bypasses the computing equipment and mixes with hot discharge air, thereby lowering
return air temperature. If air paths through or between the datacom equipment racks exist, then
some of the cool supply air will bypass the datacom equipment, and some of the discharge air
will recirculate back to the front equipment intakes. To avoid air bypass and recirculation,
blanking or filler panels must be used in all open and unused equipment rack spaces. The more
complete the separation, the more effective and energy efficient the cooling system will be.
Aisle containment is a highly effective method of further reducing air mixing problems.
Cool bypass air reduces the return air temperature, decreasing the system ΔT, which in turn decreases the effective cooling capacity of the
air-conditioner coils, requiring an increase in airflow to meet the load. Hot-air recirculation
increases ITE inlet temperature. If the supply air temperature has been set toward the upper
limit of the ASHRAE recommended envelope, this can result in air delivered to the ITE that is
warmer than the design temperature, potentially increasing ITE fan speeds and energy use and
shortening ITE service life.
Hot Aisle/Cold Aisle. The first step in avoiding air
mixing is to arrange cabinets in a hot aisle/cold aisle configuration. This means that racks and
cabinets are installed facing back-to-back and front-to-front, negating the effect of legacy
cabinet arrangements where hot-air discharge from one row of cabinets directly entered the
intakes of cabinets in the next row. Hot aisle/cold aisle configurations assume that all datacom
hardware has been designed with industry-standard front-to-rear airflow. Equipment that uses a
nonconventional airflow pattern must be dealt with using special racks, cabinets, and air
deflectors, as discussed previously, to achieve proper cooling within a datacom room designed
predominantly for front-to-back cooling.
Containment. Containment further segregates the supply
and return airflow paths by preventing mixing at the top of the equipment racks and at the ends
of equipment rows. There are two classifications of containment: hot-aisle containment (HAC) and
cold-aisle containment (CAC). Either of these can be full or partial. Full containment requires
solid panels above cabinets and sealed to cabinets and ceiling, with door panels enclosing row
ends. Partial containment usually means row end doors only, or plastic strips (which still have
air leakage). There is also rack-based containment, which is commonly associated with active or
passive chimneys. These main types of containment are illustrated in Figure 11.
Computational Fluid Dynamic (CFD)
Analysis
Overview. One of the main challenges to maintaining
the high availability required for datacom rooms is delivering cooling effectively and
efficiently to all the equipment, wherever it is in the room, and by whatever means the cooling
is provided. Complexities created by widely variable heat densities, plus the disruptions to
airflow patterns created by obstacles in the air paths, make it difficult to envision air
movement in the space without modeling tools that provide graphic representations.
Underfloor cooling can be particularly difficult to envision and optimize because it is driven by
many design factors, such as underfloor plenum geometry, piping and cabling obstacles, and
perforated tile types and their airflow characteristics. CRAC/CRAH performance parameters
(particularly fan type and orientation) and their locations relative to tile rows and cabinet
heat loads are also major factors. However, CFD modeling is also very useful for above-floor
cooling designs that use overhead or row-based cooling, particularly if more than one type of
cooling system is used in the same space.
Reliable CFD simulations require building an accurate 3D computer-generated model of the datacom
room and all its components. A model is only as good as its input data, regardless of the
program’s sophistication, so of most practical importance is the way in which the user
defines the space, the cooling, and IT equipment in it. A CFD model needs to represent the
physical room geometry, and anything that might add or stimulate airflow or heat transfer, such
as fans and vents. It must also include items that impede airflow, such as underfloor pipes and
cables, and interactions with the surrounding environment, such as columns and oddly shaped
walls and cabinets (the boundary conditions). The granularity requirements for the model may be
different at different points in a project, and most definitely after the room is occupied,
since the level of actual data will become more refined as the project progresses.
Depending on the sophistication of the modeling tool, CFD models can be run for a total
air-cooled room and its equipment or for individual components (e.g., individual racks and
cabinets, or even specific pieces of hardware in them). The numerical data obtained from each
level is used to process further levels.
Generally it is not necessary to model individual items to evaluate a room design. The
physics-based representations for the majority of items present in datacom rooms are likely to
be already included in a data center specific toolset. If a general-purpose CFD tool is used,
the user may need to create models for a wide variety of components, some of which could have
operational parameters that are outside the range of normal building environmental modeling. In
any case, the user should verify with the CFD tool provider that all items are appropriately
modeled, ASHRAE RP-1675’s final report (Hu et al. 2022) provides some guidance for CFD
modeling of data centers.
Application. Several simulations are commonly
completed for datacom rooms. These may be based either on assumed datacom equipment layouts and
projected heat densities, or on actual datacom equipment installations, and often include
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Testing different cooling system types and strategies
-
Comparing different arrangements and positions of cooling, power, and computing
hardware
-
Optimizing cooling paths, including raised-floor height, ceiling height, return air
plenum size, duct sizes, and containment
-
Testing cooling effectiveness with part-load configurations and examining failure
modes, particularly in redundant designs intended to maintain adequate cooling
during maintenance and equipment failure conditions
-
Determining where the highest-heat-density datacom equipment is best located from a
cooling perspective
Although CFD is a powerful tool, it is also easy for it to be misapplied and misinterpreted.
Datacom facilities are complex, and infrastructure and equipment must be simplified for models
to be practical. It is critical, therefore, that the modeler understands the key elements of the
datacom facility and the fundamentals of CFD modeling for the application of CFD to be
successful. Proper use of CFD can help the designer identify and avoid most major cooling
problems before construction occurs, but expecting the model to be a 100% accurate
representation of the finished installation is not realistic.
In the conceptual design phase of most enterprise facilities, the modeler will probably not know
detailed information about the datacom equipment types or configurations. Similarly, the precise
locations and routings of cables and other physical infrastructure may not be known, and even
the cooling system manufacturer or model may not yet have been selected. In such instances there
is little point in putting excessive detail into the model, but at the same time the modeler
must interpret the results accordingly: that is, they must understand that the predictions are
limited to high-level system design decisions and must recognize that performance will likely be
a best-case solution because best practice has been assumed. Nevertheless, a knowledgeably
developed CFD model at an early stage can help avoid design decisions that would become
problematic in the future, such as inadequate space for the required numbers and sizes of air
conditioners, or insufficient raised-floor height.
Where real facilities are being modeled, the models must be more representative of the actual
installation. This normally means basing the model on a physical survey of the facility,
infrastructure, and datacom equipment configurations. Even so, the real infrastructure and
equipment cannot be represented in ultimate detail. For example, a bundle of cables will be
represented by an approximate obstruction or resistance to airflow rather than explicitly
modeling each and every cable.
To ensure that judgments are made appropriately and that the model is accurate, it is best to
compare simulation results with actual measurements of airflow and temperature once the facility
is completed and operational. This is generally regarded as a calibrated model, because actual conditions can be
measured and compared. Even this will have discrepancies from reality, which will be difficult,
if not impossible, to resolve, but at least they will be known. Then, and only then, should the
model be used for sensitivity studies to upgrade the facility, troubleshoot problems, or make
deployment decisions.
Although CFD’s primary focus for datacom facilities is determining the effectiveness and
efficiency of cooling delivery to the computing equipment in the computer room, it can also be
used to analyze such things as airflow around air-cooled chillers, condensers, generators, and
other critical equipment. However, a CFD analysis on equipment located outdoors cannot use the
commercially available CFD tools developed specifically for computer room modeling. Developing a
CFD model and configuring the simulation of outdoor equipment is significantly more complex and
requires a higher level of expertise from the CFD modeler.
CFD is also a recommended component of The Green Grid’s (www.thegreengrid.org) most recent
performance assessment tool: the Performance Indicator (PI). The PI is an extension of the PUE
metric (see the section on Energy Efficiency) and examines a composite of energy efficiency
(PUE), thermal conformance, and thermal resistance. Each of these parameters can be optimized in
different ways. The PI illustrates them in a spider diagram format as an aid to achieving an
efficient and cost-effective balance among the variables. Linking the PI parameters to a
calibrated CFD simulation gives a clearer picture of how cooling is performing in the room, and
allows scientific analysis of which physical and operational changes will deliver the most
effective improvements.
For further details, see the section on CFD and Flow Network Analysis under the Liquid Cooling
heading.
Liquid-Cooling System
Configurations
The datacom industry is beginning to need to implement alternative cooling technologies required
to deal with the heat rejection of the higher-power CPUs, GPUs, accelerators, and other
high-power ASIC devices. Simply put, traditional air-cooled technologies are limited in their
ability to remove the increasing amount of heat density within silicon while managing the lower
chip temperatures required for next-generation high-performance computing applications. Liquid
cooling will become essential and may be integrated with a facility-level cooling system in
various ways, including the following.
Modular Room-Based Systems. The most common liquid cooling requires that facility chilled water
be delivered to a heat exchanger (often called a cooling distribution unit [CDU]) located in or
adjacent to the datacom room. The CDU has piping that connects to the datacom equipment; this is
called the technology cooling system (TCS). The TCS connections may be to a centralized heat
exchanger at the datacom equipment rack or may connect with the datacom equipment itself (e.g.,
multiple connections per rack). An example of this configuration is shown in Figure
12. The secondary loop or TCS is responsible for distributing the coolant in the loop to
pick up the dissipated heat in IT and deliver it to the CDU. The secondary loop consists of
supply/return row manifolds, supply/return rack manifolds, server-level cooling loops, hoses and
tubes, valves, quick disconnects, sensors, and controllers.
Quick disconnects in the secondary loop or TCS are required for easy access to each server or
rack. Using quick disconnects allows hot-pluggable servers, which means that each server or rack
can be disconnected and then reconnected without coolant leaks while the other servers are still
operating. Classifications of quick disconnects are necessary as a guideline for selecting the
appropriate quick disconnects for liquid-cooling systems. Quick disconnects can be classified
based on applications, materials, design parameters.
The fluid in the technology cooling system may be chilled water, deionized water, reverse
ionization (RO) water, refrigerant, or other liquids, such as different concentrations of
propylene glycol or ethylene glycol. The coolant distribution unit typically also contains
pumps, valves, temperature/pressure/flow sensors monitoring and control, and operating software.
Refrigerant-based systems have many of the same components as well as compressors, condensers,
and/or pumps and related control components. CDUs can only have compressors on the primary side,
because compressors can only operate with gases. CDUs that operate with refrigerant on the
secondary side need to be operated using pumps, since refrigerant leaves cold plates as a
mixture. One of the most important functions of the CDU, or whatever alternative distribution
and control mechanism may be utilized, is to maintain coolant temperatures above the dew point.
It can be easy to create condensation with liquid-cooled systems if not properly controlled.
Pure (100%) liquid cooling is only available in a full-immersion approach, as discussed later.
Except for immersion, the datacom room needs to support a hybrid of air and liquid cooling. The
more server components cooled by liquid, the less demand for working fans. To maintain
liquid-cooling performance in the event of a failure in the loop, large mutual headers in the
secondary piping design may be suitable as reservoirs to keep the coolant temperature within the
acceptable range until the failed equipment is restored.This may require small, supplemental
pumps on UPS for the most critical equipment. Note that redundancy of the proposed design is of
vital importance in the liquid-cooling method. A chilled-water reservoir can also be used as a
backup when the primary cooling system fails.
Direct Component Liquid Cooling. This type of system
delivers the cooling medium directly to each individual datacom equipment chassis, and then
often straight through to the components. This approach is typically used in high-performance
computing (HPC) or supercomputing platforms. However, due to the rapidly increasing power
densities of components, direct liquid solutions are expected to become more common in a wider
range of installations. They require completely dedicated piping distribution, specialized heat
exchangers, and related components between the liquid cooling equipment and the facility climate
control systems. In this type of cooling system (usually using cold plates on chip, as shown in
Figure
13), the heat is rejected directly to the TCS/FWS water loops, which thereby removes
this portion of the heat from the room.
Immersion Cooling. In this type of system (Figure
14), the datacom chassis are fully or partially immersed in a nonconductive liquid bath.
Immersive solutions can be chassis level, where servers mount in standard racks and scale
vertically, or tank level, where servers are suspected vertically and scale horizontally. The
cooling medium (typically single- or two-phase dielectric) completely surrounds the devices, and
circulates through the datacom enclosures or individual chassis subsystems. The pumped fluid
transfers the heat to a dedicated coolant-to-water heat exchanger, which is connected to the
facility chilled-water or condenser-water loop. The thermal mass of the liquid vat often enables
these systems to “ride-through” a cooling failure with little or no supplemental
circulation. As with direct component liquid cooling, immersion offers the benefit of rejecting
heat directly to the TCS. FWS water loops and thereby from the room completely. In this system,
however, with all components immersed in the cooling fluid, nearly 100% of the heat would be
rejected, which could effectively remove the need for auxiliary air-cooling infrastructure (Figure
15).
Piping and Distribution Systems
Facility water distribution systems that serve datacom equipment should be designed to the same
standards of quality, reliability, and flexibility as other datacom room support systems. Piping
quality standards typically require steel or copper piping with welded, bolted flanged, or
brazed. joints. Although grooved joint coupling failures are rare, they can be sudden and
catastrophic when they occur, so measures to prevent such failures are recommended. Where
flexible pipe connections are required at equipment, steel braided couplings are preferred over
rubber materials. Reliability and flexibility are achieved through a piping configuration that
can be expanded or modified as needed to accommodate changes in datacom equipment or major
cooling components without requiring extensive system shutdowns. Every section of the main
piping, and every major component and valve, should be configured so that it can be isolated and
replaced without degenerating the system design below its design level (N, N+1, 2N).
Maintenance should include a valve exercise schedule where valves are closed and then reopened
annually to loosen debris from the valve seats and break free any rust in rotating parts.
Filters and strainers should then be cleaned.
Figure
16 illustrates a double-ended, looped chilled-water distribution system with sectional
valves and multiple valved branch connections. The branches could serve air handlers or
liquid-cooled datacom equipment, and the valves allow modifications or repairs without a
complete system shutdown. Additional piping concepts are detailed in ASHRAE (2015a).
Various kinds of fluids used in TCS cooling loops, including glycol-based liquids, water with
additives, refrigerants, and dielectric fluids. The selection of a coolant is a critical task,
as one must investigate wetted material compatibility and equipment serviceability, as well as
liquid maintenance and operational needs.
Water with additives is one of the most common fluids. Water is used as a coolant because of its
high thermal mass; however, additives lower its heat transfer capacity so their impact on the
heat transfer properties needs to be accounted for. Another concern is that the concentration of
additives in water can degrade with time, leading to corrosion and bacterial growth.
Glycol-based fluids are often used to minimize bacterial growth and corrosion, as well as to
lower the freezing temperature in cold climates, although they can significantly reduce water
heat transfer properties. Propylene glycol and ethylene glycol are the most frequently used
additives. At glycol levels above 25% there will be no bacterial growth in the liquid.
Glycol-based fluids also have additives and inhibitors, which must be periodically checked for
concentration
Due to their high global warming potential (GWP), most commonly used refrigerants, such as
R-134a, are being phased out. As a result, it is critical to find a “green”
refrigerant that can be used in the system without negatively influencing its performance.
Physical properties, thermal performance, stability, flammability, GWP, toxicity, and
availability are all aspects that go into selecting a climate-friendly refrigerant. Preliminary
investigation is showing R-515b to be the most appropriate alternative for R-134a in two-phase
rack-level cooling systems. Other potentially suitable replacements are R-513a, R-1234yf, and
R-471A
Computational Fluid Dynamic (CFD)
and Flow Network Analysis
To perform a complete investigation of a hybrid (air and liquid) solution, both computational
fluid dynamics (CFD) and flow network modeling (FNM) should be run in parallel to create a clear
picture of the proposed liquid cooling approach. Datacom facility cooling systems can be
considered as networks of flow paths through components such as screens, filters, fans, pumps,
ducts, bends, valves, heat exchangers, and cold plates. FNM is a generalized methodology of
calculating system-wide distributions of flow rates and temperatures in a network representation
of a cooling system. Deployment of liquid-cooled server systems that have not been analyzed with
FNM might experience issues with pressure, flow rates, or cooling limits. This method focuses on
the interactions among the various components incorporated in the cooling network to determine
system-wide performance. The thermohydraulic performance of the cooling network is predicted
using the imposition of conservation of mass, momentum, and energy in the flow network.
The simulation process starts with a single liquid-cooled electronic model using a CFD tool to
measure the thermohydraulic characteristics of the cooling system. Then the performance data are
used as the input for a CFD/FNM model of a server cooling loop consisting of several
liquid-cooled electronics. All the components (tubes, QDs, valves, tees, etc.) are included in
the cooling loop FNM model. Pressure drop and temperature change of the cooling loop are used as
the input for the next step, which is rack modeling. In the rack flow network model, elevation
effect and uniformity of flow distribution are checked. In the final step, the flow network of
the full data center can be modeled, and the secondary flow loop can be analyzed in detail by
showing flow distribution in the loop, system pressure, secondary pressure drops, and
temperature rise in the secondary loop. Rack and datacom room level CFD analysis explores the
air stream circulation, impedance of the system, required air flow rate, supply and return air
temperature to racks and cooling equipment, and ASRAE allowable temperature of the ITE.
3.4 WATER USAGE AND ENERGY EFFICIENCY
Conservation and sustainability practices should be at the forefront of every design project today,
but in many cases they are now required by code, environmental reality, or both.
Water usage in datacom facilities has gained much attention in recent years. Although water usage
does not generally contribute as much to the total cost of ownership (TCO) as does energy
efficiency, water has become a very precious commodity in many areas, and there are several
environmental regulations that restrict water usage by datacom facilities.
Water Usage Effectiveness
(WUE™)
WUE is a site-based metric, developed and popularized by The Green Grid (Patterson et al. 2011),
to assess the water used on site for operation of the datacom facility. It presents a
comprehensive evaluation of water usage in a datacom facility, where it is affected by a range
of factors such as location, IT load, quality of available water source, type and efficiency of
cooling equipment, and humidification loads. The formula for calculating WUE is the annual water
usage (in litres) consumed by the entire datacom facility, divided by the IT equipment energy
usage (in kWh). The physical unit for WUE is liters per kilowatt-hour (L/kWh).
Energy efficiency is at the forefront of modern building design. Datacom rooms are large energy
users. They are difficult to consistently operate at peak efficiency because of their dynamic
natures, and also because reliability must usually take precedence over the risks of absolute
maximum-efficiency operation. Nevertheless, there are many opportunities to design and operate
datacom rooms at high energy efficiencies.
Because cooling typically accounts for the highest energy use (after the IT equipment itself), it
is often a primary focus for energy-saving measures such as economization. Datacom facilities
were excluded from energy code requirements until the 2010 edition of ASHRAE Standard 90.1, which eliminated the exclusion and required datacom
facilities to have some means of economization.
In response to industry concerns about potential economizer reliability issues, the challenges of
installing economizers on existing high-rise buildings, and the prescriptive nature of Standard 90.1, the new ASHRAE Standard
90.4, Energy Standard for Data Centers, was developed. Standard 90.4
is written to specifically address datacom facility efficiency in a nonprescriptive manner, and
to recognize the balance between energy efficiency and reliability that is critical to datacom
facility design. This standard is considered a “sister standard” to Standard 90.1. It was officially incorporated into Standard 90.1 in the 2016 edition as a recognized method of confirming
datacom facility energy efficiency in the design stage by using whatever best practices
techniques best suit the aggregate needs of the project (e.g., space, location, climate, cooling
approach, budget).
Standard 90.4 uses new metrics for both mechanical and electrical
efficiencies that were developed specifically to simplify conformance calculations in the design
phase of a project, as well as to make it easy to demonstrate compliance to the AHJ. Standard 90.4 applies to data centers (called “computer
rooms” in Standard 90.1) with IT design loads above 10 kW,
power densities above 20 W/s, and mechanical and electrical systems dedicated to the datacom
facility. Since Standard 90.4 is recognized as an alternative
compliance path in Standard 90.1, Standard 90.4 can be used whenever the code enforcement jurisdiction
recognizes the applicable 90.1 standard.
Power Usage Effectiveness
(PUE™)
PUE is an efficiency metric developed and popularized by The Green Grid. Since the concept was
introduced (see, e.g., Rawson et al. [2007]), the metric has been revised to make it more
understandable and the methods and reporting of measurement numbers more reliable, culminating
in the 2014 release of a joint TGG/ASHRAE TC 9.9 publication (ASHRAE 2014b). In 2012, TGG
transferred ownership of the PUE metric to the ISO/IEC JTC 1/SC 39 Work Group 1 standard
committee to further develop and expand on the work previously done by TGG. JTC 1/SC 39 WG1
expanded on the PUE metric and published ISO/IEC Standard 30134-2,
Key Performance Indicators, Part 2: Power Usage Effectiveness (PUE). This standard introduced
new PUE derivatives, such as design PUE (dPUE) and partial PUE (pPUE).
PUE measures how effectively an operating datacom facility delivers energy to the datacom
equipment inside. The formula for calculating PUE is simply the energy consumed by the entire
datacom facility (measured at the meter for the facility or room) divided by the energy consumed
by the facility’s datacom equipment. The PUE is an average of 12 months of measurement.
It is important to understand that the PUE metric was developed as a means for individual
operations to monitor and track their own energy efficiencies. It was never intended as a means
of comparing the efficiencies of different datacom facilities, because too many conditions,
including climate zone and level of redundancy, can affect the number. It is also important to
understand that an enterprise can take steps to reduce its total energy consumption, yet achieve
a worse PUE. Extensive consolidation and virtualization, for example, and the purchase of ENERGY
STAR® rated servers, could significantly lower the datacom equipment energy
number in the denominator of the PUE equation. However, unless a massive renovation of the power
and cooling systems was also done, which would not likely be justifiable in most facilities, the
energy consumption of those systems would not be reduced in the same proportion as the datacom
loads. Although that would result in a larger PUE quotient, it should still be recognized as a
very positive step, because total energy use has still been reduced.
It should also be recognized that the PUE metric, despite the existence of the dPUE metric, is
impractical to use as a means of quantifying projected energy efficiency in the design stage of
a datacom facility. A significant amount of effort would need to be invested in calculating the
large number of electrical path efficiencies and losses, and precision energy modeling would be
necessary to develop a realistic number. Note also that the calculated PUE number would still
not result in a number likely to be realized when the facility is put into operation,
potentially misleading owners into expecting something that is unachievable. It is for these
reasons that different metrics were developed for use in the design stage, as set forth in the
ASHRAE Standard 90.4.
Partial PUE (pPUE) is a complementary metric to the
existing definition of PUE. pPUE allows datacom facility managers to easily focus on a certain
portion of their facility within a defined boundary condition for the analysis, and to neglect
the other components that contribute to total energy. pPUE is used mostly to enable managers to
exclude portions of their facility that are complicated to measure from the analysis, or that
are intended for use only in certain situations. In short, pPUE is mainly suitable for
management purposes, enabling a more complete understanding facility design, whereas the full
PUE is the proper metric for evaluating and tracking the energy efficiency of the complete,
operating facility.
A datacom facility is dynamic in terms of electrical and mechanical loading. However, the design
of a datacom facility cooling system, whether single plant or modular, must be based on the
maximum anticipated datacom equipment load of the space, even though this maximum load is
rarely, if ever, achieved.
Even if the maximum design load is someday realized, the day-one load at move-in will most always
be much lower than the ultimate design load in order to provide for long-term growth.
Additionally, over the course of its lifetime (which may be 10 to 20 years or more), the datacom
facility load constantly fluctuates. The load also changes in both density and location within
the datacom space as systems are installed in one location and decommissioned in another.
These below-peak, fluctuating loads mean that the cooling plant operates in part-load conditions
nearly of the time. It is therefore critical to ensure that the cooling plant selection can
modulate capacity over the full, anticipated range, and that it also has good part-load
efficiency.
Economizers use ambient outside air temperature to remove heat without using mechanical
refrigeration, The process is commonly referred to as free
cooling. Although it is not totally without cost, in that the mechanical
movement of air or liquid is still necessary, the energy to remove the heat is far less than the
energy required for refrigeration. There are three fundamental approaches for air-cooled ITE:
(1) direct air, (2) indirect air (single-step), and (3) indirect fluid (two-step) economizers,
shown in Figure
17.
Direct air economizers are systems that draw air into
the data hall directly from the outdoors, and exhaust a comparable amount of hot air back out.
Indirect (single-step) air economizers exchange hot
data hall air with cooler outdoor ambient air using an air-to-air heat exchanger.
Indirect (two-step) fluid economizers have two heat
exchangers and use an intermediate fluid to move heat between the air inside the data hall and
the ultimate heat rejection to the atmosphere. These systems may use single-phase fluids, such
as water or glycol, or two-phase fluids, such as refrigerant. Additional steps may be added by
including intermediate heat exchangers to transfer energy between different fluids. Although
they require more energy than the other two systems to move fluids, indirect, two-step fluid
systems still avoid the need for mechanical refrigeration, making them highly efficient
economizers.
Economizer systems for datacom facilities can also be differentiated by the type of ultimate heat
rejection to the atmosphere: dry, wet, or hybrid. Dry heat
rejection provides free cooling whenever the ambient dry-bulb conditions
are suitable. Wet heat rejection, also called
evaporative or adiabatic cooling, consumes water to provide free cooling, leveraging the ambient
wet-bulb conditions. Hybrid heat rejection is able to
operate either wet or dry, automatically taking advantage of the benefits of one mode or the
other, depending on ambient conditions. Wet heat rejection is typically the most energy
efficient, but dry mode saves water and enhance freeze protection, as well as protects against
the contingency of drought conditions.
Datacom facilities can often make greater use of economization than office buildings because of
the higher temperatures that are usually used. The percentage of the year for which partial
(integrated) or full economizer operation is available is a function of the ITE Class (see Table
1). the cooling system design, and the climatic conditions. Classes H1, A1, and A2 ITE
(the most common equipment types) should enable significant use of integrated, or even full,
economizer operation for much of the year in most climates. For example, the use of Class A3
ITE, which has an allowable inlet air temperature of up to 40°C, should make it
possible to use chiller-less operation with water-side free cooling year-around in many
climates. Similarly, for Class A4 ITE, with allowable air inlet temperatures up to
45°C, year-round chiller-less operation with either air- or water-side free
cooling should be possible in most climates.
Economization for datacom facilities is similar to other economization designs, except that
reliability, particularly during changeovers between mechanical refrigeration and economization,
must be paramount. The unique environmental and reliability requirements of datacom facilities
have spawned several data-center-specific cooling products with built-in, innovative economizer
cycles. Alternatively, equipment must be selected to enable seamless and highly reliable
transitioning. Since the primary energy users in a datacom facility cooling system are the
refrigerant compressors, it is common to leverage favorable ambient conditions by integrating
economizers into cooling systems so as to minimize annual compressor use. This usually means
selecting chillers that can reduce capacity and mix condenser water flow until full economizer
operation is achieved.
Detailed Explanations of Free Cooling Approaches. Direct air
economizers, as shown in Figure
18, introduce ambient air directly into the space so that it flows through the datacom
equipment to remove the heat, thereby providing free cooling. This system offers the highest
theoretical energy efficiency of any free cooling system. However, since outdoor air is often
not as clean or at a humidity level that matches the IT equipment requirements, close attention
must given to the filtration system as well as to supplemental cooling. Supplemental systems may
be evaporative (wet, hybrid) or redundant DX (hybrid, dry). Regardless of type, the goal is to
ensure adequate cooling when outdoor conditions deviate too much from required free cooling
parameters. Note that one reason for the allowable range in the ASHRAE (2021) Thermal Guidelines is to enable the continuation of free cooling
operation through those periods of the day when outside air conditions exceed the recommended
range for relatively short periods of time.
Indirect Single-Step Air Economizers incorporate
air-to-air heat exchangers such as plate or heat transfer wheels into the system or AHU. Free
cooling can start whenever the ambient air (dry bulb for dry economizers, wet bulb for hybrid
economizers) is lower than the datacom facility return air dry bulb temperature. Figures
19 and 20
show examples of air-to-air heat exchangers performing this function. In both cases, the heat
exchanger provides environmental protection as the datacom room is not directly exposed to
outdoor air temperatures, humidity, and/or contaminants.
Indirect Two-Step Fluid Economizers with single phase
fluid, use a fluid such as water or glycol to transfer heat from the data hall to an outside
heat rejection device. For CRACs (Figure
21), a room-air-to-water heat exchanger/free cooling coil is added and connected to an
outdoor dry, wet, or hybrid heat rejection device such as a dry cooler (dry) or cooling tower
(wet, hybrid). The free-cooling coil is located upstream of the mechanical refrigeration coil.
The water loop usually serves the free-cooling coil first, and then picks up the heat rejection
from the indoor compressors prior to ambient heat rejection. Free cooling in integrated
economizer mode can start a few degrees below datacom room return air temperature.
For CRAHs (Figure
22), a means to use ambient air to remove heat from the recirculating chilled-water
system is added. An example is free-cooling coils integrated with the chillers (dry). Free
cooling in integrated economizer mode can start a few degrees below the return water temperature
to the chiller, precooling the return water and reducing or eliminating the mechanical
refrigeration load.
Indirect Three-step Fluid Economizers with
single-phase fluid include an additional fluid-to-fluid heat exchanger between separate fluid
circuits. To provide economizer cooling between a condenser water loop and a chilled-water loop,
as shown in Figure
23, a liquid-to-liquid heat exchanger is included to precool warm heat rejection water
from the datacom room prior to final cooling by a water chiller. Various piping arrangement
alternatives are available to allow for bypassing either the heat exchanger or the water chiller
depending on the relative temperatures of the two liquid loops.
Indirect Two-Step Fluid Economizers with two-phase
fluid use a fluid such as refrigerant to transfer heat via phase change from the data hall to an
outside heat rejection device such as an air-cooled condenser or cooling tower. For CRACs (Figure
24), the air-cooled condenser (dry) can be used for economizer cooling by adding a set
of valves, a liquid receiver, and a refrigerant pump. As ambient conditions allow, the
compressor(s) are shut off and the pump activates to move the refrigerant between the indoor
evaporator coil and the outdoor condenser coil. A typical system has multiple circuits, which
allows for partial economizer cooling.
For CRAHs (Figure
25), the refrigerant circulates between the evaporator and condenser coils by
thermosiphon, though a refrigerant pump may also be used if needed. As ambient conditions allow,
the compressor(s) stage off and cooling shifts from the active condenser to the passive (dry)
free cooling condenser. A typical system has multiple circuits, which allows for partial
economizer cooling.
X-Factor Reliability Analysis
The x-factor analysis is a unique control strategy developed by the IT sub-committee of TC9.9 to
increase the number of hours that can be cooled in 100% economizer mode without negatively
impacting ITE reliability on an annualized basis. It uses a floating temperature set point to
increase economizer hours without sacrificing server reliability.
ITE equipment is more likely to fail at higher than at lower temperatures, and statistical data
on failure rates as a function of inlet temperature has been made available from ITE
manufacturers. The x-factor concept is to trade off excursions into the high end of the
allowable operating range during the summer with operation at the low end of the allowable
operating range in the winter. An annualized x-factor relative reliability value can then be
calculated. This concept was first introduced in the 3rd edition of Thermal
Guidelines. More recently, time-weighted example calculations and reliability tables
can be found in Appendices H and I of the 5th edition of Thermal
Guidelines (ASHRAE 2021).
Liquid Cooling of ITE as Means to
Increase Economizer Use
The gradual migration from air cooling to liquid cooling, particularly for high-density ITE,
allows for reduced approach temperatures of the heat rejection system and increased economizer
operation for the liquid cooling classes (see Table
2). One advantage of liquid cooling, especially direct-to-chip liquid cooling, is that
it can reduce the approach temperature between the chip operating temperature and the ambient
heat rejection temperature. This is possible primarily because fewer heat transfer steps can
occur between the chip and the ambient air. It is also because liquid-to-component and
liquid-to-liquid heat exchangers have lower approach temperatures than heat transfer using air
at lower density. As such, if the choice is available, liquid cooling will likely allow for a
greater number of economizer hours than air-cooling, and the potential for cooling without the
use of mechanical refrigeration.