News in Data Center Cooling

Wednesday, 8th May 2013, 16:00h

Benjamin Petschke, Director Export - Products

Stulz GmbH

News in Data Center Cooling

Almost any News in Data Center Cooling is about increase of efficiency :

Cooling only when and where it is required,
without compromises on reliability and availability.

Different Zones for Cooling

The CRAC Aircooled and Chilled Water

CRAC Cooling Systems Air- and Watercooled

CRAC Cooling System Chilled Water and CW2

Indirect Freecooling System

Direct Freecooling System

Row Cooling Systems

News in Data Center Cooling

1. Implementation of Best Practices
2. Airflow Guidance / Data Center Temperatures
3. Efficient use of Standby CRAC
4. CRAC with fan in the Raised Floor
5. Water as Refrigerant

1. Implementation of Best Practices

TIA942TypicaldatacenterLayoutforcabinets/CRAC

Proper Hot and Cold Aisle Configuration with raised floor

TIA942EquipmentRacksPlacementandCRACunitsalignment

14

BICSIlimitationforCabinetslayinglimitationand
recommendations

15

PlacementofCablestoenhancetheairflow

PutDATAcablesinHOTaisles,uphigh
PutPOWERcablesinCOLDaisles,downlow

16

The Raised Floor 1

The Raised Floor 2

Airflow Leakage 1
Airflow leakages (short air circuit) leads to dramatic inefficiencies due to air
circulation back to the CRAC unit without taking heat from the computer equipment.
Close all unwanted openings in the raised floor
Close all unwanted openings below the racks
Close all cable cut outs use cable sealings
All gaps (near walls and CRAC units) have to be sealed

Airflow Leakage 2

The target is to create an overpressure under the raised floor to realize

an even air supply to all areas of the data-centre.

This overpressure can only be achieved with an as low as possible

amount of unwanted airflow leakage.

Perforated Tiles Quantity and Opening Factor

The number of perforated tiles must be in line with:
the design
the actual / real airflow

Tile number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Example:
Design Airflow: 50.000 m/h, ESP 20Pa
Chosen tile: Airflow: 500 m/h, 20Pa
100 tiles are required
Actual Airflow: 30.000 m/h,
Tile number to be reduced to 60

Perforated Tiles: With modulating damper

Perforated tiles with integral adjustable dampers can
be used to avoid having to replace perforated tiles
with solid tiles.
In this case the number of perforated tiles can
remain unchanged but all tiles need to be adjusted
according to the actual requirements in the room.
It is also possible to work with different adjustments to vary the
amount of air in different areas of the Data Center.
In any case the static pressure under the raised floor has to be kept
at the design level.

Blanking Panels
Recirculation of cooling air
inside the rack leads to
overheating of servers.
Blanking panels installed in
unused areas or slots of a
rack eliminate a possible
internal recirculation of the
hot air.

2. Airflow Guidance / Data Center Temperatures

Data Center Temperatures 1

22C

35C
13C

35C
35C

13C

13C

20C

Data Center Temperatures 2

35C
35C

22C

Well organised airflow

Data Center Temperatures 3

What does this mean for the cooling equipment design?
Less Airflow
-> Reduced fan speed and/or smaller CRAC
Higher Return Air Temperature
-> Smaller CRAC for same capacity
Higher Air Temperature Difference
-> Smaller CRAC for same capacity
Higher Water Temperature
-> Smaller Chiller for same capacity

3. Efficient use of Standby CRAC

Standby Management EC Fan Characteristic

100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%

100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Airflow

Absorbed Power

1/2
Airflow
1/8
Absorbed
Power

Airflow

Absorbed Power

Standby Management 1
Airflow = 3x 48.000 m/h = 144.000m/h
Fan power cons. = 3x 9,1 kW = 27,3 kW
Lpa,2m = 3x 61,3 dB(A) = 66,1 db(A)

Standby
Capacity: 3x 201,0 kW = 603,0 kW net sensible

Airflow = 4x 36.000 m/h = 144.000m/h

Fan power cons. = 4x 3,9 kW = 15,6 kW
Lpa,2m = 4x 54,5 dB(A) = 60,5 db(A)
Capacity: 4x 163,4 kW = 653,6 kW net sensible

Reduction of fan power consumption by 43%

Savings: 13.320,-- /year @ 0,13 /kWh

Standby Management 2
Airflow = 3x 48.000 m/h = 144.000m/h
Fan power cons. = 3x 9,1 kW = 27,3 kW
Lpa,2m = 3x 61,3 dB(A) = 66,1 db(A)

Standby
Capacity: 3x 201,0 kW = 603,0 kW net sensible

Airflow = 4x 32.700 m/h = 130.800m/h

Fan power cons. = 4x 3,0 kW = 12,0 kW
Lpa,2m = 4x 52,2 dB(A) = 58,2 db(A)
Capacity: 4x 151,3 kW = 605,2 kW net sensible

Reduction of fan power consumption by 56%

Savings: 17.420,-- /year @ 0,13 /kWh

4. CRAC with fan in the Raised Floor

CRAC with fan in the Raised Floor

CRAC with fan in the Raised Floor

CRAC with fan in the Raised Floor

1

Fan power consumption

12,0

Fan power [kW]

10,0

8,0
6,0
4,0
2,0
0,0
18.000

22.000

26.000

30.000

34.000

38.000

42.000

46.000

50.000

Air flow [m /h]

CRAC with fan above the raised floor

CRAC with fan in the raised floor

25% higher airflow

Reduction of the fan power consumption by 47%

ESP = 20Pa

54.000

5. Water as Refrigerant

Water as Refrigerant
New technology for data centers
Designed for a no-cost, environmentally friendly refrigerant
Provides the very hightest efficiency and sustainability
Moving from technical to economical feasibility

Water as Refrigerant
Standard water from water supply system
No water treatment required
Water hardness not a problem
Fully environmentally compatible
Infinitely available refrigerant - free of charge

Water as Refrigerant
No toxicity or flammability
No production energy required
ODP = 0
No LGWP, but ZeroGWP GWP = 0
TEWI never reached before

Environmental Sustainability
ODP Ozone Depletion Potential
Relative indicator for the ozone depletion related to the ODP value 1
of the substance Trichlorfluoromethane (R11)

=0

GWP Global Warming Potential

Relative measure of how much heat a greenhouse gas traps in the
atmosphere comparing the amount of heat trapped by a certain
mass of the gas in question to the amount of heat trapped by a
similar mass of carbon dioxide as reference value (CO2=1)
Commonly calculated over a period of 100 years, f. e. methane
GWP = 25, R 134a = 1430

=0

Environmental Sustainability

TEWI Total Equivalent Warming Impact

CO2 emmision per

Energy unit (kg/kWh)

TEWI = GWP x L x n + GWP x m x (1 R) + n x Ea x

Leackage rate (kg/a)

Operating period(a)

Filling quantity(kg)

Recovery rate (kg)

Annual energy
Consumption (kWh/a)

Worlds
Lowest

TEWI: Calculation method to evaluate the influence of cooling systems on the greenhouse effect

high

Sustainability

low

Economy (TCO, ROI)

CRAC with water

as refrigerant

low

Ecologic Compatibility

high

Thermodynamics
Water is an environmentally-friendly substance, however water offers difficult thermodynamic
attributes that need to be overcome.
Water characteristics require a special cooling circuit and compression process.
Water (R718)
0.246 psi

R410a

Vapour pressure

0,017 bar

12,5 bar

181 psi

Vapour density

0,0128 kg/m 0.0008 lb/ft

48 kg/m

3 lb/ft

Volumetric refrigerant capacity

30,8 kJ/m

0.828 Btu/ft 7355 kJ/m

197 Btu/ft

Pressure ratio for temperature

lift 32K

6,6

6.6

2,3

2.3

Volume flow for 45 kW

(154 Btu/h) capacity

5.250 m/h

3,090 cfm

22 m/h

12.95 cfm

Mass flow for 45 kW

(154 Btu/h) capacity

67 kg/h

2.47 lb/min

1056 kg/h

38.8 lb/min

System Design
CRAH Air
Section

Drycooler
Primary
side pump

eChiller
Water
Piping
Secondary
side pump

CRAH
Underfloor Fan Section

Thermodynamics

Warm water
Cold water
Heat Removal OUT
Heat Removal IN

Thermodynamics

An entirely new evaporating,

compressing
and condensing process has
been developed

Operating Principle - 1

Operating Principle - 2

Operating Principle - 3

Operating Principle - 4

The Turbine

Unique three dimensional structure

Specially developed, composed granulate material
Absolutely oil free operation of all components
Extremely high turbo compressor efficiency

The EC Motor

Highest EC motor efficiency

Efficiency > 98% (w/o inverter) and 95% with inverter
Quasi loss-free magnetic bearing (axial and radial)
Lubrication free bearing
Unmatched emergency operation capability, passively stable
Tested up to 100.000 rpm
Friction and wear free
Vibration free, super low noise operation

Free Cooling
Build-in Indirect Free Cooling
Free cooling operations starts a few degrees
below desired supply air temperature
No additional free cooling heat exchanger required;
very low internal pressure loss,
thus increased efficiency and lower sound pressure
Precise temperature control with step-less high efficiency pump;
No control valves, thus low hydraulic pressure drop
Step-less adjusting condensing temperature without the
high condensing pressures of conventional systems

Free Cooling Stages

Ambient
Temperature
Mode
CRAH Fan

102-77 F
39-25C

76-64 F
24C-18C

63-54 F
17C-12C

<53 F
<11C

DX Stage 2

DX Stage 1a

DX Stage 1b

Free Cooling

Fixed Speed or Raised Floor Pressure Controlled

CRAH Pump
eChiller Turbines
eChiller Pumps

Speed Controlled on Air Temperature Setpoint

3x proportional

2x proportional

2x proportional

Off

3x
maximum

3x
medium

3x
minimum

2x minimum /
1x proportional

Drycooler Pump

maximum speed

proportional

Drycooler Fan

maximum speed

proportional

Highest System EER

14
CRAC with water as refrigerant
12

Aircooled CRAC

EER

10

Absorbed Power (all system components)

EER =

Cooling Capacity

6
4
2
0

12

16

20

24

Ambient Temperature [C]

28

32

36

Excellent COP
70
CRAC with water as refrigerant
60

Aircooled CRAC

50

COP

Absorbed Power (Compressor / eChiller)

COP =

40

Cooling Capacity

30
20
10
0

12

16

20

24

Ambient Temperature [C]

28

32

36

Part Load Efficiency

Relative Power Consumption

100

80

35C Ambient Temperature

20C Ambient Temperature
10C Ambient Temperature
Linear

60

40

20

0
20%

40%

60%

Heatload

80%

100%

ROI
120
CRAC with water as refrigerant
Aircooled CRAC

TCO [k]

100
80
60
40
20

@ 0,13/kWh

ROI ~ 3 Years

0
1

Year

Regulations
CRAC with water as refrigerant anticipates
new upcoming regulations
Avoids tax regulations
Examples for 134a:
Denmark 17.5/Kg, Norway 39/Kg
Taxation coming up in Sweden and Australia

CRAC with water as refrigerant avoids room safety regulations

for installation and service

Water as refrigerant - Summary

Water as refrigerant
Innovative, reliable and secure system
Highest efficiency and sustainability
Competitive energy savings
Build-in indirect free cooling
Anticipates new upcoming regulations

Many thanks for your attention.