Modular Data Center Cooling with Redundant Chilled Fluid Plumbing
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Solution Overview
Problem
Current data center cooling systems, particularly those using raised floor plenums, are inefficient in handling high heat densities due to limitations in airflow and cooling capacity, leading to significant inefficiencies and the need for extensive infrastructure changes to transition from air-cooled to liquid-cooled systems.
Innovation Solution
A modular cooling system where alternating rows of air-cooled and liquid-cooled racks share redundant chilled fluid plumbing, allowing for seamless transition between cooling methods without disrupting airflow or requiring substantial infrastructure changes, using standard fluid couplings to connect air conditioners and liquid conditioners to the same plumbing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If air-cooled racks are used to handle high heat densities, then cooling capacity is improved, but extraordinary amounts of air handling equipment are required
Solution Approach 1:
The data center is divided into alternating rows of air-cooled racks and liquid-cooled racks, segmenting the cooling load between two different cooling methodologies. This allows each row type to be optimized independently while sharing common infrastructure.
Solution Approach 2:
The raised floor plenum is designed to serve dual functions: as an air supply plenum for air-cooled racks and as a liquid coolant distribution manifold for liquid-cooled racks. This universal infrastructure supports both cooling methods without requiring separate systems.
2Loss of energy
If liquid-cooled systems are implemented, then cooling efficiency is improved, but major infrastructure overhaul and substantial downtime are required
Solution Approach 1:
The transition to liquid cooling is segmented into phases, with alternating rows converted at different times. This allows the data center to maintain operational capacity while progressively implementing liquid cooling, avoiding complete shutdowns.
Solution Approach 2:
The raised floor plenum is pre-configured with liquid coolant distribution infrastructure during the initial build or during planned maintenance windows. This preliminary setup enables future liquid cooling deployment without requiring major infrastructure changes at the time of conversion.
3Ease of operation
If raised floor plenum designs are used, then cooling distribution is simplified, but airflow is impeded by cabling and obstructions
Solution Approach 1:
The liquid coolant acts as an intermediary heat transfer medium, removing heat from liquid-cooled racks directly at the source without requiring airflow through the plenum. This bypasses the airflow obstruction problem while maintaining simplified cooling distribution through the existing plenum infrastructure.
4Ease of manufacture
If perforated tiles are used for floor vents, then airflow from plenum is limited to approximately 6 cubic meters per minute, but this is below the 60 cubic meters per minute required by some server racks
Solution Approach 1:
The system transitions from purely pneumatic air cooling to hydraulic liquid cooling for the liquid-cooled racks. Liquid coolant is pumped through the racks at high flow rates, delivering the required cooling capacity without being constrained by the airflow limitations of perforated floor tiles.
5Quantity of substance
If blowers are used to actively pull cold air from plenum, then airflow is improved, but balancing airflow throughout data center requires substantial trial and error
Solution Approach 1:
The system replaces the complex mechanical airflow balancing system (blowers, dampers, controls) with a simpler liquid pumping system. Liquid coolant flow is controlled by pumps and valves, which are inherently easier to balance and control than large-scale air movement systems.
6Ease of manufacture
If air cooling is used for high heat capacity racks, then cooling is simpler to implement, but extraordinary amounts of air are required to remove heat
Solution Approach 1:
The system uses hydraulic liquid cooling for racks requiring high cooling capacity. Liquid coolant provides superior heat transfer coefficients compared to air, enabling efficient removal of high heat densities without requiring extraordinary air volumes or complex air handling equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances cooling efficiency, increases power handling capacity, and allows for flexible migration from air-cooled to liquid-cooled systems without downtime or major overhauls, improving data center performance and reducing operational complexities.
Implementation Method 1
chilled fluid, such as water or a refrigerant, for the air conditioners or liquid conditioners is supplied through redundant plumbing
Implementation Method 2
The air conditioners and liquid conditioners use the same chilled fluid so that they may share the redundant plumbing
Data Source
AI summary
A data center is configured in a room using alternating rows of racks containing heat-generating electronic devices and air conditioners or liquid conditioners. Chilled fluid, such as water or a refrigerant, for the air conditioners or liquid conditioners is supplied through redundant plumbing comprising first and second supply and return pipes below a raised floor. Attached to this redundant plumbing are standard fluid couplings configured to couple to either air conditioners or liquid conditioners. The air conditioners and liquid conditioners use the same chilled fluid so that they may share the redundant plumbing and continually receive chilled fluid in the event of the failure of one of the chilled fluid supplies.