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

HVAC System Design
Taylor Engineering, LLC
Mark Hydeman, P.E., FASHRAE Taylor Engineering, LLC mhydeman@taylor-engineering.com
How do you effectively fight a fire?

it takes 2,000 to 3,000 times the volume of air to cool what you can with water! With air, or with water?
State of the present: with air
Air system design overview

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

Server airflow front to back or front to back and top are recommended
Cold Aisle Hot Aisle
2004, American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. (www.ashrae.org). Reprinted by permission from ASHRAE Thermal Guidelines for Data Processing Environments. This material may not be copied nor distributed in either paper or digital form without ASHRAEs permission.
Data center layout
Underfloor Supply
Cold Aisle Hot Aisle Only 1 pressure zone for UF!

Data center layout

You can incorporate VAV on each branch
Overhead Supply
Typical temperature profile with UF supply

Too hot Too hot
Just right
Too cold Elevation at a cold aisle looking at racks

There are numerous references in ASHRAE. See for example V. Sorell et al; Comparison of Overhead and Underfloor Air Delivery Systems in a Data Center Environment Using CFD Modeling; ASHRAE Symposium Paper DE-05-11-5; 2005
Typical temperature profile with OH supply

Too warm Too warm
Just right
Elevation at a cold aisle looking at racks
Hot aisle lid
Aisle capping
End cap
Cold Aisle Caps
APC reprinted with permission
10
Aisle capping
LBNL has recently performed research on aisle capping
Cold Aisle Caps
11
Overhead (OH) vs. Underfloor (UF)

Issue Capacity Balancing Overhead (OH) Supply Limited by space and aisle velocity. Continuous on both outlet and branch. Underfloor (UF) Supply Limited by free area of floor tiles. Usually limited to incremental changes by diffuser type. Some tiles have balancing dampers. Also underfloor velocities can starve floor grilles! Only one pressure zone per floor, can provide multiple temperature zones. Commonly cold at bottom and hot at top. Generally worse. Worst. Hot or cold aisle possible.
Control Temperature Control First Cost Energy Cost Aisle Capping
Up to one pressure zone by branch. Most uniform. Best (if you eliminate the floor). Best. Hot or cold aisle possible.
12
Airflow design disjoint

IT departments select servers and racks Engineers size the fans and cooling capacity Whats missing in this picture?
13
Airflow with constant volume systems
Hot spots Higher hot aisle temperature Possible equipment failure or degradation
V HVAC _ Supply V Servers
14
Least hot spots Higher air velocities Higher fan energy Reduced economizer effectiveness (due to lower return temperatures)
15

Note most of these observations apply to overhead and underfloor distribution With constant volume fans on the servers you can only be right at one condition of server loading! The solution is to employ variable speed server and distribution fans
Airflow with variable volume systems
Partial flow condition
Best energy performance but difficult to control
17
How Do You Balance Airflow?
Spreadsheet CFD Monitoring/Site Measurements
Image from TileFlow http://www.inres.com/Products/TileFlow/tileflow.html, Used with permission from Innovative Research, Inc.
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Thermal report
From ASHRAEs Thermal Guidelines for Data Processing Environments Taylor Engineering, LLC 19
Whats the server airflow?

SUN V490 SUN V240 DELL 2850 DELL 6850 num fans 9 3 n/a n/a total CFM (max) 150 55.65 42 185 total CFM (min) 27 126 fan speed single speed variable 2 speed 2 speed fan control n/a inlet temp. 77F inlet 77F inlet Form Factor (in U's) 5 2 2 4 heat min config (btuh) 798 454 heat max config (btuh) 5,459 1,639 2,222 4,236 heat max (watts) 1,599 480 651 1,241 dT min config 13 3 dT max config 33 27 48 21 servers per rack 8 21 21 10 CFM/rack (hi inlet temp) 1,200 1,169 882 1,850 CFM/rack (low inlet temp) 1,200 567 1,260 max load / rack (kW) 13 10 14 12
20
Best air delivery practices
Arrange racks in hot aisle/cold aisle configuration Try to match or exceed server airflow by aisle
Get thermal report data from IT if possible Plan for worst case

Get variable speed or two speed fans on servers if possible Provide variable airflow fans for AC unit supply
Also consider using air handlers rather than CRACs for improved performance (to be elaborated on later)
Use overhead supply where possible Provide aisle capping (preferably cold aisles, refer to LBNL presentation for more details) Plug floor leaks and provide blank off plates in racks Draw return from as high as possible Use CFD to inform design and operation
21
Air-side economizer
22
Air-Side Economizer issues
Hygroscopic dust
LBNL
is doing some research on this
Design humidity conditions

See
following slides
23
Design conditions at the zone
2005, American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. (www.ashrae.org). Reprinted by permission from ASHRAE Design Considerations for Data and Communications Equipment Centers. This material may not be copied nor distributed in either paper or digital form without ASHRAEs permission.
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San Francisco
40
80
.020
75
.019
.018
PSYCHROMETRIC CHART
Normal Temperature
I-P Units
35
.017
75
70
WE TB
.016
UL BT EM PE RA
.015
TU R E-
.014
HUMIDITY RATIO - POUNDS MOISTURE PER POUND DRY AIR
16 FEET
BAROMETRIC PRESSURE: 29.904 in. HG
30
65
Upper Allowed Humidity Limit

14.0
70
.013
.012
San Francisco Climate Data Bins with Data Center Guideline Zones
Weather Hours 360 to 321 320 to 281 280 to 241 240 to 201 200 to 161 160 to 121 120 to 81 80 to 41 40 to 1
55
60
65
UME VOL
.011
25
.010
Design Target
60
.FT. - CU
.009
PER D LB.
20
50
% 90
% 80
55
X
Class1;Recommend
25
.008
A RY IR
.007
45
% 70
50
.006
Negligible time of possible concern for humidification

10
15
40
45
% 60
Class1;Allow
15%
.005
35
40
13.0
50%
40%
NEBS;Recommend
.004
35
.003
30%
30
20%
.002
E HUMIDITY
Lower Allowed Humidity Limit (20%RH)

.001 65 70 75 80 85 90 95 100
10% RELATIV
30
35
40
45
50
55
60
Chart by: HANDS DOWN SOFTWARE, www.handsdownsoftware.com
DRY BULB TEMPERATURE - F
25
Los Angeles
40
.020
80
75 .019
.018
PSYCHROMETRIC CHART
Normal Temperature
I-P Units
35
70
.017
75
WE
TB
.016
UL BT
EM PE RA TU
.015
RE
.014

60
.013
.012
Los Angeles Climate Data Bins with Data Center Guideline Zones
55
65
.011
25
.010
Design Target
P .FT. - CU
60
.009
20
50
% 90
% 80
55
X
Class1;Recommend
25
.008
.007
45
% 70
% 60
45
50%
40%
30%
20%
50
.006
Only a few hours of possible concern for humidification

10
15
40
Class1;Allow
15%
.005
35
40
NEBS;Recommend
.004
35
30
.003
.002
10% RELATIV
E HUMIDITY

.001 65 70 75 80 85 90 95 100
30
35
40
45
50
55
60
105 FEET
30
65
70
14.0 UME VOL ER D LB. A RY IR
13.0
26
Sacramento
40
80
75 .019 .020 .018
PSYCHROMETRIC CHART
Normal Temperature
I-P Units
35
70
.017
75
WE T
.016
BU LB TE MP ER AT
.015
UR
E-
.014

14.0
70
.013
.012
Sacramento Climate Data Bins with Data Center Guideline Zones

55
60
65
25
.011
.010
Design Target
60
.009
20
50
% 90
% 80
45
55
X
Class1;Recommend
25
.008
.007
% 70
50
.006
Negligible time of possible concern for humidification

10
15
40
% 60
45
50%
40%
Class1;Allow
15%
.005
35
40
NEBS;Recommend
.004
35
30
30%
20%
10% RELATIV E HUMIDITY
.003
.002

.001 60 65 70 75 80 85 90 95 100
30
35
40
45
50
55
26 FEET
30
65
UME VOL .FT. - CU PER D LB. A RY IR
13.0
27
Lower humidity limit
Mitigate electrostatic discharge (ESD)
Recommended procedures

Personnel grounding Cable grounding Grounding wrist straps on racks Grounded plate for cables Grounded flooring Servers rated for ESD resistance Telecom industry has no lower limit The Electrostatic Discharge Association has removed humidity control as a primary ESD control measure in their ESD/ANSI S20.20 standard
Recommended equipment

Industry practices

Humidity controls are a point of failure and are hard to maintain Many data centers operate without humidification This needs more research Old technology not found in most data centers It is best to segregate these items rather than humidify the entire data center
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And for some physical media (tape storage, printing and bursting)

ESD control: floor grounding
Image from Panduit, reprinted with permission
29
Water-Side Economizer
Integrated
Heat Exchanger in series with chillers on CHW side
Economizer Summary
Air-Side Economizers
Water-Side Economizers
Provides free cooling when dry-bulb temperatures are below 78F-80F. May increase particulates (LBNL research indicates this is of little concern). Should be integrated to be most effective. Improves plant redundancy! Can work in conjunction with water-side economizers on data centers! Need to incorporate relief.
Provides low energy cooling when wet-bulb temperatures are below 55F-60F. Avoids increased particulates (and low humidity if that concerns you). Should be integrated to be most effective (see previous slide). Improves plant redundancy! Can work in conjunction with air-side economizers on data centers!
31
Both are proven technologies on data centers!

A case study of two designs
Collocation facility in the Bay Area Side by side designs in same facility over two phases Motivation for the second design was to reduce cost
Case study was developed by Lawrence Berkeley National Laboratory (LBNL)
Data Centers 8.1 and 8.2
Both sections at ~30% build-out during monitoring
32
A tale of two designs: overview
Phase 1 Data Center (8.1)

Phase 2 Data Center (8.2)

26,200 ft2 27 W/ft2 design Traditional under-floor design with CRAC units Air-cooled DX Humidity controls (45%-55%)
73,000 ft2 50 W/ft2 design Under-floor supply from central AHUs with CHW coils Water-cooled plant Air-side economizers No humidity controls
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A tale of two designs: a closer look

Normalized efficiency metric: cooling
1.60 1.40 1.20
Normalized energy
kWcooling _ systems kWservers

~1/4 of the normalized energy
Phase 1 Data Center (8.1) Phase 2 Data Center (8.2)
1.00 0.80 0.60 0.40 0.20 Computer Loads UPS Losses HVAC Lighting
Data normalized to computer loads

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

Airside
economizers No humidity controls Water-cooled chilled water system AHUs instead of CRAC units
36
Custom CRAH Unit (Large)
37
Example CRAH Unit Comparison

Model Budget Cost Number of units net total cooling (btuh) net sensible (btuh) sensible (tons) CFM SAT airside dT Internal SP no. fans fan type no. motors HP/motor total HP BHP/motor Unit BHP unit width depth height filter type Water PD (ft) CHW dT GPM Total GPM Total BHP Option 1 Option 2 Std CRAC Custom Model 1 Custom Model 2 $ 16,235 $ 23,000 $ 41,000 21 13 4 434,900 410,000 841,000 397,400 399,000 818,000 33.1 33.3 68.2 16,500 25,000 50,000 49.90 59.30 59.00 25.10 15.70 16.00 2 0.8 0.8 1.8 1.8 3 3 2 Centrifugal Plenum Plenum 1 3 2 15 5 15 15 15 30 15 4.7 11.5 15 14.1 23 122 122 122 35 36 72 76 156 168 ASHRAE 20% MERV 13 MERV 13 13.5 ft 11.1 11.1 14F 20 20 66.80 44.00 88.00 1,403 924 66% 315 275 87%
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Example CRAH Unit Comparison
34% less water flow 13% less fan energy
More if you consider the supply air temperature and airflow issues
Excess fan capacity on new units 36% higher cost for units, but

Fewer piping connections Fewer electrical connections Fewer control panels No need for control gateway Can use the existing distribution piping and pumps (case study) Can use high quality sensors and place them where they make sense
Possibly less turbulence at discharge?
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Air cooling issues
Limitations on the data densities served (~200w/sf)

Air delivery limitations Real estate Hot aisles are approaching OSHA limits
Working conditions
Costly infrastructure High energy costs Management over time Reliability

Loss of power recovery Particulates
40
Take Aways

Use air- or water-side economizers where possible Consider personal grounding in lieu of humidification Consider AHUs as an alternative to CRACs Consider VSDs on fans, pumps, chillers and towers Refer to ASHRAE, LBNL and Uptime Institute for more recommendations
41
State of the future: cooling with liquid
42

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HVAC System Design

Taylor Engineering, LLC

Mark Hydeman, P.E., FASHRAE Taylor Engineering, LLC mhydeman@taylor-engineering.com

How do you effectively fight a fire?

Taylor Engineering, LLC

State of the present: with air

Taylor Engineering, LLC

Air system design overview

overhead or underfloor Control: constant or variable volume

Airflow issues Economizers Humidity control issues

Taylor Engineering, LLC 4

Data center layout

Cold Aisle Hot Aisle

Taylor Engineering, LLC

Data center layout

Cold Aisle Hot Aisle Only 1 pressure zone for UF!

Taylor Engineering, LLC

Data center layout

Cold Aisle Hot Aisle

Taylor Engineering, LLC

Typical temperature profile with UF supply

Too cold Elevation at a cold aisle looking at racks

Typical temperature profile with OH supply

Elevation at a cold aisle looking at racks

Taylor Engineering, LLC

Hot aisle lid

Cold Aisle Hot Aisle

Taylor Engineering, LLC

Cold Aisle Hot Aisle

Taylor Engineering, LLC

Overhead (OH) vs. Underfloor (UF)

Control Temperature Control First Cost Energy Cost Aisle Capping

Taylor Engineering, LLC

Airflow design disjoint

Taylor Engineering, LLC

Airflow with constant volume systems

Taylor Engineering, LLC

V HVAC _ Supply V Servers

Airflow with constant volume systems

Taylor Engineering, LLC

V HVAC _ Supply V Servers

Airflow with constant volume systems

Taylor Engineering, LLC 16

Airflow with variable volume systems

Partial flow condition

Best energy performance but difficult to control

Taylor Engineering, LLC

V HVAC _ Supply V Servers

How Do You Balance Airflow?

Spreadsheet CFD Monitoring/Site Measurements

Taylor Engineering, LLC

Whats the server airflow?

Taylor Engineering, LLC

Best air delivery practices

Taylor Engineering, LLC

Taylor Engineering, LLC

Air-Side Economizer issues

is doing some research on this

Design humidity conditions