HVAC System Design

Mark Hydeman, P.E., FASHRAE

Taylor Engineering, LLC
mhydeman@taylor-engineering.com
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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?

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State of the present: with air

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Air system design overview
 Data center layout
 Airflow configurations
 Distribution:
overhead or underfloor
 Control: constant or variable volume
 Airflow issues
 Economizers
 Humidity control issues

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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 ASHRAE’s permission.

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 Data center layout

Underfloor Supply

Cold Aisle

Hot Aisle

Only 1 pressure
zone for UF!
© 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 ASHRAE’s permission.

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 Data center layout
You can
incorporate VAV
on each branch

Overhead Supply

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 ASHRAE’s permission.

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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

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Typical temperature profile with OH supply
Too warm Too warm

Just right

Elevation at a cold aisle looking at racks

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 Hot aisle lid

Aisle capping
End cap
Cold Aisle Caps
© APC reprinted with permission

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 ASHRAE’s permission.

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Aisle capping
LBNL has recently performed
research on aisle capping
Cold Aisle Caps

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 ASHRAE’s permission.

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

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Airflow design disjoint
 IT departments select servers and racks
 Engineers size the fans and cooling
capacity
 What’s missing
in this picture?

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Airflow with constant volume systems

 Hot spots
 Higher hot aisle
temperature
 Possible equipment
failure or degradation

• •
V HVAC _ Supply < ∑V Servers
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Airflow with constant volume systems

 Least hot spots

 Higher air velocities
 Higher fan energy
 Reduced economizer
effectiveness (due to
lower return
temperatures)
• •

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V HVAC _ Supply > ∑V Servers 15
Airflow with constant volume systems

 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…

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Airflow with variable volume systems

Partial flow condition

 Best energy performance
but difficult to control

• •
V HVAC _ Supply > ∑V Servers
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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 ASHRAE’s Thermal Guidelines for Data Processing Environments

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What’s the server airflow?
SUN SUN DELL DELL
V490 V240 2850 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

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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

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Air-side economizer

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Air-Side Economizer issues
 Hygroscopic dust
 LBNL is doing some research on this
 Design humidity conditions
 See following slides

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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 ASHRAE’s permission.

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 San Francisco
40
.020

80
R
75 .019
I
A

.018 Y
R
D

.017 D

PSYCHROMETRIC
35
N
U

CHART
75
70 W .016 O
ET P
BU
LB
TE
MP R

Normal Temperature
ER
ATU .015 E
RE
- P
°F

I-P Units E
.014 R
30 U

16 FEET 65 70

Upper Allowed Humidity Limit

T
.013 S
I
BAROMETRIC PRESSURE:
BAROMETRIC 29.90429.904
PRESSURE: in. HG in. HG O
M
.012

1 S

San Francisco Climate Data Bins 60

65
4
.
D
.011 N
0
with Data Center Guideline Zones 25
V
U
O
P
O
.010
L

Weather Hours 55 Design Target U

M
-

360 to 321 60 E .009 O

I
-
320 to 281 T
C
280 to 241

X
A
U
240 to 201 90% .008 R
20 50 .
F 25%
200 to 161 Y
55 T
160 to 121 % T
80 .
.007 I
120 to 81 Class1;Recommend P
80 to 41 D
45 E
I
40 to 1 70% R
50 .006 M
L U
15 40 B H
Negligible time of possible 60% Class1;Allow .
D
.005
45
concern for humidification 35 50%
15% R
Y
.004
40
1 0%
NEBS;Recommend A
4 I
3 R
35 .
10 0 .003
30%
30

.002
20%

Lower Allowed Humidity Limit (20%RH) .001

10% RELATIVE HUMIDITY

30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

DRY BULB TEMPERATURE - °F

Chart by: HANDS DOWN SOFTWARE, www.handsdownsoftware.com

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 Los Angeles
40
.020

80
R
75 .019
I
A

.018 Y
R
D

.017 D

PSYCHROMETRIC 35

75
N
U

CHART 70 WE
T
BUL
BT
EM
.016 O
P

PER R
Normal Temperature ATU
RE
-
°F
.015 E
P

I-P Units E
.014 R
30 U

105 FEET
65 70 T
Upper Allowed Humidity Limit .013 S
I
BAROMETRIC PRESSURE:
BAROMETRIC 29.80829.808
PRESSURE: in. HG in. HG O
M
.012

Los Angeles Climate Data Bins 60

S
D
1
.011 N
with Data Center Guideline Zones 25
65
4
.
U
O
0
P
V .010

Weather Hours 55 Design Target O

L
-

U O
396 to 353 60 .009
M I
352 to 309 E T

X
308 to 265 - A
%
264 to 221 20 50 90 C %
.008 R
25
U
220 to 177 Y
55 .
176 to 133 F
80%
T
.007
132 to 89 Class1;Recommend T I
. D
88 to 45 45
% P I
44 to 1 70
50 E .006 M
R U

Only a few hours of possible

15 40 H
60% Class1;Allow L
B .005
45
concern for humidification 35 50%
. 5%
1
D
R
.004
40 NEBS;Recommend Y
%
1 40
A
3
35 I
10 . R .003
0
30%
30

.002
20%

Lower Allowed Humidity Limit (20%RH) .001

10% RELATIVE HUMIDITY

30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

DRY BULB TEMPERATURE - °F

Chart by: HANDS DOWN SOFTWARE, www.handsdownsoftware.com

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 Sacramento
40
.020

80
R
75 .019 I
A

.018 Y
R
D

.017 D

PSYCHROMETRIC
35
N
U

CHART
75
70 W .016 O
ET P
BU
LB
TE
MP R

Normal Temperature ER
ATU
RE
-
°F
.015 E
P

I-P Units E
.014 R
30 U

26 FEET
65
70 T

Upper Allowed Humidity Limit .013 S

I
BAROMETRIC PRESSURE:
BAROMETRIC 29.89329.893
PRESSURE: in. HG in. HG O
M
.012

1 S

Sacramento Climate Data Bins 60

65
4
.
D
.011 N

with Data Center Guideline Zones 25

0

V
U
O
P
O .010
L

Weather Hours 55 Design Target U

M
-

O
270 to 241 60 E .009
I
240 to 211 -
T

X
210 to 181 C A
90%
U .008 R
180 to 151 20 50 . 25%
150 to 121 F
Y
55 T
120 to 91
80%
T
. .007 I
90 to 61 Class1;Recommend
P
60 to 31 45 E
D
% I
30 to 1 70 R
50 .006 M
L U

Negligible time of possible 15 40

60
%
Class1;Allow
B
.
.005
H

concern for humidification

45 D
15% R
35 50%
Y
.004
40 NEBS;Recommend A
1
0%
3 4
I
R
35 .
10 0 .003
30%
30

.002
20%
Lower Allowed Humidity Limit (20%RH)
.001
10% RELATIVE HUMIDITY

30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

DRY BULB TEMPERATURE - °F

Chart by: HANDS DOWN SOFTWARE, www.handsdownsoftware.com

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

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ESD control: floor grounding

Image from Panduit, reprinted with permission

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Water-Side Economizer
Integrated

Heat
Exchanger in
series with
chillers on
CHW side
Economizer Summary
Air-Side Economizers
 Provides free cooling when dry-
bulb temperatures are below
78°F-80°F.
 May increase particulates
(LBNL research indicates this is
of little concern).
 Should be integrated to be
most effective.
 Improves plant redundancy!
 Can work in conjunction with
water-side economizers on
data centers!
 Need to incorporate relief.
Both are proven technologies on data centers!
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Water-Side Economizers
 Provides low energy cooling
when wet-bulb temperatures
are below 55°F-60°F.
 Avoids increased particulates
(and low humidity if that
concerns you).
 Should be integrated to be
most effective (see previous
slide).
 Improves plant redundancy!
 Can work in conjunction with
air-side economizers on data
centers!
31
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
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 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)
 26,200 ft2
 27 W/ft2 design
 Traditional under-floor design
with CRAC units
 Air-cooled DX
 Humidity controls (45%-55%)
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 Phase 2 Data Center (8.2)
 73,000 ft2
 50 W/ft2 design
 Under-floor supply from
central AHUs with CHW coils
 Water-cooled plant
 Air-side economizers
 No humidity controls
33
A tale of two designs: a closer look
kWcooling _ systems
Normalized efficiency metric: ηcooling = kWservers

1.60 Phase 1 Data Center (8.1) ~1/4 of the

1.40
Phase 2 Data Center (8.2) normalized energy
1.20

1.00

0.80

0.60

Normalized energy
0.40

0.20

-
Computer Loads UPS Losses HVAC Lighting

Data normalized to computer loads

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

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Two data centers: summary
 What made the difference?
 Airsideeconomizers
 No humidity controls
 Water-cooled chilled water system
 AHUs instead of CRAC units

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Custom CRAH Unit (Large)

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Example CRAH Unit Comparison
Option 1 Option 2
Model Std CRAC Custom Model 1 Custom Model 2
Budget Cost $ 16,235 $ 23,000 $ 41,000
Number of units 21 13 4
net total cooling (btuh) 434,900 410,000 841,000
net sensible (btuh) 397,400 399,000 818,000
sensible (tons) 33.1 33.3 68.2
CFM 16,500 25,000 50,000
SAT 49.90 59.30 59.00
airside dT 25.10 15.70 16.00
Internal SP 2 0.8 0.8
1.8 1.8
no. fans 3 3 2
fan type Centrifugal Plenum Plenum
no. motors 1 3 2
HP/motor 15 5 15
total HP 15 15 30
BHP/motor 15 4.7 11.5
Unit BHP 15 14.1 23
unit width 122 122 122
depth 35 36 72
height 76 156 168
filter type ASHRAE 20% MERV 13 MERV 13
Water PD (ft) 13.5 ft 11.1 11.1
CHW dT 14F 20 20
GPM 66.80 44.00 88.00
Total GPM 1,403 924 66%
Total BHP 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
 Working conditions
 Hot aisles are approaching OSHA limits
 Costly infrastructure
 High energy costs
 Management over time
 Reliability
 Loss of power recovery
 Particulates

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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

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State of the future: cooling with liquid

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