APC InRow™ Cooler Prototype€¦ · 03/12/2012 · APC InRow™ Cooler Prototype Initial Report...

APC InRow™ Cooler Prototype

Initial Report - Test Setup Verification

H. Coles, S. Greenberg

Contributing: J. Bean (APC)

November 18, 2011

1

Contents

• Introduction

• Technology Description/Attributes

• Installation

• Analysis Metrics, Methods, Metering, Test Description

• Results

• Next Steps

• Conclusions

2 SVLG 2011 Data Center Efficiency Summit - LBNL

Introduction

• Project funding – California Energy Commission (CEC)

– APC: In-kind Funding

• LBNL Role - Identify and demonstrate new data center energy saving technologies

• Goal - Reduction or Elimination of Compressor Cooling

• Technology Selected: APC dual heat exchanger InRow™ Cooler

• Status: Initial trial setup and data collection completed


APC Unit Description


IT

Rack

IT

Rack

IT

Rack

IT

RackIT

Rack

IT

Rack

IT

Rack

IT

Rack

IT

Rack

IT

RackIT

Rack

IT

Rack

Cold Aisle

Hot Aisle

Hot Aisle

Air to Water Hex (chilled)

Air to Water Hex (treated)

Fans

(3 EC type)

Air to Water

Heat Exchanger

(chilled water)

Air to Water

Heat Exchanger

(“treated” water)

Chilled

Water

Connection

“treated”

Water

Connection

Hot

Air

Entering

Cooled

Air

Leaving

Chilled

Water

Modulating

Valve

Treated

Water

Modulating

Valve

filter

Product Attributes

• Redundancy: dual water cooling loops and heat exchangers

• Self contained: additional CRAH/CRAC units not required

• Use min. chilled water – use only where/when needed for data center hot spots

• Some additional plumbing required


APC Unit Installation Building 50 Data Center Rm 1275

Lawrence Berkeley National Laboratory

Front – Air Exit

Cold Aisle

Rear – Air Entry

Hot Aisle Front Door

Display/Control

Filter


COP Metric Definition

COP [ kWthermal / kWelec. ] = cooling provided / power needed

power needed (kW) = (kW/ton * tons) + (kW/ton * tons) + APC Unit Power

7

APC Unit

Power

cooling provided (kW) = treated water cooling + chilled water cooling – APC Unit Power

y = 0.0000051561x3

- 0.0008596432x2

+ 0.0327788257x

+ 0.3552353121

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

40 45 50 55 60 65 70 75 80 85 90

Ele

ctri

cal

Po

we

r N

ee

de

d (k

W/t

on

)

Cooling Water Temperature (°F)

kW/ton vs. Chilled Water Temperature (CWT)distribution pumping included

Taylor Engineering

Santa Clara CAYear Average

Plant Model ASHRAE 90.1 Code Minimum

Water-Side Economizer Equipped – Santa Clara CA Climate Year Average (Taylor Engineering)

Heavy Use of Chiller

Little or No Chiller Use (water side economizer)

aka “treated”


(CHWT)

Chilled Water Temperature (°F)

Test Methods

• Short duration preliminary tests – Manual Mode • Test 1: cooling tower only (single coil)

• Test 2: chilled water only (single coil)

• Test 3: chilled and treated water combined (both coils)

• Key Metric – Coefficient of Performance (COP)


Metering

Cooling Tower

(“treated”)

Chilled

Cooling

Water

Flow

Sensor

Temperature

Sensors

Flow

Sensor

Power

Meter

Chilled Water

Btu Meter

Treated Water

Btu Meter

Air Temp. Sensors

Air Temp.

Sensors


Onicon Btu Meter

(treated water)

Onicon Btu Meter

(chilled water)

Ion Power Meter

(APC Unit)

Installed Power and Btu Meters

Synapsense Wireless Air Temperatures

Preliminary Results: Compare Cooling Modes (manual operation, valves 100% open, fans @ slow speed)

SVLG 2011 Data Center Efficiency Summit - LBNL 11

Chilled

Water

Chilled+

Treated

Water

Treated

Water

Ne

t C

oo

ling

Treated

+ Chilled

Cooling

Chilled

Water Only

Cooling

“Treated”

Water

Only

Cooling

Tre

ate

d H

2O

Co

olin

gC

hill

ed

Wa

ter

Co

olin

g

CO

PCh

ille

d W

ate

r C

oo

ling

Ne

t C

oo

ling

CO

P

Ne

t C

oo

ling

CO

P

Tre

ate

d H

2O

Co

olin

g

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

En

erg

y R

ate

(kW

th

erm

al, k

W e

lectr

ica

l)

CO

P (

kW

/kW

)

0.5

8 k

W/ton

0.4

6 k

W/ton

0.2

8 k

W/ton

AP

C P

ow

er

Re

qu

ire

d

AP

C P

ow

er

Re

qu

ire

d

AP

C P

ow

er

Re

qu

ire

d

Compare Exit Temperature with Similar Inlet Temperature

(manual mode)

SVLG 2011 Data Center Efficiency Summit - LBNL

12

657075808590

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Air Entering/Leaving APC InRow Unit

Air from Hot Aisle Entering APC Unit (°F)

Air to Cold Aisle Leaving APC Unit (°F)

405060708090

0 2 4 6 8 10 12 14 16 18 20 22 24




405060708090

0 2 4 6 8 10 12 14 16 18 20 22 24




Test #1

69.1°F

Test #2

50.2°F

Test #3

48.9°F

Treated

Chilled

Treated and Chilled

Treated Water Cooling Metering Test

SVLG 2011 Data Center Efficiency Summit - LBNL

13

0.250

0.310

0.370

0.430

0.490

0.550

0.610

0.670

0.730

0.790

0.8504.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Pe

rfo

rman

ce (k

W e

lec

/ to

n )

CO

P (k

W c

oo

lin

g /

kW e

lect

rica

l)COP Treated Water Cooling Only

COP [kW/kW] = cooling / total electrical (plant + APC unit) needed

Treated Water Cooling Performance (COP)

150

170

190

210

230

250

0 5 10 15 20 25 30 35

CFM

/ k

W C

oo

led

Treated Only Coil Test - CFM per Net Cooled kW

cfm per kW

Next Steps

• Test control system – temperature modulation, fan speed (data presented not typical in some cases – manual mode)

• Test at various output set point temperatures

• Monitor cfm/kW supported

• Investigate power used and COP change at high fan speeds

• Longer term test

• Test performance when both coils use treated water

• Test with warmer air inlet

• Re-check air temperature sensor calibration


Conclusions

• Test setup working

• Efficiency Points – Chilled water ~14kW cooling (4 tons) at COP =6 (0.58kW/ton)

– Treated water ~14kW cooling (4 tons) at COP =12 (0.28kW/ton)

• Unit appears to support typical server cfm/kW – E.g. treated water test = ~1000cfm for ~5kW cooling (170-230cfm/kW)

• Compare to others – Chilloff 2 Results (Row Coolers) SCOPc = ~6 using ~45°F cooling water

– COP this test = ~6 using 47°F cooling water


End

Questions?


Appendix


Test 1 – Treated Water Only Cooling

50

52

54

56

58

60

62

64

66

68

70

72

74

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Wat

er

Sup

ply

Te

mp

. (°F

)

The

rmal

Co

oli

ng

(kW

)

Time (hours)

Cooling vs. Water Supply TemperatureTreated Water- Manual Control, APC Fans at Low Speed

Treated Water Supply Temperature (°F)

Treated Water Cooling (kW)

midnight noon midnight noon

657075808590

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36




22.0

22.2

22.4

22.6

22.8

23.0

23.2

23.4

23.6

23.8

24.0

-3.0

-2.0

-1.0

0.0

1.0

2.0

3.0

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Flo

w (g

pm

)

De

lta

Tem

p. (

F)

Treated Coil Only Cooling - water delta temp. (°F), flow (gpm)

Treated Water Flow (gpm)

Treated Water dt (°F)


Test 1 – Treated Water Cooling Only (continued)

900

1000

1100

1200

0 5 10 15 20 25 30 35

Air

Flo

w (c

fm)

Treated Only Coil Test - Calculated air flow (cfm)

calculated air flow

150

170

190

210

230

250

0 5 10 15 20 25 30 35

CFM

/ k

W C

oo

led

Treated Only Coil Test - CFM per Net Cooled kW

cfm per kW


4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

CO

P (

kW c

oo

ling

/ kW

ele

ctri

cal)

COP Treated Water Cooling OnlyCOP [kW/kW] = cooling / total electrical (plant + APC unit) needed


.251

.271

.293

.320

.352

.391

.440

.502

.586

.703

.879

Test 2 – Chilled Water Only Cooling

38

39

40

41

42

43

44

45

46

47

48

12

13

14

15

16

17

18

19

20

0 2 4 6 8 10 12 14 16 18 20 22 24

Wat

er

Sup

ply

Te

mp

. (°F

)

The

rmal

Co

oli

ng

(kW

)

Time (hours)

Cooling vs. Water Supply TemperatureChilled Coil Only - Manual Mode, CRAH Fans at Low Speed

Chilled Water Cooling (kW)

Chilled Water Supply Temperature (°F)

midnightnoon

405060708090

0 2 4 6 8 10 12 14 16 18 20 22 24




22

23

24

25

26

27

28

29

30

-3.00

-2.00

-1.00

0.00

1.00

2.00

3.00

4.00

5.00

0 2 4 6 8 10 12 14 16 18 20 22 24

Flo

w (

gp

m)

De

lta

Tem

p. (

F)

Chilled Coil Cooling - water delta temp. (°F), flow (gpm)

Chilled Water dt (°F)

Chilled Water Flow (gpm)


Test 2 – Chilled Water Only Cooling (continued)

1000

1100

1200

1300

1400

0 2 4 6 8 10 12 14 16 18 20 22 24

cfm

Chilled Coil Only Test - Calculated Total CFM

cfm

80

85

90

95

100

0 2 4 6 8 10 12 14 16 18 20 22 24

cfm

/ k

W

Chilled Coil Only Test - CFM / kW Cooled

cfm per kW


4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

0 2 4 6 8 10 12 14 16 18 20 22 24

CO

P (

kW c

oo

ling

/ kW

ele

ctri

cal)

Time (hours)

COP Chilled Water Cooling (manual mode) COP [kW/kW] = cooling / total electrical (plant + APC unit) needed

Chilled Water Cooling Performance (COP)

midnightnoon

.251

.271

.293

.320

.352

.391

.440

.502

.586

.703

.879

Test 3 – Chilled and Treated Cooling Combined (24 hour test, both coils at full water flow rate)

-20-15-10-505101520253035404550556065707580

3456789

1011121314151617181920

0 2 4 6 8 10 12 14 16 18 20 22 24

Wat

er

Sup

ply

Te

mp

. (°F

)

The

rmal

Co

oli

ng

(kW

)

Time (hours)

Cooling vs. Water Supply TemperatureTreated and Chilled Water Combined - CRAH Fans at Low Speed

Chilled Water Cooling (kW)

Chilled Water Supply Temperature (°F)

Treated Water Supply Temperature (°F)

Treated Water Cooling (kW)

midnight noon

405060708090

0 2 4 6 8 10 12 14 16 18 20 22 24




22

23

24

25

26

27

28

29

30

-3.00

-2.00

-1.00

0.00

1.00

2.00

3.00

0 2 4 6 8 10 12 14 16 18 20 22 24

Flo

w (

gp

m)

De

lta

Tem

p. (

F)

Both Coils Cooling - water delta temp. (°F), flow (gpm)Chilled Water dt (°F)

Chilled Water Flow (gpm)

Treated Water Flow (gpm)

Treated Water dt (°F)


Test 3 (both coil) continued Energy Use Efficiency – COP and kW/ton

Notes: both coils full flow ( ~ 23-25 each), APC fans at low speed

Time (hours)

10/04/2011 -17:00 10/05/2011 -17:00

1050

1150

1250

1350

1450

0 2 4 6 8 10 12 14 16 18 20 22 24

cfm

Treated and Chilled Coils Used - Total Cfm

cfm

75

80

85

90

95

100

0 2 4 6 8 10 12 14 16 18 20 22 24

cfm

/ k

W

Treated and Chilled Coils Used - Total Cfm / kW Cooled

cfm / kW


4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

0 2 4 6 8 10 12 14 16 18 20 22 24

CO

P (

kW c

oo

ling

/ kW

ele

ctri

cal)

COP Treated , Chilled Water Cooling and CombinationCOP [kW/kW] = cooling (kW) / total electrical (plant + APC unit) needed (kW)


Chilled Water Cooling Performance (COP)

Combined Cooling Performance (COP)

.251

.271

.293

.320

.352

.391

.440

.502

.586

.703

.879

Initial Check Air Flow Using Energy Balance Cubic Feet per Minute


900

1000

1100

1200

0 5 10 15 20 25 30 35

Air

Flo

w (c

fm)

Treated Only Coil Test - Calculated air flow (cfm)

calculated air flow

1000

1100

1200

1300

1400

0 2 4 6 8 10 12 14 16 18 20 22 24

cfm

Chilled Coil Only Test - Calculated Total CFM

cfm

1050

1150

1250

1350

1450

0 2 4 6 8 10 12 14 16 18 20 22 24

cfm

Treated and Chilled Coils Used - Total Cfm

cfm

Test #1

69.1°F

Test #2

50.2°F

Test #3

48.9°F

Ave. Air Temp.

@ Fans

Air CFM = f (net cooling, air delta temp.)

low?

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APC InRow™ Cooler Prototype€¦ · 03/12/2012 · APC InRow™ Cooler Prototype Initial Report...

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