APC InRow Cooler Prototype Initial Report - Test Setup Verification H. Coles, S. Greenberg Contributing: J. Bean (APC) November 18, 2011 1
Introduction Contents Technology Description/Attributes Installation Analysis Metrics, Methods, Metering, Test Description Results Next Steps Conclusions 2
Project funding Introduction 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 3
APC Unit Description Fans (3 EC type) Air to Water Heat Exchanger (chilled water) Cooled Air Leaving Air to Water Heat Exchanger ( treated water) Air to Water Hex (chilled) Chilled Water Modulating Valve Air to Water Hex (treated) IT Rack IT Rack Hot Aisle IT Rack IT Rack IT Rack IT Rack Treated Water Modulating Valve Chilled Water Connection treated Water Connection Hot Air Entering filter IT Rack IT Rack Cold Aisle IT Rack IT Rack Hot Aisle IT Rack IT Rack 4
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 5
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 6
COP Metric Definition COP [ kw thermal / kw elec. ] = cooling provided / power needed cooling provided (kw) = treated water cooling + chilled water cooling APC Unit Power power needed (kw) = (kw/ton * tons) + (kw/ton * tons) + APC Unit Power APC Unit Power 7
Electrical Power Needed (kw/ton) Plant Model ASHRAE 90.1 Code Minimum Water-Side Economizer Equipped Santa Clara CA Climate Year Average (Taylor Engineering) 0.7 0.6 0.5 0.4 kw/ton vs. Chilled Water Temperature (CWT) distribution pumping included Santa Clara CA Year Average (CHWT) y = 0.0000051561x 3-0.0008596432x 2 + 0.0327788257x + 0.3552353121 0.3 0.2 0.1 0 40 45 50 55 60 65 70 75 80 85 90 Chilled Cooling Water Water Temperature ( F) Taylor Engineering Heavy Use of Chiller Little or No Chiller Use (water side economizer) aka treated 8
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) 9
Synapsense Wireless Air Temperatures Air Temp. Sensors Metering Installed Power and Btu Meters Power Meter Ion Power Meter (APC Unit) Onicon Btu Meter (treated water) Cooling Tower ( treated ) Treated Water Btu Meter Air Temp. Sensors Chilled Water Btu Meter Chilled Cooling Water Onicon Btu Meter (chilled water) Flow Sensor Temperature Sensors Flow Sensor 10
Preliminary Results: Compare Cooling Modes (manual operation, valves 100% open, fans @ slow speed) Energy Rate (kw thermal, kw electrical) COP (kw/kw) 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Chilled Water Chilled Water Cooling Net Cooling APC Power Required COP 0.58 kw/ton Chilled+ Treated Water Treated H2O Cooling Chilled Water Cooling Net Cooling APC Power Required COP 0.46 kw/ton Treated H2O Cooling Treated Water Net Cooling APC Power Required COP 0.28 kw/ton Chilled Water Only Cooling Treated + Chilled Cooling Treated Water Only Cooling 11
Treated Compare Exit Temperature with Similar Inlet Temperature (manual mode) Test #1 69.1 F 90 85 80 75 70 65 Air from Hot Aisle Entering APC Unit ( F) Air to Cold Aisle Leaving APC Unit ( F) Air Entering/Leaving APC InRow Unit 26 28 30 32 34 36 Test #2 50.2 F Chilled 90 80 70 60 50 40 Air from Hot Aisle Entering APC Unit ( F) Air to Cold Aisle Leaving APC Unit ( F) Air Entering/Leaving APC InRow Unit Test #3 48.9 F Treated and Chilled 90 80 70 60 50 40 Air from Hot Aisle Entering APC Unit ( F) Air to Cold Aisle Leaving APC Unit ( F) Air Entering/Leaving APC InRow Unit SVLG 2011 Data Center Efficiency Summit - LBNL 12
CFM / kw Cooled COP (kw cooling / kw electrical) Performance (kw elec / ton ) Treated Water Cooling Metering Test 14.0 13.0 12.0 11.0 10.0 9.0 8.0 7.0 6.0 5.0 4.0 COP Treated Water Cooling Only COP [kw/kw] = cooling / total electrical (plant + APC unit) needed Treated Water Cooling Performance (COP) 26 28 30 32 34 36 0.250 0.310 0.370 0.430 0.490 0.550 0.610 0.670 0.730 0.790 0.850 250 Treated Only Coil Test - CFM per Net Cooled kw 230 210 cfm per kw 190 170 150 0 5 10 15 20 25 30 35 SVLG 2011 Data Center Efficiency Summit - LBNL 13
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 14
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 15
End Questions? 16
Appendix 17
Flow (gpm) Delta Temp. (F) Thermal Cooling (kw) Water Supply Temp. ( F) Test 1 Treated Water Only Cooling 14.0 13.0 12.0 11.0 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 Cooling vs. Water Supply Temperature Treated Water- Manual Control, APC Fans at Low Speed Treated Water Supply Temperature ( F) Treated Water Cooling (kw) midnight noon midnight 26 28 30 32 34 36 Time (hours) noon 74 72 70 68 66 64 62 60 58 56 54 52 50 90 85 80 75 70 65 Air from Hot Aisle Entering APC Unit ( F) Air to Cold Aisle Leaving APC Unit ( F) Air Entering/Leaving APC InRow Unit 26 28 30 32 34 36 3.0 2.0 1.0 0.0-1.0-2.0-3.0 Treated Water dt ( F) Treated Water Flow (gpm) Treated Coil Only Cooling - water delta temp. ( F), flow (gpm) 26 28 30 32 34 36 24.0 23.8 23.6 23.4 23.2 23.0 22.8 22.6 22.4 22.2 22.0 18
CFM / kw Cooled Air Flow (cfm) COP (kw cooling / kw electrical) Test 1 Treated Water Cooling Only (continued) 14.0 COP Treated Water Cooling Only COP [kw/kw] = cooling / total electrical (plant + APC unit) needed.251 13.0 12.0.271.293 11.0 10.0 9.0 8.0 7.0 6.0 5.0 Treated Water Cooling Performance (COP).320.352.391.440.502.586.703 4.0 1200.879 26 28 30 32 34 36 Treated Only Coil Test - Calculated air flow (cfm) 1100 1000 900 250 230 210 calculated air flow 0 5 10 15 20 25 30 35 cfm per kw Treated Only Coil Test - CFM per Net Cooled kw 190 170 150 0 5 10 15 20 25 30 35 19
Delta Temp. (F) Thermal Cooling (kw) Test 2 Chilled Water Only Cooling Flow (gpm) Water Supply Temp. ( F) 20 Cooling vs. Water Supply Temperature Chilled Coil Only - Manual Mode, CRAH Fans at Low Speed 48 19 18 17 Chilled Water Supply Temperature ( F) 47 46 45 44 16 15 14 13 Chilled Water Cooling (kw) 43 42 41 40 39 12 38 noon Time (hours) midnight 90 80 70 60 50 40 Air from Hot Aisle Entering APC Unit ( F) Air to Cold Aisle Leaving APC Unit ( F) Air Entering/Leaving APC InRow Unit 5.00 4.00 3.00 2.00 1.00 0.00-1.00-2.00-3.00 Chilled Coil Cooling - water delta temp. ( F), flow (gpm) 30 29 28 Chilled Water dt ( F) 27 26 25 24 Chilled Water Flow (gpm) 23 22 20
cfm / kw cfm COP (kw cooling / kw electrical) Test 2 Chilled Water Only Cooling (continued) 14.0 13.0 12.0 11.0 10.0 9.0 8.0 7.0 6.0 COP Chilled Water Cooling (manual mode) COP [kw/kw] = cooling / total electrical (plant + APC unit) needed Chilled Water Cooling Performance (COP).251.271.293.320.352.391.440.502.586 5.0 4.0.703.879 noon Time (hours) midnight 1400 1300 1200 1100 1000 Chilled Coil Only Test - Calculated Total CFM cfm 100 95 90 85 80 Chilled Coil Only Test - CFM / kw Cooled cfm per kw 21
Flow (gpm) Delta Temp. (F) Thermal Cooling (kw) Water Supply Temp. ( F) Test 3 Chilled and Treated Cooling Combined (24 hour test, both coils at full water flow rate) 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 Cooling vs. Water Supply Temperature Treated and Chilled Water Combined - CRAH Fans at Low Speed Treated Water Supply Temperature ( F) Chilled Water Supply Temperature ( F) Chilled Water Cooling (kw) Treated Water Cooling (kw) midnight Time (hours) noon 80 75 70 65 60 55 50 45 40 35 30 25 5 10 15 20 0-5 -10-15 -20 90 80 70 60 50 40 Air from Hot Aisle Entering APC Unit ( F) Air to Cold Aisle Leaving APC Unit ( F) Air Entering/Leaving APC InRow Unit 3.00 2.00 1.00 0.00-1.00-2.00-3.00 Both Coils Cooling - water delta temp. ( F), flow (gpm) Chilled Water dt ( F) 30 29 28 Treated Water dt ( F) 27 Chilled Water Flow (gpm) 26 25 Treated Water Flow (gpm) 24 23 22 22
cfm / kw cfm COP (kw cooling / kw electrical) Energy Use Efficiency COP and kw/ton Test 3 (both coil) continued 14.0 COP Treated, Chilled Water Cooling and Combination COP [kw/kw] = cooling (kw) / total electrical (plant + APC unit) needed (kw).251 13.0.271 12.0 11.0 10.0 9.0 8.0 7.0 6.0 Treated Water Cooling Performance (COP) Combined Cooling Performance (COP).293.320.352.391.440.502.586 5.0 4.0 Chilled Water Cooling Performance (COP).703.879 1450 1350 1250 1150 1050 Treated and Chilled Coils Used - Total Cfm Time (hours) cfm 100 95 90 85 80 75 Treated and Chilled Coils Used - Total Cfm / kw Cooled 10/04/2011-17:00 10/05/2011-17:00 cfm / kw Notes: both coils full flow ( ~ 23-25 each), APC fans at low speed 23
cfm cfm Air Flow (cfm) Ave. Air Temp. @ Fans Test #1 69.1 F Initial Check Air Flow Using Energy Balance 1200 1100 1000 900 low? calculated air flow Cubic Feet per Minute Treated Only Coil Test - Calculated air flow (cfm) 0 5 10 15 20 25 30 35 Test #2 50.2 F 1400 1300 1200 1100 1000 Chilled Coil Only Test - Calculated Total CFM cfm Test #3 48.9 F 1450 1350 1250 1150 1050 Treated and Chilled Coils Used - Total Cfm cfm Air CFM = f (net cooling, air delta temp.) 24