HVAC Duct Calculator For Engineers

HVAC System Design
Mark Hydeman, P.E., FASHRAE

Taylor Engineering, LLC
[email protected]
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
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
Cold Aisle
Hot Aisle
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
Cold Aisle
Hot Aisle
10
Aisle capping
LBNL has recently performed
research on aisle capping
Cold Aisle Caps
Cold Aisle
Hot Aisle
11
Overhead (OH) vs. Underfloor (UF)

Issue
Capacity
Balancing
Overhead (OH) Supply

Limited by space and aisle velocity.
Continuous on both outlet and branch.
Control
Up to one pressure zone by branch.
Temperature
Control
First Cost
Energy Cost
Aisle Capping
Most uniform.
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.
Best (if you eliminate the floor).

Best.
Hot or cold aisle possible.
Generally worse.
Worst.
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
16
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.
18
Thermal report
From ASHRAEs Thermal Guidelines for Data Processing Environments

19
Whats the server airflow?

SUN
V490
SUN
V240
DELL
DELL
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
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
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.
24
San Francisco
40
.020
80
.019
75
.018
.017
35
75
70
WE
TB
Normal Temperature
.016
UL
BT
EM
PE
RA
.015
TU
R
I-P Units
30
16 FEET
65
E-
70
Upper Allowed Humidity Limit
BAROMETRIC PRESSURE: 29.904 in. HG
.014
.013
.012
65
25
Class1;Recommend
45
35
13.0
40
.008
.007
.006
50
%
60
40
25
IR
55
A
RY
%
70
D
LB.
45
15
%
90
%
80
.009
PER
60
50
.010
Design Target
55
20
.011
.FT.
- CU
Negligible time of possible

concern for humidification
60
UME
VOL
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
14.0
San Francisco Climate Data Bins

with Data Center Guideline Zones
Class1;Allow
.005
15%
50%
.004
NEBS;Recommend
40%
35
10
.003
30%
30
.002
20%
10% RELATIV
30
35
HUMIDITY RATIO - POUNDS MOISTURE PER POUND DRY AIR
PSYCHROMETRIC
CHART
40
45
50
Chart by: HANDS DOWN SOFTWARE, www.handsdownsoftware.com
55
Lower Allowed Humidity Limit (20%RH)
E HUMIDITY
60
.001
65
70
75
80
85
90
95
100
DRY BULB TEMPERATURE - F
25
Los Angeles
40
.020
80
75
.019
.018
.017
35
75
70
WE
TB
.016
UL
BT
EM
PE
RA
TU
Normal Temperature
.015
RE
I-P Units
30
105 FEET
65
.014
70
.013
.012
60
40
13.0
35
.006
50
Class1;Allow
.004
NEBS;Recommend
40%
.003
.002
20%
10% RELATIV
35
.005
15%
50%
30%
30
30
.007
IR
45
35
10
Class1;Recommend
%
60
40
.008
A
RY
%
70
25
D
LB.
45
.009
ER
55
%
80
15
%
90
50
.010
Design Target
55
20
.011
P
.FT.
- CU
Only a few hours of possible

65
25
UME
VOL
Weather Hours
396 to 353
352 to 309
308 to 265
264 to 221
220 to 177
176 to 133
132 to 89
88 to 45
44 to 1
60
14.0
Los Angeles Climate Data Bins

PSYCHROMETRIC
CHART
40
45
50
55
E HUMIDITY
60
.001
65
70
75
80
85
90
95
100
26
Sacramento
40
.020
80
.019
75
.018
.017
35
75
70
WE
T
Normal Temperature
.016
BU
LB
TE
MP
ER
AT
.015
UR
I-P Units
30
26 FEET
65
E-
.014
70
.013
.012
65
25
45
35
13.0
40
.008
IR
Class1;Recommend
.007
.006
50
%
60
40
25
A
RY
%
70
D
LB.
45
15
55
%
80
.009
PER
60
%
90
50
.010
Design Target
55
20
.011
.FT.
- CU
Negligible time of possible

60
UME
VOL
Weather Hours
270 to 241
240 to 211
210 to 181
180 to 151
150 to 121
120 to 91
90 to 61
60 to 31
30 to 1
14.0
Sacramento Climate Data Bins

Class1;Allow
.005
15%
50%
.004
NEBS;Recommend
40%
35
10
.003
30%
30
.002
20%
10% RELATIV
30
35
PSYCHROMETRIC
CHART
40
45
50
55

E HUMIDITY
60
.001
65
70
75
80
85
90
95
100
27
Lower humidity limit
Mitigate electrostatic discharge (ESD)
Recommended procedures
Recommended equipment
Grounding wrist straps on racks

Grounded plate for cables
Grounded flooring
Servers rated for ESD resistance
Industry practices
Personnel grounding
Cable grounding
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
28
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
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.
Water-Side Economizers
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!
Both are proven technologies 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
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%)
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

Normalized efficiency metric: cooling
1.60
1.40
kWcooling _ systems
kWservers
~1/4 of the
normalized energy
Normalized energy
1.20
1.00
0.80
0.60
0.40
0.20
Computer Loads
UPS Losses
HVAC
Lighting
Data normalized to computer loads

34
A tale of two designs: results

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

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%
38
Example CRAH Unit Comparison
34% less water flow

13% less fan energy
Excess fan capacity on new units

36% higher cost for units, but
More if you consider the supply air temperature and airflow issues
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?
39
Air cooling issues
Limitations on the data densities served (~200w/sf)
Working conditions
Air delivery limitations

Real estate
Hot aisles are approaching OSHA limits
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

HVAC Duct Calculator For Engineers

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HVAC System Design

Mark Hydeman, P.E., FASHRAE

Taylor Engineering, LLC

How do you effectively fight a fire?

Taylor Engineering, LLC

State of the present: with air

Taylor Engineering, LLC

Air system design overview

Taylor Engineering, LLC

Data center layout

Taylor Engineering, LLC

Data center layout

Taylor Engineering, LLC

Data center layout

Taylor Engineering, LLC

Typical temperature profile with UF supply

Typical temperature profile with OH supply

Elevation at a cold aisle looking at racks

Taylor Engineering, LLC

Hot aisle lid

Taylor Engineering, LLC

Taylor Engineering, LLC

Overhead (OH) vs. Underfloor (UF)

Overhead (OH) Supply

Up to one pressure zone by branch.

Underfloor (UF) Supply

Best (if you eliminate the floor).

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

Least hot spots

V HVAC _ Supply V Servers

Airflow with constant volume systems

Taylor Engineering, LLC

Airflow with variable volume systems

Partial flow condition

Taylor Engineering, LLC

Best energy performance

V HVAC _ Supply V Servers

How Do You Balance Airflow?

Image from TileFlow

Taylor Engineering, LLC

From ASHRAEs Thermal Guidelines for Data Processing Environments

Whats the server airflow?

Taylor Engineering, LLC

Best air delivery practices

Arrange racks in hot aisle/cold aisle configuration

Get thermal report data from IT if possible

Get variable speed or two speed fans on servers if possible

Use overhead supply where possible

Taylor Engineering, LLC

Taylor Engineering, LLC

Air-Side Economizer issues

is doing some research on this