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Waterside Economizing in Data Centers: Design and Control Considerations

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Waterside Economizing in Data Centers: Design and Control Considerations © 2009, American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. (www.ashrae.org). Published in ASHRAE Transactions 2009, vol. 115, part 2. For personal use only. Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE’s prior written permission. LO-09-015 Waterside Economizing in Data Centers: Design and Control Considerations Jeff Stein, PE Member ASHRAE ABSTRACT energy savings from airside economizing are significantly reduced but can still be substantial1. However, if adiabatic Free cooling was not common in data centers in the past humidification (direct evaporation) is used then the savings for a variety of reasons including the philosophy that data can be even greater than airside economizing without center cooling should be designed for maximum reliability and humidification2. Furthermore, more and more data center not for energy efficiency. Recently times have changed. Energy managers are realizing that humidity control has little if any and sustainability are more important to many data center impact on data center operations and therefore more and more owners now and sophisticated owners and designers know that data centers are relaxing or eliminating humidity control. free cooling can provide a good return on investment while still On the other hand, air economizers have some concerns maintaining adequate reliability. Many data centers are being that waterside economizers do not share including introducing designed or retrofitted with airside economizers, waterside unwanted particulates, and gaseous contaminants. Lawrence economizers, and even “wet bulb” economizers (direct evap- Berkeley National Labs recently measured particulate concen- orative coolers). This paper briefly compares airside and trations in several data centers with and without airside econ- waterside economizers, then briefly compares the two types of omizers. They found that with proper filtration particulate waterside economizers (CRAC and chiller plant) and then concentrations in data centers with airside economizers are not focuses on design and control considerations for chiller plant necessarily higher than in data centers without airside econo- waterside economizers serving data centers. mizers and can easily be maintained below the most conser- vative standards3. Recent research projects by Microsoft and AIR VERSUS WATER Intel have also showed that airside economizers do not affect 4,5 An airside economizer will generally be more energy effi- data center reliability . More research is needed but so far cient than a waterside economizer, if space humidity is not there is no research showing that airside economizers compro- required to be tightly controlled. Airside free cooling is imple- mise data center reliability. mented at each air handler and thus the amount of free cooling Air side economizers will generally be more expensive can be maximized at each air handler. The energy savings of than waterside economizers. Furthermore, the deal killer for a chiller plant economizer, on the other hand, can be reduced airside economizers in many installations is the extra space or eliminated for the entire installation by a single “rogue” required for outside air intake and exhaust louvers, dampers zone. Furthermore, waterside economizers (WSE) require and ducts, particularly when the data center is buried at the pump and tower energy and typically three steps of heat trans- bottom of an office building. In many cases the only option for fer (e.g. ambient air to condenser water, to chilled water, to economizing is a waterside economizer. supply air). Airside economizers do not require pump or tower energy or any steps of heat transfer. TYPES OF WATERSIDE ECONOMIZERS If humidity is required to be tightly controlled and humid- There are two basic types of waterside economizers: ification is provided by steam, or infrared humidifiers then the CRAC (computer room air conditioner) unit economizers and Jeff Stein is a principal at Taylor Engineering in Alameda, CA. 192 ©2009 ASHRAE chiller plant economizers. A typical water-side economizer in of return water from the loads and cold supply water from the a CRAC unit is a water-cooled direct expansion CRAC unit common leg [the valve in the common leg is modulated to with a water coil upstream of the DX coil. The water coil can maintain the required minimum flow rate through the be served by chilled water or by condenser water (making it a chiller(s)]. waterside economizer coil). The free cooling provided by the Figure 3 shows a non-integrated waterside economizer waterside economizer coil is largely offset by the added pres- piped in parallel with the chillers on both the condenser and sure drop of the extra coil (e.g. selections from one major chilled water sides. If the economizer cannot meet the entire CRAC manufacturer indicate that the economizer coil load then it must be shut off. Otherwise, the relatively warm increases fan brake horsepower by 40%). economizer leaving water will be mixed with the cold chiller A chiller plant economizer consists of a heat exchanger leaving water and the plant leaving water temperature will be that allows condenser water to cool the chilled water directly. above setpoint. The chillers might be able to compensate by Such an economizer would be used in a data center where the over cooling their leaving water but with chiller(s) operating data floor is served by chilled water computer room air the primary loop flow will likely exceed the secondary flow handlers (CRAHs) rather than DX CRAC units. The CRAH which will result in colder primary return water which will units would only have the pressure drop of one coil, not two. reduce or eliminate the economizer capacity. Non-integrated Perhaps the biggest difference, however, between a CRAC economizers do not save as much energy as integrated econ- unit economizer and a chiller plant economizer is that pack- omizers and there is no real advantage of non-integrated over aged DX CRAC units usually have constant speed fans while integrated. Non-integrated economizers do not meet the econ- chilled water CRAH units can have variable speed drives omizer requirement in California Title 24 or in ASHRAE (VSDs) on the supply fans. Fan energy accounts for about half 90.1-2007 for some climate zones. of data center cooling energy and properly controlled VSD CRAH fans can dramatically reduce fan energy. The rest of HEAD PRESSURE CONTROL this paper is devoted to plant economizers. A critical feature of a chilled water plant with a waterside INTEGRATED VERSUS NON-INTEGRATED economizer is head pressure control on all chillers, air condi- A chiller plant waterside economizer can be integrated, tioners and heat pumps served by the condenser water. To gain meaning the economizer can meet all or some of the load while benefit from the economizer the cooling towers must produce the chiller meets the rest of the load, or non-integrated, mean- very cold condenser water but if the condenser water leaving ing the economizer can only operate when it can meet the a chiller is too low then the chiller could trip on low head pres- entire load. Figure 1 shows an integrated waterside econo- sure. Most chillers require a minimum head pressure (the pres- mizer in a primary/secondary chiller plant with two chillers. sure differential between the condenser and the evaporator) in The heat exchanger is in parallel with the chillers on the order to insure adequate refrigerant flow and adequate oil flow condenser water side and in series with the chillers on the to lubricate the compressor and provide the seal between the chilled water return side. rotor or impeller and its housing. Without head pressure When the outdoor air wet-bulb temperature is low, the control most chillers cannot operate with entering condenser cooling tower fans are run at high speed to produce cold water below about 70°F during normal operation or below condenser water (e.g. in the 40’s or 50’s). This water is about 55°F at start up. pumped through the heat exchanger where it cools chilled Adequate head pressure can be maintained by modulating water to within a couple degrees of the tower water tempera- the condenser water flow to maintain the head pressure at or ture. If the economizer cannot bring the chilled water temper- above minimum head pressure setpoint. Most chiller control- ature down to the supply temperature setpoint then the lers have an analog output signal that allow the chiller to chiller(s) pick up the remaining load and bring the water leav- directly control a modulating condenser water valve or ing the plant down to setpoint. condenser water pump in order to maintain adequate head The HX is located in the secondary loop on the return side pressure for that chiller. If the chiller does not have a head pres- just before the common leg. Locating the HX in the secondary sure control output, a stand alone controller can easily be loop, rather than the primary loop is important because it added to measure head pressure (or leaving condenser water allows the heat exchanger to see the warmest possible water temperature) and modulate the condenser water valve. As with which maximizes the hours when the economizer can operate. all control loops, the PID loop modulating the valve/pump The secondary loop is also better than the primary loop must be tuned to avoid hunting. because it allows the primary pumps to be shut off when the Some chillers are specifically designed to handle cold economizer can handle the entire load. entering condenser water (e.g. 55°F during normal operation Figure 2 shows an integrated economizer in a primary- and 40°F during start up) but even these chillers should have only chiller plant. The HX is located on the load side of the head pressure control to allow the economizer to maximize common leg so that it sees the warmest return water.
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