Commissioning the Data Center The Integrated Systems Test

Transcription

1 Cmmissining the Data Center The Integrated Systems Test Michael Rsenberg Senir Engineer Glenmunt Glbal Slutins Optinal: Insert Cmpany Lg

2 Curse Descriptin Overview f the Integrated Systems Test (IST) Testing prtcls perfrmed during the IST. Trend lgs t demnstrate results f testing prtcls ver multiple test days including Electrical/ thermal lad capacitance Equipment staging Simulated mechanical failures Electrical failure scenaris. Case studies t illustrate the value f the IST Ptential facility failures Catastrphic breakdwn f the facility systems

3 Glenmunt Glbal Slutins Current 2012 Beynd GLENMOUNT GLOBAL ENERGY SOLUTIONS ENERGY EXPERTISE ENERGY INTELLIGENCE, MANAGEMENT SYSTEMS ENERGY EFFECTIVENESS SOUTIONS Prgram Develpment Effectiveness Benchmarking Prcurement Analysis Technlgy Assessments Enterprise Energy Management Plant, Site EMS / AMR ADR / DR Systems Metering Systems Central Plant Implementatin Prductin Prcess Imprvement BOP, Utilities Optimizatin Measurement & Verificatin Technlgist Autmatin & Cntrls Specialist Engineering, Expertise Prcurement & Offerings Segment Specific Cnstructin Slutins

4 Critical Systems Testing Funded in 1998 the Cmpany has established itself as ne f the premier missin critical facilities testing cmpanies. Cnducted ver 200 data center and high perfrmance facility cmmissining, retr-cmmissining r energy prjects Specialists in High Perfrmance Building Cntrls Fcused n assuring, maintaining and imprving the reliability f critical facilities. Prvider f NETA, NIST unbiased testing Prvider f Energy efficiency services, cnsulting, cmmissining and design and cnstructin services

5 Cmmissining Prcess fr Data Centers Pre-Cnstructin Activities Design Reviews (drawings and specificatins) Prepare Cmmissining Specificatins Submittal Reviews Prvide quality assurance/ quality cntrl Review cntractr test prcedures Verify functinality f systems and equipment Lp checks/ pint t pint Cntrls sequences Mdes f peratin Failure and safety mdes Alarm verificatin Trend cntrl variables fr stable peratin Assist in slving prblems and reslving issues Manage the Integrated Systems Test (IST)

6 Integrated Systems Testing Prtcl Fully crdinated test ver a 3-4 day perid Mechanical and Electrical testing while under thermal lad Mechanical systems peratin under several mdes f peratin Nrmal peratins Ecnmizer mde Thermal energy (TES) discharge mde Validatin f peratins at N (design) and N + 1 (redundancy mdes) Validatin under nrmal pwer and during emergency pwer cnditins Simulated equipment, system and critical device failures Trending multiple variables t validate prcess, energy and interactins

7 Heat Lad Capacitance Test Validate thermal cnditins f data center under design lad Thermal and electrical capacitance test under multiple lad steps Validate design cnditins. Disable redundant equipment. Set design cnditins In data center set equipment t maintain SLA cnditins Design cnditins in electrical spaces and central plant Validate multiple design related perating mdes, examples Set a fixed design cndenser water setpint Set a reduced cndenser water setpint if reset is a basis f design and cnditins permit Validate peratins under ecnmizer mde f cntrl

8 Central plant lading Heat Lad Capacitance Test Results Validate basis f design Validate peratinal cnditins at each lad step Temperature differential Plant Flw Chilled Water Temperature, F Chilled Water Lad, tns Chilled water flw, GPM Plant GPM ChW Return Temperature ChW Supply Temperature Plant Tnnage Validate staging f central plant Validate system ability t maintain functinal prcesses Ttal plant Plant tnnage Bypass GPM Bypass cntrl Individual chiller staging CH-14P CH-5T CH-6U CH-7R

9 Overhead ducted system Capacitance Test Temperature Prfile Over head air distributin system Damper trque issue Dampers manually frced pen Design f air diffusers was imprper Imprper diffuser placement High Velcity Lw Static Diffusers were re-engineered

10 Under flr system cntrl Capacitance based Test n return Temperature air temperature Prfile Observatins Under flr air distributin system Cntrl set-up resulted in scillatry cntrl f VFDs and valves Uneven cntrl between adjacent CRAH units Oscillatry cntrl f chilled water pumps, bypass valves and chiller surging Slutins CRAH unit teaming Cnvert t discharge air temperature

11 Specialized Testing: Central Plant waterside ecnmizatin verificatin under lad Central plant with 2,000 tn design lad Tested under lad in three mdes f peratin Full mechanical chillers Partial free cling Full free cling Chillers stage prperly during transitins Clcatin temperature remain stable Clcatin temperature Ttal plant lading Heat exchanger lading Chiller lading

12 Specialized Testing: Facility Energy Impact f Ecnmizatin Under Lad 20,000 tns f refrigerant. 2,500 hp cmpressr pwer Air handler fan pwer, 770 hp Direct expansin AHUs Direct ecnmizatin AHUs Test validated perfrmance under Full refrigerant cling Full ecnmizatin Test validated lad and PUE reductins Test validated lad switch

13 Specialized Testing: Temperature distributin Basis f design: 53 F chilled water temperature 60 F discharge air temperature. Maintain sensible cling range. Avid latent cling Avid humidificatin Data lggers placed at multiple lcatins alng the air pathway Cincident relative humidity distributin Cnstant dewpint temperature Validated sensible cling prcess

14 Specialized Testing: Cld aisle test with simulated AHU failures Test t demnstrate lad capacitance f a single cld aisle at varying lad steps 50% design 80% design 100% design 120% design Test t demnstrate t alternate mdes f peratin Wireless aisle sensrs AHU return air sensrs Test t demnstrate capacity during air handler failures.

15 Electrical/ Mechanical Failure Test Mechanical Failures Validate pump failures and alarms thrugh multiple means Validate chiller failures and alarms thrugh multiple means Fail chiller at lcal discnnect Fail chillers at MCC discnnect Fail chillers by discnnecting internal flw switch Fail chillers by verriding islatin valve(s) clsed Additinal failure scenaris Air handlers and CRAH units Cling twers Prcess critical mnitring devices - Static pressure - Chilled water differential - Temperature - Flw Panel/ netwrk cmmunicatins Electrical Failures Full utility pwer failure, transfer t generatr, Pull the Plug MSB Failures (Transfer and Retransfer)

16 Central plant cntrl during electrical failures Simulated lss f utility pwer Retransfer f pwer frm generatr t utility Simulated failure f MSB panels and recvery Validate facility peratins under UPS pwer Verify Clcatin/ data center temperature and humidity cnditins during all events

17 Englewd, CO Data Center Case Study Prject Descriptin Data Center lcated in Englewd, Clrad Husing primary servers serving the internet auctin functins Mechanical systems serving the data flr were cmprised f 30 tn split DX Liebert cmputer rm air cnditining (CRAC) units, with pad munted cndensing units in a secure yard. IST scenari highlights the critical need fr Integrated Systems Testing utilizing lad banks n the data flr t simulate a fully ccupied and peratinal data center prir t ccupancy. Issues & Slutin Functinal tests and subsequent capacitance tests with lad banks revealed that the refrigerant charges in the CRAC units were lw. After additinal refrigerant was added, the tested cling capacity f the CRAC units was well belw the engineers design. Limited the number f servers that this facility culd hst. During the simulated utility lss test under full electrical lad, multiple CRAC unit failures were experienced. Emergency pwer generatrs started, heat plumes nt the cndensers CRAC units failed n high head pressure.

18 Ls Angeles Data Center Case Study Prject Descriptin High prfile data center, with ver 75,000 square feet f cnditined data flr area. Shrtly after cmpleting the prject in mid 2006, the Ls Angeles metr area suffered a significant brwn ut Multiple failures in many f the lcal data centers. Data Center with the IST perfrmed flawlessly, with n interruptin t services experienced. Issues & Slutin Functinal testing revealed many critical flaws which culd have caused this facility t fail had they nt been identified and remediate. During the failure testing under lad it was nted that the chillers wuld shut dwn in a cascading failure causing cmplete lss f cling t the data flr. Building autmatin system was shutting the chillers ff during the restart sequence after the simulated lss f utility pwer test.

19 Questins? Michael Rsenberg Glenmunt Glbal Slutins Mark Warren WSP Flack + Kurtz Mark.Warren@wspfk.cm Jim Shigley Critical Systems Testing JShigley@criticalsystemstesting.cm