Cooling Infrastructure Replacement & Expansion for Data Center

Data centers rely on efficient, reliable cooling infrastructure to keep servers and other equipment in top condition, even during power outages. An enterprise facility engaged Trefz to design and install a new cooling system configuration that could support increased IT and printing loads while maintaining cooling reliability and redundancy.

The Scope

The project required a multi-disciplinary pre-design study to analyze the server room needs. The full scope of design, engineering, pre-construction, and construction services was needed to replace the existing cooling infrastructure, expand capacity, and connect the new cooling systems to emergency power. The new cooling system configuration would need to be designed without a new generator due to cost constraints. The project also required a phased construction plan to keep the facility operational throughout construction.

The Process

Trefz conducted a coordinated mechanical, controls, and electrical assessment of the server room. The mechanical engineering team evaluated the cooling system’s capacity, performed an IT load analysis, and reviewed airflow management for the server racks. The team also developed airflow and cooling-load calculations and modeled four conditions to evaluate future capacity scenarios.

The controls engineering team analyzed the operational reliability and integration requirements to ensure the existing BAS could integrate with the proposed cooling equipment. The electrical engineering team conducted an emergency power study to determine how much cooling capacity could realistically be supported during a utility outage.

Based on the combined analyses, Trefz recommended replacing the existing CRAC units, dry coolers, pumps, piping, and controls with larger cooling systems, expanding emergency power support where possible, and integrating the equipment into the BAS. To achieve the highest level of cooling redundancy and operational resilience without replacing the existing generator, Trefz investigated load-shedding strategies and equipment interlocks to maximize available emergency cooling capacity.

The Result

Construction and installation were completed in 2019. The facility remained operational throughout construction and during installation, testing, and commissioning of the new cooling infrastructure.

The upgraded cooling system included four downflow CRAC units for the server room and two downflow CRAC units for the printer room, with one unit in each room serving as standby. Dry coolers and dual pump packages were selected to support the new units.

To support emergency operation, Trefz modified the electrical distribution system and utilized BAS-based load-shedding controls. This opened capacity for two CRAC units to run on emergency power, without requiring a new generator.

Let’s Collaborate

Trefz delivers comprehensive, innovative solutions driven by future-focused engineering and building system expertise. If you have a data center project in the works, our passionate team of problem solvers is ready to help! Contact us to find the best solution for your unique needs.