Essential liquid cooling test for data centre

The demand for AI, and increased data centre capacity requirements has meant that traditional air-cooled server racked data centre’s  are being superseded by Liquid Cooled Server racks. This new technology allows more server capacity within a similar footprint.  However, testing these systems to replicate the Coolant Distribution Units (CDU), and / or the server racks has caused much debate within the industry. Something that Aggreko has recognised and designed a solution for to support this evolving market.

Recognising the potential risks and to assess the effectiveness of their cooling infrastructure, our client asked us to conduct a series of liquid heat-load tests under real-world conditions, testing the hot loop cooling of their installation over a 12-week period. This rigorous testing process was essential in validating the system’s performance and ensuring that the installed infrastructure was operating to full capacity.

We understand the importance of testing in the life cycle process and our team acted quickly to identify a solution. First carrying out multiple site visits and then agreeing a 12-week meeting schedule to coordinate the different trades on-site.

To simulate the heat load produced in the server rooms rack bays, we installed six electric 600 kW clean and certified boilers, expansion vessels, hoses and cables. The boilers were installed strategically in the data centres’ primary cooling loop and heated to 43 C as instructed, stress testing the chillers circuit, whilst also replicating the conditions the installed CDUs would endure in normal data centre operations.

With the cooling units located on the roof and the boilers installed at ground level, the ability to remotely control key parameters such as temperature, pressure, deltaT setpoints, and power output via analog signals was critical. This approach allowed the client to operate and adjust the system seamlessly across the 5 floors.

The client specifically sought our expertise due to a similar project we delivered in London in 2021. Our in-house engineering team collaborated closely with the client’s team to adapt power requirements and deliver a tailored solution, including custom wiring and installation diagrams, PID Proportional Integral Derivative (PID) control schemes, and other technical documentation. We also designed the solution to replicate the loss of the CDU which means we tested the pressure that could be delivered by the CDU.

Thanks to their modular design, the boilers were easily manoeuvered into place fitting seamlessly within the data hall.

Our rigorous testing procedures provided the client with the assurance that the cooling system could reliably maintain optimal thermal conditions for server equipment, prior to the data hall being populated with servers.

The tests were a success and can be used in lots of ways:

• Testing new chillers on-site before a data centre goes live to ensure that cooling systems are fully operational and reliable from day one.
• Testing refurbished chillers before going live to reduce the risk of operational failures and extend the lifespan of existing equipment.
• Simulating load for new generation of water-cooled servers, testing downstream of CDU 
  Tests electrical infrastructure supporting UPS and station generators, ensuring they can handle the demands of modern, energy-efficient data centres.
• By offering a comprehensive suite of services, including chiller testing, real-time monitoring, and comprehensive heat simulation, we’re proud to help data centre operators optimise cooling infrastructure with confidence.

The client was pleased with our solution, as it enabled them to fully comply with their stringent specifications, meeting all operational and regulatory requirements without compromise.