Applied Energy: Mateusz Borkowski, Adam Krzysztof Piłat
Applied Energy: Mateusz Borkowski, Adam Krzysztof Piłat
Applied Energy
journal homepage: www.elsevier.com/locate/apenergy
Keywords: This elaboration presents the configuration of the cooling system of the POLCOM Data Center which utilizes
Data center commercially available components, proposes steering strategy and analyzes their functionality. The designed
Chiller architecture of cooling and dedicated control system is presented to demonstrate the novelty and customization
Freecooling
with respect to the demanding outdoor temperatures existing in the climate of the Małopolska Province. The
COP
cooling system control and operation is illustrated by a comprehensive analysis of compressor and freecooling
Compressor mode
Experimental data
modes. The discussion on embedded functionality of chillers is undertaken. According to features and
limitations of the complex solution, the cooling system reached the annual average coefficient of performance
of 8.63 in 2015 (increase of 110% compared to the year 2014), operating 65% of the time during the year in
compressor mode and 35% in freecooling mode. This coefficient in compressor mode amounted to 4.39 while
in freecooling mode totaled 16.50. It was proved that in the real case under consideration they generated
losses in electricity consumption amounting to 557MWh per year. The real-time experimental data collected
from the commercial Data Center installation are used to present a unique operation of a such complex system.
∗ Corresponding author.
E-mail addresses: [email protected] (M. Borkowski), [email protected] (A.K. Piłat).
https://doi.org/10.1016/j.apenergy.2021.117975
Received 10 June 2021; Received in revised form 25 September 2021; Accepted 27 September 2021
Available online 20 October 2021
0306-2619/© 2021 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
M. Borkowski and A.K. Piłat Applied Energy 306 (2022) 117975
into account air temperature and humidity criteria (see [26]). Study on
airflow in Data Center [27] found that a significant amount of cooling
energy could be saved by operating the chiller system efficiently. It
could be done when the control system has open architecture. In prac-
tice, the choice of the cooling method means striking a balance between
financial outlays, reliability, energy efficiency and service complexity.
In many cases, it is an individual choice dictated by the specificity of
a given building and even the company’s financial standing. A direct
liquid cooling method [28] can also be used, but its crash has a direct
impact on the server and any repair of the server requires intervention
in the cooling system. An thought-provoking recent literature survey on
data center cooling systems technology, power consumption modeling
and control strategy optimization is presented in [29]. In the literature
there is missing information devoted to detailed analysis of real cooling Fig. 1. Outdoor temperature in 2014.
system composed of different components, and methods to steer their
operating modes with respect to requests and external conditions. It is
due to the protected data of Data Center.
freecooling, with a nominal cooling capacity 2 × 129 kW and 2 reserve
chillers with a nominal cooling capacity 2 × 110 kW, which in total
2. Subject of interest
gives 478 kW) would not ensure coverage, with a continued upward
trend, of the projected demand for cooling (with the required N+1
The POLCOM Data Center building is located in Poland, in Skawina,
redundancy). Based on the analysis of historical outdoor temperature
near Krakow. Its geographical location means that the building is in
data, it was found that there was a sufficiently low outdoor temperature
a transitional climate. This climate is defined as a transition between
throughout the year, for a significant proportion of the time, potentially
sea and continental climate. It is characterized by significant rainfall
conducive to the operation of the chillers in freecooling mode. The
throughout the year, large annual fluctuations in air temperature and
frequent weather changes. This is because dry air masses from the historical data also showed a high fluctuation of outdoor temperature
Eurasian continent and humid air from the Atlantic clash over Poland. (both within one day and throughout the year). The significant fluctu-
As a result, the annual temperature amplitude is about 55 ◦ C, and ations in temperature changes and the limited measurement resolution
the daily amplitude is 25 ◦ C. The minimum temperatures in winter in 2014 (amounting to 30 min) provide uncertainty in knowing the
are around −20 ◦ C, and the maximum temperatures in summer are in dynamics of temperature changes in the future. Nevertheless, the ob-
excess of 35 ◦ C. Such a wide range of outdoor air temperature places served changes in temperature over the course of a day indicate a
high demands on the server room’s cooling system. problem with the control of chillers. On the basis of collected outdoor
The building has six modules with an area of about 300 m2 each, temperatures measurements, unsatisfactory performance of chillers,
which are broken down into six independent modules for IT equipment. limited data recorded in parts at 30 min intervals, and with requested
In line with the assumptions of the server room design, IT equipment in increase of cooling system capacity a decision about new chillers in-
each of the modules can be supplied with electrical power of up to 600 stallation and control system modification was established. Till 2014
kW. Therefore, the total power consumed by IT equipment installed in the cooling system had been at the development phase. The chillers
the server room can reach 3.6 MW. The supply of IT modules is secured working in compressor mode only were used in the cooling stage. It
by redundant UPSs on each supply track. The supply of air conditioning was observed that request for cold was increasing. On the basis of the
cabinets is also maintained by UPS. As standard, the IT modules can recorded temperature measurements, the analysis was conducted and
hold eight cubes built from racks. Each cube consists of 16 racks. In it was noted that the temperature changes throughout the year in a
total, each IT modules can hold 128 racks. non-linear manner, the maximum temperatures occurred in the summer
Separation of hot and cold zones was used. The cold air zone is period and reaching 34.0 ◦ C, the minimum temperatures of about -
under the raised floor and inside the rack cubes. The warm air zone is 16.5 ◦ C were recorded in the winter period. During the 24-h period,
above the raised floor, outside the rack cubes. The Computer Room Air the temperature variation can reach up to 21.7 ◦ C and the average 24-h
Handlers (CRAHs) draw warm air from the top of the server module temperature amplitude reaches 10.1 ◦ C. The outside temperature data
and, after cooling, blow it underneath the raised floor. Chilled water are presented in Fig. 1.
from chillers is transported via a pipe to CRAH in the IT modules. The
During the year 2014, an increase in the demand for cooling capac-
cooling pipe is redundant, i.e. CRAH is supplied by two independent
ity was observed. This trend was approximated using linear regression.
pipes. Each CRAH has two independent heat exchangers.
The cooling capacity demand amounted to 336 kW and 402 kW at the
The cost of operating a cooling system is a decisive factor for the
beginning and the end of the year respectively. Thus, demand increased
profitability of server room operations; therefore, optimizing its oper-
by 20% over the course of the year. Based on this approximation, a
ating parameters is crucial. A competitive advantage could be obtained
further increase in cooling power demand to 469 kW at the end of
by extending the functionality of the components by modifying control
2015 was estimated. Therefore, in order to increase the capacity of the
algorithms or their parameters [30].
The architecture of the cooling system in the POLCOM Data Centre cooling system with redundancy, its modification is required. Further
allows for the installation of various types of chillers in order to meet efficiency gains are possible by changing the components of the cooling
the demand for the supply of cooling regardless of the temperature system and gaining at least partial control over their operation.
conditions outside the building. The following questions are raised and finding the answers should
show the operating conditions of the system and allow making future
2.1. Motivation decisions related to the configuration of cooling systems. What is the
variability of outside temperature at the location of the Data Center?
On the basis of historical data from the year 2014, it was deter- How can the cooling system architecture be modified to achieve better
mined that the demand of the server room for cooling capacity was performance and controllability? How does the COP coefficient evolve
characterized by a constant upward trend. The original configuration throughout the year? How can the freecooling operation time of a
of the chillers (2 units of compressor chillers without the possibility of cooling system be maximized?
2
M. Borkowski and A.K. Piłat Applied Energy 306 (2022) 117975
3
M. Borkowski and A.K. Piłat Applied Energy 306 (2022) 117975
Fig. 4. Chillers cooling power 𝑃 in compressor (CP) and freecooling (FC) modes. On
the courtesy of manufacturer.
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M. Borkowski and A.K. Piłat Applied Energy 306 (2022) 117975
Table 1
is unknown. This is to guarantee reliable operation of the device. Statistical values of the outdoor temperature in individual seasons of the year 2015.
However, this is a serious limitation for the master control system, Season Temperature [𝑜 C]
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M. Borkowski and A.K. Piłat Applied Energy 306 (2022) 117975
Table 2
Statistical values of the outdoor temperature in individual months of the year 2015.
Month Temperature [𝑜 C]
𝑇𝑚𝑖𝑛 𝑇𝑚𝑎𝑥 𝑇̄ 𝜎 variability over
15 minutes
January −13.5 13.8 3.8 3.8 1.1
February −9.1 13.4 4.3 4.3 1.1
March −5.9 19.7 4.8 4.8 1.4
April −2.7 24.3 6.3 6.3 1.4
May 0.5 26.6 4.7 4.7 1.2
June 6.0 33.9 5.5 5.5 1.3
July 6.6 34.8 5.9 5.9 1.2
August 6.0 36.2 6.6 6.6 1.3
September 2.3 35.9 5.4 5.4 1.3
October −2.8 23.3 4.9 4.9 1.1
November −7.4 16.4 4.9 4.9 1.1
December −11.6 14.5 4.3 4.3 1.2
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M. Borkowski and A.K. Piłat Applied Energy 306 (2022) 117975
Table 3
COP profile parameters.
Data 23-Feb-2015 8-Oct-2015
𝐶𝑂𝑃𝑚𝑖𝑛 4.08 3.25
𝐶𝑂𝑃𝑚𝑎𝑥 11.94 13.55
̄
𝐶𝑂𝑃 8.37 5.30
𝜎 2.94 2.59
switching on the second chiller and thus the transition to freecooling Historical data for 2015 do not contain information on the operation
mode took place at a much lower outdoor temperature compared to the mode of the cooling system. This had to be estimated based on the
maximum temperature recorded when the system was in freecooling analysis of data on electric power consumption by each of the chillers.
mode. The average daily power consumption increased from 46 kW to For this purpose, chillers were started in conditions of maximum elec-
97 kW, i.e. by 51 kW (111%). tric power consumption in freecooling mode. The amount of electrical
power consumed was measured. The maximum power consumption of
6.2. Cooling system performance a single chiller in freecooling mode was 30 kW.
Based on historical observations, it was assumed that the minimum
The operation of the Data Center is a dynamic process, due to the
power consumption of a single chiller working in compressor mode was
variable demand for cooling power resulting from updated IT config-
clearly higher than the maximum power consumption of one chiller
uration and the variable load related to the use of individual servers.
working in freecooling mode. Based on this, it was determined that the
Over the course of the year, the amount of IT hardware installed in
power consumption of a single chiller of up to 30 kW meant that it
the server room increased. Thus, the demand for cooling capacity to be
worked in freecooling mode, and above 30 kW — that it worked in
realized by chillers increased. The profile of the change in demand for
compressor mode.
cooling power is shown in Fig. 8. At the beginning of the year 2015,
Fig. 10 shows the operating time of the cooling system in a given
the trend of demand for cooling capacity was 425 kW, and at the end
operating mode in relation to the outdoor temperature. There are two
of the year it reached 562 kW. Thus, demand increased by 63% over
distributions corresponding to compressor and freecooling work. Their
the course of the year. Trend was approximated using linear regression
analytical representation (3) was computed and obtained parameters
(Offset of regression was 425, slope of regression was 1.413 × 10−3 and
are listed in Table 4. Peak values corresponds to temperatures of 0.6 ◦ C
𝑅2 = 0.872).
Based on the 2014 data, it was estimated that at the end of 2015 and 11.0 ◦ C. The freecooling mode is characterized by symmetrical
the cooling capacity demand was going to reach 469 kW. In reality it distribution, while compressor mode asymmetrical one due to asymme-
reached 562 kW, 93 kW more than anticipated. The rate of increase try of outdoor temperature profile for warm days. Both distributions
was higher than expected. overlap. The reason is the hysteresis of switching the cooling system
The cooling system’s demand for cooling capacity is closely related between modes, as well as the increasing demand for cooling capacity
to the amount of IT equipment installed by POLCOM customers and throughout the year. One can find that the knowledge of tempera-
presents the actual dynamics of business processes. ture model can be used for prediction of cooling system operation.
The increase in demand for cooling power has the greatest impact Moreover, the distribution parameters show week dynamics in year to
on the chiller’s COP factor at outdoor temperature range below 10 ◦ C in year outdoor temperature fluctuations, but strong correlation of cooling
freecooling mode (see Fig. 9). The reason is the relatively low efficiency system operating modes to temperature confirm the correct operation
of chillers in freecooling mode. Moreover, the demand for cooling of the cooling system.
capacity increases above the freecooling capacity of a single chiller The actual operating time of the cooling system in freecooling mode
during the year. Therefore, with increased demand for cooling power, amounted to 35% and was 3% less than the hypothetical operating time
it is necessary to run both chillers in freecooling work. assumed. Taking into account the different temperature distribution
The control system does not work properly in this case, as it does not between the years 2014 and 2015, the freecooling operating time was
switch chillers in freecooling mode at favorable temperature conditions. even 6% less than the hypothetical operating time of 41% updated on
With a perfectly working control system, it would be possible for the the basis of the 2015 temperature data.
chillers to work longer in freecooling mode and thus conserve electric- It is important to note that it is the chiller’s internal controller, not
ity. The reason for this is that direct control of the operating mode of the control system that determines whether the chiller is taken out
the chillers is not possible. Based on the tests and analyses carried out, of freecooling mode and switched to compressor mode. Direct control
it is concluded that the custom control algorithm works correctly in of the switching is not possible due to the closed architecture of the
a dynamic outdoor environment. Despite the occurring fluctuations in chiller.
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M. Borkowski and A.K. Piłat Applied Energy 306 (2022) 117975
Fig. 10. Histogram of freecooling/compressor work. Fig. 11. Annual cooling power demand.
Table 4
Gaussian distribution coefficients.
𝑛 𝑇2014 𝑇2015 FC+CP FC CP
4 4 4 2 2
𝑤1 107.676 1947.300 1412.910 2404.520 1292.277
𝜇1 −0.353 0.541 0.851 0.394 8.637
𝜎1 1.586 4.149 2.673 4.219 −4.976
𝑤2 378.253 789.433 2027.480 1300.582
𝜇2 9.453 9.096 8.363 15.149
𝜎2 11.874 4.261 9.850 −9.745
𝑤3 175.608 503.713 696.471
𝜇3 2.427 −22.929 −2.412
𝜎3 1.197 0.521 1.701
𝑤4 16.150 1522.979 448.489
𝜇4 49.999 12.317 20.289
𝜎4 1.628 11.907 10.593 Fig. 12. Annual outdoor temperature.
The reason for the too short, in relation to the expected operation corresponding to the following situations: single chiller operation in
time in freecooling mode, was therefore the lack of possibility to freecooling mode, operation of two chillers in freecooling mode, work
directly control the selection of the cooling mode for the chillers. The in compressor mode. The following data samples were analyzed: electri-
deficiency of the only indirect control available in this configuration, cal power absorbed by chillers, cooling capacity, outdoor temperature
which consists only of sharing the cooling capacity between the chillers, and the chillers’ coefficient of performance (COP).
is apparent. The analyzes carried out later in the paper showed that the Fig. 11 illustrates the efficiency of the cooling system with the
cooling system in freecooling mode is possible at temperatures below separation of the chillers’ operating modes meeting the desired demand
about 7÷11 ◦ C (depending on the system load, compare to Fig. 16). for cooling power (compare with Fig. 8). Operation of one chiller in
freecooling mode was possible until the second half of March. This was
The temperature histogram shows that such temperatures occur more
due to the correlation between low demand for cooling capacity and
often during the year than higher temperatures. The most common
low outdoor temperatures (see Fig. 12). Over time, the demand for
temperatures during the year are temperatures between 0 ◦ C and 2 ◦ C.
cooling capacity increased, which prevented the cooling system from
Therefore, the climatic conditions of the server room are favorable for
working on one chiller in freecooling mode. In the middle of the year
using freecooling as a way of cooling the server room.
(May till the end of September), the cooling system worked mainly in
Should component manufacturers provide full control over the
compressor mode. The increase in demand for cooling capacity was
equipment fitted with such advanced cooling systems? From the man-
relatively small in this period (by 10%, from 400 kW to 440 kW), and
ufacturer’s standpoint, this is obviously risky, but from the point of
there was no significant impact of such a change on the COP value
view of the server room operator, this is desirable. In other words,
(Fig. 14). At the end of the year, when the outdoor temperatures had
the automation system of the device delivered should be equipped
returned to around a few degrees Celsius, it was necessary to work on
with the ability to safely reconfigure parameters through an external both chillers in freecooling mode to ensure the production of cooling
master control system, with an open form of the control algorithm. The capacity at the appropriate level.
chillers are designed as universal devices. However, based on the data
analyzed, it was found that the specifics of the server room’s cooling 6.4.1. Electrical power consumption
system prefer an individual control mode, going beyond the available Fig. 13 shows the total power consumption of the chillers over 2015.
functionality. The analyzes show that the chillers delivered have good The impact of the operating mode on the amount of electrical power
functionality; however, the efficiency of work in the entire cooling consumed is clearly visible. The lowest power consumption is assigned
system could be higher. to the freecooling operation of one chiller.
With reference to the power consumption described in Section 6.3,
6.4. Impact of the change in demand for cooling capacity of chillers on their the power consumption for the two chillers operating in freecooling
operating efficiency — based on the analysis of annual work ranged from 30 kW to 60 kW. The mode with the highest demand for
electric power was the compressor mode, where the power consump-
Apart from outdoor air temperature, the demand for cooling ca- tion reached 250 kW. The compressor mode was also characterized by
pacity is a major factor affecting the operating conditions of chillers. the largest amplitude of changes in electric power consumption (190
To illustrate this relationship (see Figs. 11÷15), an appropriate data kW), where it was 10 kW in freecooling mode on one chiller, and 20
analysis was made. It involved the separation of measuring points kW on both chillers.
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M. Borkowski and A.K. Piłat Applied Energy 306 (2022) 117975
Table 5
Cooling system work time in individual operating modes.
Operating mode Working time COP
[days] [%] mean [%]
Compressor 236 65 4.39 100%
Freecooling
single chiller 69 19 17.69 403%
Freecooling
both chillers 60 16 15.09 344%
Fig. 14). This is due to the fact that the chiller consumes part of its
electrical power for ‘‘idle’’ work not directly related to the production of
cooling energy. Mainly it involves pumping glycol through circulation 6.5. Remarks on control
pumps. Regardless of what load the chiller works with, the circulation
pumps must be started and consume the same amount of electrical In order to estimate the maximum achievable working time in
freecooling mode at the temperature conditions observed in 2015, the
power. In the tested chiller, this was about 20 kW. The element that
maximum outdoor temperature was established, at which freecooling
regulates its efficiency in freecooling mode are fans, which consume
mode work took place on each day of the year in which the system went
up to 10 kW of electrical power, i.e. only 33% of the maximum total
into compressor mode (see Fig. 16). Trend was approximated using
power consumed by a chiller working in freecooling mode. Hence, by linear regression (offset of regression was 12.7, slope of regression was
increasing the chillers’ load with thermal power, the power consump- −12.621 × 10−3 and 𝑅2 = 0.638). Based on the analysis of maximum
tion of the fans is only increased. Therefore, increasing the load on the temperatures, it was assumed that the maximum outdoor temperature
chiller in freecooling mode causes a simultaneous increase in its COP at which it is possible to work in freecooling mode is determined by
(the effect of the outdoor temperature should be ignored here). a straight line connecting points at 12.7 ◦ C at the beginning of the
It was also observed that the system achieved the highest effi- year and 8.3 ◦ C on the last day of the year. Many of the maximum
ciency with one chiller working. The reason was that only the circu- temperatures significantly deviate from the values resulting from the
lation pumps in one chiller worked. The pumps of the second chiller designated straight line. Values below the straight line represent losses
were turned off and therefore did not increase the electric power during freecooling operation caused by the cooling system leaving
the freecooling mode when the outdoor temperature is too low. The
consumption.
decrease in the maximum temperature at which the cooling system
Fig. 15 illustrates the scope of the cooling system’s work in in- worked in freecooling mode results from the increase in demand for
dividual modes of operation in relation to the outdoor temperature cooling power (which is presented in Fig. 8).
and the demand for cooling power. The increase in the demand for Starts during freecooling operation translated into losses associated
cooling power causes a decrease in the maximum outdoor temperatures with increased electricity consumption. The average power consump-
at which the cooling system works in freecooling mode. It also limits tion for freecooling operation (single and both units), for the outdoor
the possibility of working on a single chiller in freecooling mode. temperature ranged from 3 ◦ C to 12 ◦ C (temperature range for which
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M. Borkowski and A.K. Piłat Applied Energy 306 (2022) 117975
7. Conclusions
CRediT authorship contribution statement
The POLCOM cooling system was upgraded by the installation of
chillers allowing operation in freecooling and compressor modes. The Mateusz Borkowski: Conceptualization, Methodology, Software,
custom control system designed and implemented to operate in real Validation, Formal analysis, Investigation, Resources, Data curation,
conditions met the design assumptions and correctly controlled the Writing – original draft, Writing – review & editing, Visualization,
operation of chillers. The cooling system, due to the location of the Data Funding acquisition. Adam Krzysztof Piłat: Conceptualization,
Center in specific climatic conditions, required effective operation with Methodology, Formal analysis, Resources, Data curation, Writing –
annual amplitudes of the outdoor temperature about 50 ◦ C and weekly original draft, Writing – review & editing, Visualization.
10
M. Borkowski and A.K. Piłat Applied Energy 306 (2022) 117975
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and Trustworthy Computing. 2008. p. 312–3.
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