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VIACOM Data Center Optimization Project

VIACOM Data Center Optimization Project. Executive Briefing May 7, 2010 John Wallerich,. Agenda. Review Project Requirements and Objectives Dell’s Gated Project Methodology ASIS State Assessment TOBE State Analyses APC InRow Cooling Analysis Implementation Cost Estimates.

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VIACOM Data Center Optimization Project

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  1. VIACOMData Center Optimization Project Executive Briefing May 7, 2010 John Wallerich,

  2. Agenda • Review Project Requirements and Objectives • Dell’s Gated Project Methodology • ASIS State Assessment • TOBE State Analyses • APC InRow Cooling Analysis • Implementation Cost Estimates

  3. Project Objectives IMPROVE Cooling Infrastructure Effectiveness Data Center Capacity IT Equipment Temperatures Cost of Operations TOOLS Computation Fluid Dynamics (CFD) 3-D Graphical Software to model airflow and thermal dynamics

  4. Cost Improvement Categories • Improvements to room density and OPEX • Cool load using less cold air volume • Reduce Bypass air • Reduce equipment Inlet air Delta-T • Raise Supply Air Temperatures • Reduce Fan Energy • Reduce DX Compressor loads • Extend useful life of this data center and avoid new build

  5. Services Engagement MethodologyAn Interface to Investment Decision-Making An efficient “gated” engagement approach designed to arrive at solutions with reduced cost and improved efficiency

  6. Glossary of Terms BLANKING PANEL A plastic or metal plate fitted to the front of a rack where no IT equipment is present. BYPASS This refers to the percentage of cold air that is generated by the cooling system, yet for one reason or another never passes through IT equipment. CAC Computer Room Air-Conditioner. This is a generic term that includes all of the cooling devices in the Viacom data center. CFD Computational Fluid Dynamics. This is the technical term for the software tool that we use to model both airflow movement and thermal dynamics for both the under-floor cold air supply plenum, the computer room itself, and if used, the hot air return plenum (above the false ceiling). CFM Cubic Feet per Minute. This is a measurement of air volume. For this study, this term is used to describe the amount of air processed by CACs as well as the volume of air flowing into the computer room through a perforated tile. RETURN AIR This is a term that refers to the air that enters to CAC cooling units to be cooled. HOT AIR RETURN PLENUM This represents an area above the false ceiling when it is used as part of an airflow management system. COLD AIR SUPPLY PLENUM This refers to the area under the raised floor where cold air is injected by the CAC units. The cold air is distributed into the room via perforated tiles.

  7. Solution Options Summary Solution Option #1: Deploy Hot Air Return Plenum Solution Option #2: Install Airflow Management Solution Option #3: Deploy Containment Strategy Special Study: APC In-Row Containment Design

  8. CFD Modeling Computational Fluid Dynamics allows for the analysis of airflow and thermal dynamics with the detail and accuracy required for fine tuning of the data center cooling infrastructure

  9. Under-Floor PRESSURE Dynamics High Pressure LowPressure resulting from high velocity High Pressure Low Pressure resulting from high tile count Low Pressure resulting from high velocity

  10. ASIS: Thermal Slice at 6ft Elevation Exhaust air contamination Exhaust air contamination Exhaust air contamination

  11. ASIS: Max Inlet Temps and CAC % USEDASHRAE Temperature Guidelines

  12. ASIS: Cooling Challenges SAN Room Exhaust air is flowing over tops of racks contaminating surrounding racks. Hot air contamination AS400’s Racks are facing same direction so exhaust air contaminates rows behind it with increasingly warmer air.

  13. ASIS: RETURN AIR STREAMS CACs 3 CACs in center of room are drawing server exhaust from servers that are closer to other CACs

  14. ASIS: AS400 AIRFLOW CONTAMINATION Exhaust air from the front rows is directed at air inlets of rows behind them. This increases the inlet air temp and puts the back rows at risk of over heating.

  15. ASIS: BEST PRACTICES OBSERVED Use of Blanking Panels good Best Practice Use of hot-aisle/cold-aisle allows for enhancements Plumbing and wire trays are well implemented Lack of combustible materials Lead-Acid batteries not on raised floor Site is clean and well maintained Cable cut-outs and floor leakage is minimal

  16. ASIS: Design Weaknesses AS400 racks are not optimized (facing same direction) SAN room suffers from very low UF pressure Room cooling is greater than needed to compensate for weak airflow management design CACs are of 2 different designs for high availability, yet redundancy is no longer an option CACs are aging and lack VFDs and multi-stage compressors Hot server exhaust contaminates server inlets as it flows towards CACs – no airflow controls Room capacity is limited by cooling effectiveness

  17. Solution Option #1: DesignBasic Airflow Control: Return Plenum By connecting the return ducts of CAC units to the area above the false ceiling, and installing return air grills above hot aisles and other heat sources, the area above the false ceiling becomes a hot air return plenum. Hot air is “pulled” from the room and returned to the CAC unit to be re-cooled. This is a foundational requirement to installing more advanced airflow control measures and yields a number of benefits.

  18. Solution Option #1: DesignHot Air Return Plenum CAC ducts connected to false ceiling turns ceiling void into a hot air return plenum CAC Duct Extensions Hot server exhaust air is removed from the room through ceiling grills and directed back to CACs at higher temperatures

  19. Solution Option #1Operational Statistics Description ASIS SO#1 Note: Number of cabinets increased as some new racks were added to establish row symmetry (racks in purple)

  20. Solution Option #1: BenefitsImpact of Enhanced Heat Removal • Hot exhaust air mixing with cool room air is reduced • Return air is warmer: CAC can reject more heat • Reduced contamination of nearby server inlets • Supply air temperature increases from 58F to 64F • Room can sustain increased IT power loads • Can cool using reduced supply air

  21. Solution Option #2: DesignESD Airflow Control Curtains Solution Option #2 introduces Electro-Static Discharge curtains to provide enhanced isolation of hot and cold air, and to direct hot exhaust air into the hot air return plenum. These curtains are located between the tops of racks and the false ceiling and help to isolate hot and cold air masses ESD curtains have been adopted as a low-cost yet highly effective mechanism for simple airflow management.

  22. Solution Option #2: DesignInstall ESD Airflow Control Curtains ESD Curtains Note: false ceiling not shown

  23. Solution Option #2: DesignInstall ESD Airflow Control Curtains ESD curtains prevent hot exhaust air from flowing over the tops of racks into cold aisles where it would contaminate server inlets Ceiling Grill ESD Curtains Hot Aisle

  24. Solution Option #2 DesignESD Curtains and Airflow Management False Ceiling is not shown, but hot air removal and effect on cold aisles is apparent as a result of deployment of ESD curtains

  25. Solution Option #2 BenefitsAmbient temperatures more stable A thermal slice at a 6ft elevation now shows dramatic improvements as a result of ESD airflow control curtains. The result is further improvements in effectiveness of cold supply air and reduction of hot air contamination

  26. Solution Option #2 BenefitsCooling Effectiveness Improved • Improved isolation of hot and cold air • CAC return air is warmer due to reduced mixing • Supply Temperature is increased from 60F to 68F • Rack Delta-T is reduced • Volume of supply air is reduced due to higher effectiveness

  27. Solution Option #2Operational Statistics Description ASIS SO#2

  28. Solution Option #3: DesignContainment Strategy Containment represents the most advanced airflow management system due to the creation of a closed airflow loop. This solution builds on Solution Options 1 and 2, and provides the ultimate solution in terms of achieving the stated project objectives. The concept behind containment is to completely enclose either a hot or cold aisle. Cold aisle containment prevents cold air exiting perforated tiles from going anywhere but through equipment. But the problem then becomes the effect of hot air entering the room. Hot aisle containment encloses the hot aisle and provides a number of major benefits.

  29. Solution Option #3: BenefitsHot Aisle Containment Benefits Creates slight negative pressure in hot aisle which “pulls” air through the air inlets Pressure difference eliminates seeping of hot air through the rack into the air inlets Entire room becomes cold air plenum: the volume of air supplied at a given perforated tile is no longer critical Allows for racks in areas where there is low UF pressure to still get enough air as long as total supply is > total demand. Rack Delta-T is very low allowing for increase in supply temps Consumes 30% less air than Solution Option #1 Supply Temperature raised to 74F

  30. Solution Option #3: DesignContainment Strategies: CAC PROS: Reduces require air volume by 20% Isolation of hot exhaust air Does not require ceiling plenum CONS: Hot air enters room Very little excess cold air capacity Example of a Cold Aisle Containment Strategy. Notice the return air ceiling grills above the hot aisles

  31. Solution Option #3: DesignContainment Strategies: HAC PROS: Reduces require air volume by 30% Isolation of hot exhaust air Pulls air through servers CONS: Requires hot air plenum Creates warm work area Example of a Hot Aisle Containment Strategy.

  32. Solution Option #3: DesignCombined Containment Model Example of a Contained and non-contained areas

  33. Solution Option #3: BenefitContainment Benefits: CAC vs. HAC Cold aisle Containment: Reduces bypass air by enclosing cold air supply Eliminates hot air exhaust contamination Does not require hot air plenum Reduces total supply air by 20% over SO#1 Hot Aisle Containment: Maximizes air bypass reduction Higher degree of airflow control (pull vs. push) Removes all hot air from room Reduces total supply air by 30% over SO#1 Increases rack density Extremely even Delta-T across rack face

  34. Solution Option #3: BenefitIncreased Supply Air Temperature Raising supply temps reduces costs of cooling, and requires less cold air volume. Ambient room temp varies only slightly and is a comfortable 75F. Heat rejection is 96% done by the CAC

  35. Solution Option #3: BenefitStable Equipment Supply Temperatures A combined containment strategy has resulted in a significant increase in supply temperature and reduction of total cold air supply needed. This translates into reduced OPEX while providing a more stable operating environment as well as the ability to increase equipment power loading.

  36. CAC Cluster Creates Low Pressure Zone One factor that is limiting CAC effectiveness is caused by 3 CACs near the middle of the room. These units and their close proximity to each other creates a low pressure zone that pulls exhaust air from Low Pressure Zone CACs

  37. Solution Option #3Operational Statistics Description ASIS SO#3

  38. Special Design Review APC High Density ClusterHot Aisle Containment: sub-optimum APC’s InRow coolers are an efficient solution, but their effectiveness is lost on hot aisle containment APCs leaking warm air 8 APC InRow Coolers with 12-12kW racks Contained area is so hot, the coolers are sending 85F air into the room

  39. Solution Design ReviewAPC High Density ClusterCold Aisle Containment APC units are optimized when in a cold aisle containment design. Total load is 216kW over the hot aisle maximum load of144kW and all equipment is experiencing inlet temps in the mid-70F range. 6 APC InRow Coolers with 12-16kW and 2-12kW racks. All rack inlets are below 78F and hot air is not affecting local racks.

  40. Solution Option Comparative Analysis Description ASIS SO#1 SO#2 SO#3

  41. Cost Basis Metrics and Calculations • 1kW of IT Electrical Load - Annual cost: $6,000 • (space, power, cooling) • Annual OPEX expense per 3kW rack $18,000 • 1F of Set Point increase = 1% energy reduction • (CAC compressor efficiency*) • If VFD’s were deployed, an additional 20% of total CAC energy • reduction would be realized as a result of reductions in fan energy. • Dependency is that Solution Option #3 would be deployed.

  42. Data Center Design Comparative Models DELTA +32 +209kW +209kW -9F (max) CURRENT STATE METRICS Number of Racks 365 Total Cooling Capacity 1213kW Total Cooling Load in Use 947kW Total Connected Power 905kW Server Temperatures 65-95F CONTAINMENT DESIGN UNDER MAX LOAD Number of Racks 397 Total Cooling Capacity 1213kW Total Cooling Load in Use 1156kW Total Connected Power 1114kW Room Temperatures 72-82F

  43. FINANCIAL ANALYSIS – Containment Costs Ceiling Grill Construction Grills (1540 sqft @ $1/sqft) = $ 1,540 Containment Curtains and Doors* = $ 78,000 Additional Racks (12) =$ 18,000 TOTAL $ 97,540 *includes CAC ducts to ceiling plenum Recommended: Replace CAC’s with more efficient units $1,800,000

  44. Containment Cost Reduction Estimates • OPEX Reduction • Reduce cooling costs by 6% annually @ $360/rack • 365 racks X $360 = $131k/yr • Equipment replacement (annual) $20k/yr • Upgraded CAC cooling efficiency gains $48k/yr • TOTAL $199k/yr • CAPEX Reduction • Increase rack power loads by 30% (avoid new racks) $200k • Avoid adding new CACs (3 @ $60k) $180k • Increase cooling system effectiveness (no cooler exp.) $500k • TOTAL $880k OTC • COST AVOIDANCE • New Data Center (20 sqft) Estimated at ~$30m

  45. Recommendations 1. Deploy Solution Option #3: combined containment strategy. This will reduce OPEX while extending the capacity of the existing Cooling infrastructure and data center. 2. Virtualize as much of the environment as possible. This will have a multiplier effect in terms of power reduction (each W of IT power removed equates to 2-3 Watts of electrical and cooling overhead reduction 3. Shorten the server refresh cycle. Consider a 3-year plan. This will provide benefits both in terms of service levels from faster servers, and will also have a multiplier effect in terms of power savings as a result of more power efficient processors.

  46. Additional Recommendations (1) 1. Replace all CACs with more efficient models: VFD fans (10% reduction in speed = 50% reduction in power) Multi-phase compressors (2 or 3 stage compressors) 2. Relocate new CACs for better distribution and coverage VFD’s and Multi-phased compressors will help reduce power Consumption for the cooling infrastructure particularly for data Centers with containment strategies. Containment allows for the same degree of cooling using less volume of air. So, VFD’s, totaling over 80kW today could be cut in half. Multi-phase compressors allow CACs to provide required cooling running in a more power efficient mode (stage 1 vs. stage 2)

  47. CAC SET POINTS and MIN SUPPLY TEMPS

  48. Thank You

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