Modular Server Vaulting

One of the things data center operators frequently ask me is how we are able to maintain the integrity of the vault with their cooling system’s needs for coolant lines penetrating the vault.  The answer is the insulated pipe penetration assemblies we install to protect this critical area.  Without the ability to adequately cool the server room equipment the data center will not function properly, and if the server room is not protected everything is lost in a disaster.

One very attactive option for cooling is the LiquiCool® Rear Door Heat Exchanger (RDHx) system offered by Coolcentric.  This type of system utilizes the airflow generated by the server equipment to push the warm air through the radiator-like heat exchangers in the units that replace the rear doors of the server cabinets.  This cools the air before it exits the rack and keeps the temperature in the server room at optimum levels.  Coolcentric’s RDHx system is very energy efficient and reliable because there are no fans or other moving parts on the server cabinets.  A Coolant Distribution Unit monitors the temperatures within the individual racks and increases or decreases the flow of chilled water to each unit as needed to achieve maximum efficiency.  Over time the total cost of ownership of RDHx systems is lower than conventional HVAC systems due to the reduced power consumption.

Coolcentric offers this product with a coolant line manifold that is located inside the vault, so only a single pair of supply and return lines is needed to penetrate the vault structure to connect to the water chiller unit.  This is ideal for maintaining the integrity of Firelock’s Class 125 data vaults.  Of course the coolant penetrations are just one component of the total vault system.  The vault structure, doors, dampers and cable penetrations must all meet the stringent Class 125 rating (the ability to maintain the temperature below 125-degrees F. even if the exterior temperature reaches 2,000-degrees).  As the old saying goes, ” a chain is only as strong as its weakest link.”  The same is true for data center design.  All components must work together to create a functional and safe environment for mission critical data center operations.

Many of the major server equipment manufacturers have recently been marketing the concept of a “data center in a box,” which is a shipping container filled with their IT equipment to create easily transportable data center modules.  This concept does have some advantages over traditional data center facilities, such as mobility, scalability and compact size.  However, these high-density modules are very much at risk of being damaged or destroyed by fire, intrusion or even adverse weather conditions.

To address these threats, Firelock has created the Secure Agile Vault Environment, or SAVE solution.  By using a 40-foot shipping container and installing a Class 125 data vault a much more secure environment is provided for mission critical systems.  The vault ensures that IT equipment will be kept safe even if exposed to the heat of a catastrophic fire.  Physical security is also greatly improved with the double door assembly.  The vestibule area in the front of the container allows the container to be sealed before opening the vault doors, so even the worst weather conditions are not a threat to the valuable servers.  The on-board mechanical room behind the vault contains the HVAC system, so only power and network communications need to be supplied to the SAVE unit.

Firelock has taken a vendor-neutral approach to the mobile data center module concept.  Eight standard server racks are in place and ready for any hardware manufacturer’s equipment.  To cool these racks the Vette LiquiCool Rear Door Heat Exchanger system is utilized.  This efficient and compact cooling system uses the airflow from the server units so no power needs to be supplied to these economical and maintenance-free units.

For more details about the SAVE by Firelock, click here for an illustrated presentation: http://www.youtube.com/watch?v=EFQ9bOuQub4

One of the most difficult aspects of server room design is managing the temperature inside this critical area.  As the density of server racks increases and the heat generated by the IT equipment escalates year over year it is no wonder data center designers must consider their cooling options carefully to maintain optimum server room temperatures.

One option we have found to be an excellent solution in high density data centers is the Vette Corporation line of rear door heat exchangers for server racks.  These systems cool the exhaust air from server cabinets before they enter the airspace within the server room by circulating chilled water through the unit.  Because this design utilizes the airflow from the fans in the server equipment there is no power consumption from the cooling units, resulting in significant operating cost savings.

To protect against ambient heat, especially in hotter climates, the R-33 insulation rating of Firelock vaults is a major advantage in maintaining the correct server room climate.  All cooling system penetrations in Firelock server vaults, such as for coolant lines and ducted air, are specially designed and installed to prevent the heat from a fire from damaging or destroying the most critical area of the data center.  And of course the vault structure and doors are capable of maintaining the temperature below 125-degrees F. for at least two hours (up to four hours in larger server vaults) even if the outside temperature reaches 2,000-degrees.  Heat must be held below this critical threshold to protect the IT equipment and the vital information it holds.  After all, mission critical data centers must be protected from all threats–from within and without.

Everyone knows data centers require the proper environment to maintain full operating capacity.  Without enough cooling to keep IT equipment within their specified operating temperatures the equipment will start to slow down, if not shut down completely.  It is also important to protect mission critical IT infrastructure with a data-rated fireproof vault, but how do you achieve both objectives?

Split HVAC unit inside a Class 125 modular server vault

Firelock protects the entry points for the HVAC service with specifically designed and installed components to allow the cooling capacity server rooms require while maintaining the Class 125 fire protection rating.  To qualify for a Class 125 rating all components of the vault must be able to keep the temperature inside the vault below the 125-degrees F. threshold, even if temperatures outside the server vault reach 2,000-degrees F.  This temperature threshold is critical, because this is the point where data can be lost.

For ducted air climate control systems, a three-stage damper assembly is utilized to keep the heat of a catastrophic fire from migrating into the server vault chamber.  Each of the three damper stages uses ceramic fiber insulation on the damper blades, and is held open by a fusible link that melts when exposed to heat (at around 165-degrees F.) and allows the dampers to close.  This damper assembly is encased in a steel housing that is filled with more ceramic fiber insulation to protect against heat exposure at the duct entry point.  These damper assemblies can be utilized in either under-floor applications or through the roof of the server vault, depending upon the design of the climate control system.  Overhead damper assemblies can also be used to remove hot air from the server room.

If a split HVAC system (such as the popular Liebert units) is used to cool the server room, Firelock installs another fireproof component.  The coolant lines between the heat exchanger outside the vault and the air handler inside the vault are protected by an insulated and heat-reactive barrier.  A steel box filled with ceramic fiber insulation is mounted on the outside face of the vault where the coolant lines penetrate into the vault.  The coolant flows through PVC lines (because metal pipes would conduct heat into the vault) and the outside junction of these lines is encased in a housing filled with intumescent caulking.  This fireproof caulking expands when it is heated to seal the entry point of the coolant lines outside the vault.  This is the same type of technology found in nuclear power plants.

These fireproof components can accommodate almost any data center HVAC system.  The coolant line penetrations and damper assemblies can be located wherever they are needed in the server vault, so the climate control system design is not limited by fireproofing requirements.  For optimum operation and protection of data centers, a Class 125 Firelock modular server vault offers the best of both worlds.