Embodiments of the present disclosure relate to data centers and, in particular, to modular, stacked equipment enclosures for use with data centers.
As the need for data centers increases, there is also a need for increasing density in the technical supporting infrastructure (for example, electrical and cooling support equipment) for the data center. That is, an increase in power capacity and cooling capacity for a given space or location can enhance the capabilities of the data center. In addition, the ability to quickly build and deploy such supporting infrastructure is also important, since a reduction in the time to market can have a direct impact on financial success of the data center.
This disclosure provides various modular, stacked equipment enclosures for use with data centers.
In a first embodiment, a system includes a stacked enclosure comprising multiple structural modules arranged in a vertically oriented stack. Each structural module is disposed at a different vertical level, and each structural module has a substantially same footprint. Each structural module is configured to house support equipment for a data center. The system also includes one or more interstitial layers disposed between adjacent structural modules.
In a second embodiment, a system includes multiple stacked enclosures arranged adjacent each other in a row. Each stacked enclosure includes multiple structural modules arranged in a vertically oriented stack. Each structural module is disposed at a different vertical level, and each structural module has a substantially same footprint. Each structural module is configured to house support equipment for a data center. Each stacked enclosure also includes one or more interstitial layers disposed between adjacent structural modules.
Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.
For simplicity and clarity, some features and components are not explicitly shown in every figure, including those illustrated in connection with other figures. It will be understood that all features illustrated in the figures may be employed in any of the embodiments described. Omission of a feature or component from a particular figure is for purposes of simplicity and clarity and is not meant to imply that the feature or component cannot be employed in the embodiments described in connection with that figure. It will be understood that embodiments of this disclosure may include any one, more than one, or all of the features described here. Also, embodiments of this disclosure may additionally or alternatively include other features not listed here.
As discussed above, as the need for data centers increases, there is also a need for increased density in the technical supporting infrastructure (for example, electrical and cooling support equipment) for the data center. That is, an increase in power capacity and cooling capacity for a given space or location can enhance the capabilities of the data center. In addition, the ability to quickly build and deploy such supporting infrastructure is also important, since a reduction in the time to market can have a direct impact on financial success of the data center.
In typical conventional data center implementations, the various components of the supporting infrastructure (e.g., generators, cooling equipment, switch gear, uninterruptible power supplies (UPSs), batteries, fuel storage, and the like) are typically planned and installed on a site-by-site basis dependent on geography, ground conditions, site risks, and available building options. This typically requires extensive per site engineering, approvals, and lengthy on-site build, integration and coordination activities.
Existing systems typically include a ground mounted generator, a ground mounted electrical building, and a chiller system that may also be assembled at or near ground level. This results in a horizontally oriented, non-modular data center system that occupies substantial ground space and is not easily scaled.
Various attempts at reducing site build complexity have been made, including the limited use of modular building and modular subsystem development. Such techniques have generally been limited to ISO shipping container building blocks, limited in vertical deployment capability or size of block, limited in integration, or a combination of these.
To address these and other issues, embodiments of the present disclosure provide modular, stacked equipment enclosures for use with data centers. The disclosed equipment enclosures are multi-level enclosures for data center support equipment arranged in a structural stack that allows for increased density of power and cooling generation and usage. The disclosed equipment enclosures feature a novel volumetric approach to building based on a vertically stacked technical infrastructure that employs a scalable, flexible, structural truss system and standardized architecture. The completed enclosures can encompass electrical generation, power distribution, battery energy storage, cooling and supporting infrastructure. As described in greater detail below, the support equipment can include one or more fuel tanks, power distribution centers (PDCs), generators, and chillers. In some embodiments, each structural stack is comprised of modular elements that can be brought on site in a flat pack configuration and assembled very quickly. Each modular element can adhere to one or more building codes or standards.
The disclosed embodiments provide multiple advantageous benefits over conventional data center equipment installations. For example, the disclosed embodiments can deliver increased capacity for a given site (e.g., twice the capacity or more) as compared to existing installations. Also, the modular design of the disclosed embodiments enables off-site integration and standardization of components (including components supported by multiple supply chain partners, clients, and integrators), and significantly faster installation on-site. In addition, the disclosed embodiments provide an installation that is very scalable in delivery and capacity. As data center needs change, the number of equipment enclosures can be increased or decreased to fit the data center requirements. Each equipment enclosure can be installed on-site systematically, regardless of geography.
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Each interstitial layer 105 comprises a three foot high open section through which piping, cabling, conduits, and the like, can extend. The piping, cabling, conduits, and the like, extend between different ones of the structural modules 101-104 and are configured to carry air, fuel, water, electricity, data, or a combination of these. This enables integration of different technologies and components between structural modules 101-104, as described in greater detail below. Each interstitial layer 105 can also include one or more louvers, vents, and the like, in the side walls to allow wind to pass through the stacked enclosure 100. This reduces lateral wind load on the sides of the stacked enclosure 100, which can be over 40 feet tall in some implementations. While the interstitial layers 105 are described as having a height of three feet, other heights are possible, such as heights between one foot and four feet, or higher.
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Each module 101-105 provides resources and functions to the modules 101-105 above and below. In some embodiments, one or more standards documents sets out various detailed requirements. Each module 101-105 may be provided in whole or in part by authorized third parties.
The stack enclosure 100 includes a pinning system that enables easy vertical assembly of the modules 101-105. For example, vertical pins positioned around the perimeter of the top (or bottom) surface of a module 101-105 can be matched to corresponding holes on the bottom (or top) surface of an adjoining module 101-105. That is, the vertical pins can be inserted into the corresponding holes in order to connect the two adjoining modules 101-105. The fuel storage module 101, which is disposed on the bottom of the stacked enclosure 100, can be installed on caissons or a concrete slab. The caissons or concrete slab can also include pins or holes that align with corresponding holes or pins of the fuel storage module 101. Each module 101-105 can be lifted with a crane and lowered into place, allowing for rapid assembly of the stacked enclosure 100. In some embodiments, certified lifting rigs can be part of the design of the stack enclosure 100.
Each module 101-105 includes piping and wiring components (and any other suitable systems) already in place when the modules 101-105 are delivered to the installation location. Wiring and piping that extend between modules 101-105 are already installed to align with each other. For example, a fuel supply pipe that extends between the fuel storage module 101 and the generator module 103 can include pipe components already installed in the fuel storage module 101, the PDC module 102, the interstitial layers 105, and the generator module 103 when the modules 101-105 are delivered on-site. To make the stacked enclosure 100 operable, it is only necessary to complete trivial wiring and piping couplings between adjacent modules 101-105.
One or more modules 101-105 can be configured with a wall knock-down structure, such that the walls are in a folded down configuration at the time of delivery to the installation location. Once on-site, the walls can be raised, and equipment installed inside. This allows for delivery of the entire frame structure of the stack in smaller transport units.
At least some of the modules 101-105 are constructed with a truss frame, which provides structural support for the entire stacked enclosure 100. The truss frames can be formed with adequate strength such that the entire stacked enclosure 100 can accommodate wind and seismic loads as required by code.
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In some embodiments, the fuel storage module 101 is constructed with openings on one or both ends to allow access to remove or replace the fuel tank 301 from the end of the fuel storage module 101 without disturbing any of the modules 102-105 above the fuel storage module 101. This contrasts with conventional systems in which the fuel tank provides a supportive structure for other parts, and thus is not easily removable.
The fuel storage module 101 also includes other components, including one or more fuel lines 302 connecting the fuel tank 301 with the generator and any other possible components that operate using fuel. The fuel storage module 101 can also include passage spaces through which incoming power cables 303 and outgoing power cables 304 can extend. The incoming power cables 303 can originate at an on-site underground routing location (or another suitable location) and connect the routing location to the PDC module 102. The outgoing power cables 304 can originate in the PDC module 102 and extend to one or more adjacent stacked enclosures 100.
The PDC module 102 provides the PDC space for the data center. In typical data center facilities, PDCs are electrical rooms that house uninterruptible power supply (UPS) modules and batteries. Many PDCs can also include specialized additional cooling systems (e.g., DX cooling, also referred to as split system cooling) that maintain the ambient air temperature inside the room between 77° F. to 104 F, depending on the type of batteries and UPS module installed.
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The PDC module 102 also includes equipment rooms 404 and 405 disposed on either side of the UPS room 402. The equipment rooms 404 and 405 house various equipment that supports the UPS modules, such as medium voltage equipment, UPS battery systems, low-voltage equipment, transformers, generators, input breakers, output breakers, reserve bus connections, and the like. Partition walls 407 and 408 separate the equipment rooms 404 and 405 from the UPS room 402. The equipment rooms 404 and 405 can include vents on the exterior walls (which may be controlled by powered louvers) to allow ambient exterior air ventilation for cooling of the UPS equipment.
The PDC module 102 also includes a raceway system that houses busway, cabling, and/or piping embedded in the floor space of the PDC module 102. In some embodiments, the raceway system is concealed under one or more floor portals that can be opened to allow access to the raceway. In some embodiments, the raceway can occupy approximately five inches of vertical space between the bottom of the PDC module 102 and the interior floor on which the equipment is placed. In some embodiments, the PDC module 102 achieves impedance balancing and matching in the raceway by utilizing busway in lieu of cabling. Busway also provides for flexibility in UPS manufacturers for both current and future installations.
The PDC module 102 also includes features for interconnectivity with other modules 101, 103, 104 of the stacked enclosure 100. For example, the PDC module 102 can include one or more fuel lines 410 that extend vertically from the fuel tank 301 below to the generator module 103 above. The fuel lines 410 can be included in the PDC module 102 during the manufacturing of the PDC module 102, and then connected to the fuel tank 301 and the generator module 103 when the stacked enclosure 100 is assembled on-site.
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The generator module 103 also includes a pump package 504 configured to pump water from the water storage tank 503 up to the chiller module 104. In some embodiments, the pump package 504 can be part of a loop feed for supply and return water that enter into the PDC module 102 and/or other portions of the stacked enclosure 100. The generator module 103 also includes a hot air exhaust plenum 505 that provides an exhaust path for air heated by the generator 501, so as to move the heated air up and away from the rest of the equipment. Ultimately, the heated air is exhausted above the top surface of the stacked enclosure 100, thus reducing noise and thermal impact on neighboring properties.
The generator module 103 also includes multiple air intakes 506 disposed in the floor and/or sides of the generator module 103. In some embodiments, the air intakes 506 are configured as one or more grates in the floor. The air intakes 506 are fluidly coupled to the interstitial layer 105 below the generator module 103, which allows for ambient external air to enter the generator module 103. In operation, the ambient air enters and passes through the interstitial layer 105 (e.g., via one or more louvers, vents, or the like, in the side walls), enters the generator module 103 through the air intakes 506, blows across the generator 501 and the engine 502, and then the heated air is exhausted through the plenum 505 and up to the top of the stack 202 above the height of the chiller module 104. As shown in
The generator module 103 also includes a cabling and piping raceway system encompassing approximately five inches of vertical space below the floor of the generator module 103, similar to the raceway system in the PDC module 102, described above. In some embodiments, the floor also can have a spill containment system around at least the engine 502; the spill containment system is provided to contain any fuel or other fluid that may spill or leak out of the engine 502.
In some embodiments, the generator module 103 can be constructed with openings on one or both ends to allow access to remove or replace components (such as the generator 501) from the end of the generator module 103 without disturbing any of the other modules 101, 102, 104, 105.
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The location of the chiller units 601 on the top surface of the chiller module 104 can depend on whether the stacked enclosure 100 is a single enclosure, an inboard enclosure, or an outboard enclosure. In some data center implementations, only a single stacked enclosure 100 is installed on-site. In other implementations, multiple stacked enclosures 100 are installed side by side. Stacked enclosures on the ends of a multi-stack arrangement are referred to as outboard enclosures, while stacked enclosures in the middle portion (i.e., not on the ends) of the multi-stack arrangement are referred to as inboard enclosures. As shown in
The chiller module 104 also includes a selective catalytic reduction (SCR) unit 602 and a urea tank 603 provided for scrubbing exhaust from the diesel engine 502. During operation, exhaust enters the bottom of the SCR unit 602, is mixed with urea from the tank 603, which removes sulfur dioxide and any other pollutants from the exhaust, and then is exhausted out the top of the SCR unit 602 through the stack 202.
As discussed above, each module 101-105 is constructed with a truss frame, which provides structural support for the entire stacked enclosure 100. The truss frames can be formed with adequate strength such that the entire stacked enclosure 100 can accommodate wind and seismic loads as required by code. In some embodiments, each module 101-105 employs a scalable, flexible, and standardized truss system architecture.
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Each stacked enclosure 100 can include components to support data center loads of various sizes, such as 3 MW, 5 MW, 10 MW, or larger. Each stacked enclosure 100 is self-supporting; that is, in many site installations, there is no need for multiple stacked enclosures 100 adjacent to each other. However, for scalability (such as to achieve hundreds of MW of load capacity), multiple stacked enclosures 100 can be placed together. When multiple stacked enclosures 100 are used, connective wiring and/or piping can be used so that the multiple stacked enclosures 100 can share chilled water, electrical power, air flow, or the like.
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It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The term “couple” and its derivatives refer to any direct or indirect communication between two or more elements, whether or not those elements are in physical contact with one another. The terms “transmit”, “receive”, and “communicate”, as well as derivatives thereof, encompass both direct and indirect communication. The terms “include” and “comprise”, as well as derivatives thereof, mean inclusion without limitation. The term “of” is inclusive, meaning and/or. The phrase “associated with”, as well as derivatives thereof, means to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like. The phrase “such as” when used among terms, means that the latter recited term(s) is(are) example(s) and not limitation(s) of the earlier recited term. The phrase “at least one of” when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one item in the list may be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.
Definitions for other certain words and phrases are provided throughout this patent document. Those of ordinary skill in the art should understand that in many if not most instances, such definitions apply to prior as well as future uses of such defined words and phrases. Although the present disclosure has been described with an exemplary embodiment, various changes and modifications may be suggested to one skilled in the art. It is intended that the present disclosure encompass such changes and modifications as fall within the scope of the appended claims. None of the description in this application should be read as implying that any particular element, step, or function is an essential element that must be included in the claim scope. The scope of the patented subject matter is defined by the claims.
This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/578,118 filed on Aug. 22, 2023, which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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63578118 | Aug 2023 | US |