This invention relates generally to the field of cooling systems and, more particularly, to a system and method for cooling a server-based data center with sub-ambient cooling.
A variety of different types of structures can generate heat or thermal energy in operation. To prevent such structures from over heating, a variety of different types of cooling systems may be utilized to dissipate the thermal energy, including air conditioning systems.
According to one embodiment of the invention, a cooling system for heat-generating structures comprises a plurality of heat exchangers, a structure which directs flow of the fluid coolant substantially in the form of a liquid to each of the plurality of heat exchangers, and a structure which reduces a pressure of the fluid coolant to a pressure at which the fluid coolant has a boiling temperature less than a temperature of the heat-generating structures. Each of the plurality of heat exchangers is in thermal communication with at least one of the heat-generating structures and has an inlet and an outlet. Thermal energy from the heat-generating structure causes the fluid coolant substantially in the form of a liquid to boil and vaporize in each of the plurality of heat exchangers so that the fluid coolant absorbs thermal energy from the heat-generating structure as the fluid coolant changes state.
Certain embodiments of the invention may provide numerous technical advantages. For example, a technical advantage of one embodiment may include the capability to enhance cooling capability for data centers at a reduced energy consumption. Other technical advantages of other embodiments may include the capability to minimize a need for conditioned air in a cooling system. Still yet other technical advantages of other embodiments may include the capability to minimize potential impact on a server upon a leak occurring the in the cooling system.
Although specific advantages have been enumerated above, various embodiments may include all, some, or none of the enumerated advantages. Additionally, other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following figures and description.
For a more complete understanding of example embodiments of the present invention and its advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
It should be understood at the outset that although example embodiments of the present invention are illustrated below, the present invention may be implemented using any number of techniques, whether currently known or in existence. The present invention should in no way be limited to the example embodiments, drawings, and techniques illustrated below, including the embodiments and implementation illustrated and described herein. Additionally, the drawings are not necessarily drawn to scale.
Conventional server based data centers are usually cooled with refrigerated air. The American Society of Heating Refrigerating and Air-conditioning Engineers (ASHRAE) has suggested organizing server cabinets in rows with cool conditioned-air in the spaces between every second row. The cool air is drawn through the front of the cabinets to cool the interior electronics and then blown out the back and toward the ceiling where it is exhausted. Further, ASHRAE papers have suggested the use of heat pipes to concentrate the heat and loop-thermosyphons to take the heat to the top of individual cabinets. The heat or thermal energy is then removed from the top of the individual cabinet by the cool conditioned-air.
Difficulties can arise with such configurations. For a modern data center, which could be on the order of 40,000 square feet (having, for example, 1,300 server cabinets), the cooling needs could be on the order of 1,000 tons (3513 kW) of refrigeration, including the ancillary cooling loads (lighting, fan heat, UPS, etc.). To meet these cooling needs, the refrigerated air cooling system may require two 500 ton chillers with variable speed compressors and forty 30 ton chilled water computer room air-conditioning units. In other words, these systems requires a lot of energy consumption. Accordingly, teachings of some embodiments of the invention recognize a cooling system that efficiently enhances cooling capability for data centers at a reduced energy consumption. Additionally, teachings of some embodiments of the invention recognize a cooling system that minimizes a need for conditioned air. Further, teachings of some embodiments of the invention recognize a configuration that minimizes impact on a server upon a leak occurring in the cooling system.
The cooling system 10 of
The structure 12 may be arranged and designed to conduct heat or thermal energy to the heat exchangers 23, 24. To receive this thermal energy or heat, the heat exchanger 23, 24 may be disposed on an edge of the structure 12 (e.g., as a thermosyphon, heat pipe, or other device) or may extend through portions of the structure 12, for example, through a thermal plane of structure 12. In particular embodiments, the heat exchangers 23, 24 may extend up to the components of the structure 12, directly receiving thermal energy from the components. Although two heat exchangers 23, 24 are shown in the cooling system 10 of
In operation, a fluid coolant flows through each of the heat exchangers 23, 24. As discussed later, this fluid coolant may be a two-phase fluid coolant, which enters inlet conduits 25 of heat exchangers 23, 24 in liquid form. Absorption of heat from the structure 12 causes part or all of the liquid coolant to boil and vaporize such that some or all of the fluid coolant leaves the exit conduits 27 of heat exchangers 23, 24 in a vapor phase. To facilitate such absorption or transfer of thermal energy, the heat exchangers 23, 24 may be lined with pin fins or other similar devices which, among other things, increase surface contact between the fluid coolant and walls of the heat exchangers 23, 24. Additionally, in particular embodiments, the fluid coolant may be forced or sprayed into the heat exchangers 23, 24 to ensure fluid contact between the fluid coolant and the walls of the heat exchangers 23, 24.
The fluid coolant departs the exit conduits 27 and flows through the vapor line 61, the condenser heat exchanger 41, the expansion reservoir 42, a pump 46, the liquid line 71, and a respective one of two orifices 47 and 48, in order to again to reach the inlet conduits 25 of the heat exchanger 23, 24. The pump 46 may cause the fluid coolant to circulate around the loop shown in
The orifices 47 and 48 in particular embodiments may facilitate proper partitioning of the fluid coolant among the respective heat exchanger 23, 24 , and may also help to create a large pressure drop between the output of the pump 46 and the heat exchanger 23, 24 in which the fluid coolant vaporizes. The orifices 47 and 48 may have the same size, or may have different sizes in order to partition the coolant in a proportional manner which facilitates a desired cooling profile.
A flow 56 of fluid (either gas or liquid) may be forced to flow through the condenser heat exchanger 41, for example by a fan (not shown) or other suitable device. In particular embodiments, the flow 56 of fluid may be ambient fluid. The condenser heat exchanger 41 transfers heat from the fluid coolant to the flow 56 of ambient fluid, thereby causing any portion of the fluid coolant which is in the vapor phase to condense back into a liquid phase. In particular embodiments, a liquid bypass 49 may be provided for liquid fluid coolant that either may have exited the heat exchangers 23, 24 or that may have condensed from vapor fluid coolant during travel to the condenser heat exchanger 41. In particular embodiments, the condenser heat exchanger 41 may be a cooling tower.
The liquid fluid coolant exiting the condenser heat exchanger 41 may be supplied to the expansion reservoir 42. Since fluids typically take up more volume in their vapor phase than in their liquid phase, the expansion reservoir 42 may be provided in order to take up the volume of liquid fluid coolant that is displaced when some or all of the coolant in the system changes from its liquid phase to its vapor phase. The amount of the fluid coolant which is in its vapor phase can vary over time, due in part to the fact that the amount of heat or thermal energy being produced by the structure 12 will vary over time, as the structure 12 system operates in various operational modes.
Turning now in more detail to the fluid coolant, one highly efficient technique for removing heat from a surface is to boil and vaporize a liquid which is in contact with a surface. As the liquid vaporizes in this process, it inherently absorbs heat to effectuate such vaporization. The amount of heat that can be absorbed per unit volume of a liquid is commonly known as the latent heat of vaporization of the liquid. The higher the latent heat of vaporization, the larger the amount of heat that can be absorbed per unit volume of liquid being vaporized.
The fluid coolant used in the embodiment of
Water boils at a temperature of approximately 100° C. at an atmospheric pressure of 14.7 pounds per square inch absolute (psia). In particular embodiments, the fluid coolant's boiling temperature may be reduced to between 55-65° C. by subjecting the fluid coolant to a subambient pressure of about 2-3 psia. Thus, in the cooling system 10 of
In particular embodiments, the fluid coolant flowing from the pump 46 to the orifices 47 and 48 through liquid line 71 may have a temperature of approximately 55° C. to 65° C. and a pressure of approximately 12 psia as referenced above. After passing through the orifices 47 and 48, the fluid coolant may still have a temperature of approximately 55° C. to 65° C., but may also have a lower pressure in the range about 2 psia to 3 psia. Due to this reduced pressure, some or all of the fluid coolant will boil or vaporize as it passes through and absorbs heat from the heat exchanger 23 and 24.
After exiting the exits ports 27 of the heat exchanger 23, 24, the subambient coolant vapor travels through the vapor line 61 to the condenser heat exchanger 41 where heat or thermal energy can be transferred from the subambient fluid coolant to the flow 56 of fluid. The flow 56 of fluid in particular embodiments may have a temperature of less than 50° C. In other embodiments, the flow 56 may have a temperature of less than 40° C. As heat is removed from the fluid coolant, any portion of the fluid which is in its vapor phase will condense such that substantially all of the fluid coolant will be in liquid form when it exits the condenser heat exchanger 41. At this point, the fluid coolant may have a temperature of approximately 55° C. to 65° C. and a subambient pressure of approximately 2 psia to 3 psia. The fluid coolant may then flow to pump 46, which in particular embodiments 46 may increase the pressure of the fluid coolant to a value in the range of approximately 12 psia, as mentioned earlier. Prior to the pump 46, there may be a fluid connection to an expansion reservoir 42 which, when used in conjunction with the pressure controller 51, can control the pressure within the cooling loop.
It will be noted that the embodiment of
With reference to
Although one example of an air removal system 190 has been shown with reference to
In
In operation, components of the each of servers or structures 312 may generate thermal energy, which is dissipated to the heat exchanger 312. Each of the heat exchangers 323 of the servers or structures 312 may interact with a common liquid line 371 and a common vapor line 361. Each of the heat exchangers 323 receives fluid in a substantially liquid state through the liquid line 371 and vaporizes the fluid in the heat exchanger 323. The fluid exits the heat exchanger 323 in a substantially vapor state to the vapor line 361.
As briefly referenced above in
In particular embodiments, the servers or structures 312 may be located inside a building while the condenser heat exchanger 341 and/or pump 346 may be located outside of a building.
One or more electronic chassis 462 may respectively be plugged into the liquid manifold line 482 and the vapor manifold line 484 to obtain cooling functionality for the electronic chassis 462. The chassis 462 may have a heat exchanger 423 in its wall, which contains an inlet port 425 (e.g., for substantial liquid fluid coolant) and an exit port 427 (e.g., for substantially vapor fluid coolant) . The inlet port 425 may fluidly couple to the liquid manifold line 482 and the exit port 427 may fluidly couple to the vapor manifold line 484 using a variety of fluid coupling techniques, including but not limited to techniques which utilize seals, O-rings, and other devices.
Although the chassis 462 has been described as fluidly coupling to the liquid manifold line 482 and the vapor manifold line 484 in the structure 412 in this embodiment, in other embodiments, the structure 412 may provide a series of coolant channels or heat exchangers plumbed into the walls of the rack 412, for example, in a manner similar to that described with reference to
Although the present invention has been described with several embodiments, a myriad of changes, variations, alterations, transformations, and modifications may be suggested to one skilled in the art, and it is intended that the present invention encompass such changes, variations, alterations, transformation, and modifications as they fall within the scope of the appended claims.