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Design and validation of a free cooling system for data centers

OptiFluides designed, simulated and built its own free cooling system to house its High-Performance Computing (HPC) cluster, which initially numbered 300 CPUs and now boasts almost 2,700.

Context

Computer farms are becoming increasingly widespread. They generate large amounts of heat in very small volumes. As processor technologies evolve, stable chip operating temperatures have risen dramatically.

When we set up our High-Performance Computing (HPC) cluster, we opted for “Free Cooling”, i.e. using filtered outside air to cool the physical infrastructure.

Objective

The principle of “free cooling” relies on the use of outside air to thermoregulate the room housing the IT infrastructure. The outside air, which is cooler than the temperature of the servers, is filtered and then circulated to cool the equipment.

OptiFluides’ objective here was to determine the thermal power to be evacuated, design the air circuit (choice of filters, fans, design of the thermal control PLC), and simulate and validate operation under different weather conditions (summer/winter).

Installation HPC OptiFluides 2015

Simulation and results

This enabled OptiFluides to design a heat removal system based on forced convection of outside air through its HPC cluster. This technology is 5 to 7 times more energy-efficient than a conventional air-conditioning system. The sizing of this heat removal system was validated by an aeraulic study of the premises.

Initially designed for around 300 computing cores, the free cooling system was then progressively modified and improved, so that today, the room accommodates almost 2,700 CPUs, cooled solely by outside air, summer and winter alike.

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To find out more on design and simulation of free-cooling systems (and other cooling solutions)