Our team provided design services to upgrade power and cooling capabilities at a confidential client’s computing facility. Over 40 megawatts (MW) of additional power and enhanced cooling were needed to support current and future supercomputers that will be implemented in two phases.
Engineering modifications were developed for civil, structural, architectural, mechanical and electrical systems. Design includes the addition of an electrical substation, cooling tower, heat exchangers, pumps, air handler modifications, overhead utilities and underground utilities. The new electrical substation consists of 40/50/60-MW transformers and will step the voltage of 115-kV down to 13.8-kV. The addition of this substation will increase the facility power supply from 45 MW to 85 MW.
ASHRAE’s W3 grade water was used to provide direct cooling using 86 degree Fahrenheit process water. Six modules of cooling towers, pumps and heat exchangers are used to provide the heat rejection requirements. One module is redundant. A new six-cell, 28,000 gallons per minute (GPM) cooling tower was placed in an existing surface parking area. The cooling tower is mounted over a concrete basin and uses vertical turbine pumps for circulating the tower water.
Two water loops were provided — one open loop for the cooling towers and one closed loop for the process water separated from each other via plate heat exchangers. The process water loop was all stainless steel and was a mix of below ground piping and above ground piping. Below ground piping was direct buried and the above ground piping is located on a structural steel trellis.
A best value analysis and an hourly energy analysis was conducted to evaluate the most viable option of 12 heat rejection configurations including packaged cooling towers, field erected cooling towers and fluid coolers. Ultimately, a factory-fabricated and field-assembled counterflow cooling tower was recommended due to its superior life cycle cost value.