CellularOne- Arizona

Overall cooling and energy performance in a data center is crucial. Without the proper temperature, systems can overheat and fail, causing major disruptions and the possibility of losing data.

Energy Efficient Technologies installed hundreds of sensors in numerous data centers since 2008 to identify how this industry uses electricity over several years.

Based on this work, our engineering team identified a known issue in every oil lubricated HVAC, computer room air conditioner, chiller and refrigeration system.

This issue causes all of these machines to lose capacity and work harder due to the fouling of heat exchange surfaces – as much as 30% over time.

ECM’s Role

Energy conservation measures (ECM) addressing HVAC were the focus of this project because their function restores the capacity of cooling systems and reduces energy use and carbon footprint. This site was validated using the third generation ECM product- now in its fourth patented generation called CryoGenX4

Restoring the systems to full operating standards would:

  • Restore capacity of the CRAC systems to satisfy fluctuating building loads
  • Produce additional CRAC system redundancy with no interruption to operations, reducing runtime and extending equipment life by 20%+
  • Improve CRAC system efficiency(coefficient of performance), lowering cost to produce each ton of cooling required
  • Restore thermal efficiency, allowing CRAC systems to achieve thermostat set points faster

The ECM was introduced into the system and required no downtime for installation. The technology is composed of highly conductive, polarized electro-magnetic molecules that act quickly to forever displace the insulating layer of non-conductive material inside any HVAC/R system (commonly referred to as oil fouling). This does not change the characteristics of the oil or refrigerant in any system, it’s simply a surface science.

These polarized nano-technology molecules prevent refrigerant oil buildup from ever reoccurring. The result is a metal surface free of efficiency and capacity-robbing stagnant oil. That same oil-free surface is then enhanced with improved heat transfer properties. In addition, CryoGenX4 delivers better lubricity, allowing compressors to run at cooler temperatures by re- circulating refrigerant at a colder rate.

By reducing the negative effects of extreme heat, the HVAC and refrigeration system life is also extended.

The Results are In! Savings of 31.8%

  • When initially tested, the pilot CRAC systems were producing 34.65 tons of cooling. Four weeks after installation, the cooling capacity was restored by 6.77 tons or 19.5% to 41.42 tons.
  • The overall cost to produce each ton of cooling on the pilot systems dropped 31.8% from 1.57 kW/ton in the baseline to 1.07 kW/ton four weeks after installation of the two ECMs. This means that for every ton of cooling the two pilot CRAC systems are asked to produce, CellularOne is spending 31.8% less to do so.
  • The projected annual kWh’s were reduced by 31.8% from 398,634 to 271,682.
  • The conditions inside the data center dropped from 74.85 degrees and 32% humidity to 73.25 degrees and 28% humidity. When properly set up to accommodate the load, this increase in capacity will enable the main CRAC system to begin to cycle which will save even more energy annually.
  • The average kW demand dropped 18.7% from 51.1 in the baseline to 41.52 in the post when comparing multiple hour-long blocks of time under similar outdoor air temperatures affecting the condensing units.

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