Cogent Communications, Somerville, MA

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) were the focus of this project because their function restores the capacity of cooling systems and reduces energy use and carbon footprint.

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

CryoGenX4, the latest multi-patented nanotechnology offered by Energy Efficient Technologies, 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 18.5%

When initially tested, the three pilot CRAC units were producing 24.26 tons of cooling. Seventeen days after implementing the ECM, the cooling capacity jumped by 3.94 tons or 16.2% to 28.2 tons.

  • The overall cost to produce each ton of cooling on the pilot systems dropped 18.5% from 1.314 kW/ton in the baseline to 1.071 kW/ton after installation of the ECM. This means that for every ton of cooling the pilot CRAC units are asked to produce, Cogent Communications is spending 18.5% less to do so.
  • The projected annual kWh’s were reduced by 18.5% from 266,760 to 217,440.
  • The dry bulb delta-T increased on average by 1.8 degrees or 20.3% across all three CRAC units. This means that before the ECM, each CRAC unit would take in 72° air and cool it down to 63.13°.
  • After the ECM, each CRAC unit can take in the same 72° air but now produce 61.33° air using less power. This means set points of 68° are reached quicker, allowing the CRAC units to cycle more often than in the past, hence reducing electricity costs and carbon footprint.
  • The increase in capacity and Delta-T is now allowing CRAC unit 1 to cycle off the second compressor more often under the same load and outside air temperatures while still maintaining the 68° setpoint.

After completion of this successful pilot, Cogent Communications is deploying CryoGenX4  in additional data centers with similar results- on average 20% reductions in energy use and carbon footprint.

Testimonial:

“Energy Efficient Technologies deployed CryoGenX4 in five Cogent Data Centers. There was no downtime required in our critical cooling systems, we saw the savings in the electric bills and did not require any additional maintenance afterwards.  I highly recommend CryoGenX4!”

 Rich Rademaker, Director of Data Center Operations, Cogent Communications

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