IT equipment cooling

Abstract

A system for cooling gas heated by passing the gas over heat-producing equipment to cool the equipment comprises a heat exchanger including a first heat transfer mechanism configured to transfer heat from the heated gas to a first coolant, and a first condensing module connected for fluid communication with the heat exchanger and including second and third heat transfer mechanisms, the first condensing module being configured to transfer heat through the second and third heat transfer mechanisms from the first coolant to second and third coolants in the second and third heat transfer mechanisms, respectively.

What is claimed is: 
     
       1. A system for cooling gas heated by heat-producing electronic equipment, the system comprising:
 a heat exchanger configured to transfer heat from the heated gas to a first coolant; 
 a first cooling module connected for fluid communication with the heat exchanger and including a first condenser configured to cool and condense incoming first coolant from vapor to liquid, the first cooling module being configured to transfer heat from the first coolant to a second coolant to cool the first coolant; 
 a second cooling module connected for fluid communication with the heat exchanger and including a second condenser configured to cool and condense incoming first coolant from vapor to liquid, the second cooling module being configured to transfer heat from the first coolant to a third coolant to cool the first coolant; and 
 a condenser-charge controller configured to regulate a first coolant liquid level in the first condenser. 
 
     
     
       2. The system of  claim 1  wherein the condenser-charge controller comprises first and second condenser-charge controller subsystems connected and configured to control liquid levels in the first and second condensers, respectively. 
     
     
       3. The system of  claim 2  wherein the first and second subsystems each include a liquid level sensor configured to determine a liquid level in the respective condenser, a pump, and a controller coupled to the pump and the liquid level sensor and configured to regulate the pump to affect the corresponding liquid level. 
     
     
       4. The system of  claim 3  wherein the liquid level sensor is a pressure differential sensor and wherein the cooling module includes a coolant container connected to the condenser and the pump and the liquid level sensor is connected to the coolant container to determine the liquid level in the coolant container, the liquid level in the coolant container being related to the liquid level of the condenser. 
     
     
       5. The system of  claim 3  wherein the first and second cooling modules further comprise:
 a container connected to the condenser and configured to store the first coolant; 
 a pump connected to the container and configured to pump the first coolant from the container; 
 a purge mechanism connected to the pump; 
 a purge controller coupled to the purge mechanism and configured to actuate the purge mechanism to purge at least some of the first coolant pumped by the pump; 
 a fill mechanism connected to the container; and 
 a fill controller coupled to the fill mechanism and configured to actuate the fill mechanism to supply liquid first coolant to the container. 
 
     
     
       6. The system of  claim 5  wherein the purge controller is configured to actuate the purge mechanism if the pump is operating at about full capacity and the liquid level of the container rises above an upper threshold level and/or more than a first threshold amount. 
     
     
       7. The system of  claim 5  wherein the fill controller is configured to actuate the fill mechanism if the pump is operating at about minimum capacity and the liquid level of the container drops below a lower threshold level and/or more than a second threshold amount. 
     
     
       8. A system for cooling gas heated by passing the gas over heat-producing equipment to cool the equipment, the system comprising:
 a heat exchanger including a heat exchanger heat transfer mechanism configured to transfer heat from the heated gas to a heat exchanger coolant; 
 a first condensing module connected for fluid communication with the heat exchanger and including a first heat transfer mechanism, the first condensing module being configured to transfer heat through the first heat transfer mechanism from the heat exchanger coolant to a first coolant in the first heat transfer mechanism; 
 a second condensing module connected for fluid communication with the heat exchanger and including a second heat transfer mechanism, the second condensing module being configured to transfer heat through the second heat transfer mechanism from the heat exchanger coolant to a second coolant in the second heat transfer mechanism; and 
 a processor coupled to the first and second condensing modules and configured to assign a cooling task to each of the condensing modules based upon expected cooling demand for the heat exchanger coolant and cooling capacities providable by at least one of the first and or second condensing modules; 
 wherein the processor is configured to assign the first condensing module as a primary module for cooling the heat exchanger coolant, to assign the second condensing module as a lag module, for cooling the heat exchanger coolant, if the expected cooling demand exceeds a cooling capacity providable by the first condensing module, and to assign the second condensing module as a redundant module if the cooling capacity of the first condensing module plus the cooling capacity of any lag condensing modules is at least as great as the expected cooling demand, the redundant module being designated for use in cooling a backup refrigerant if the primary module and any lag modules are operational and for cooling the heat exchanger coolant if the primary module or any lag modules are not operational. 
 
     
     
       9. The system of  claim 8  wherein the first and second condensing modules are coupled in parallel through a single coolant loop to the heat exchanger. 
     
     
       10. The system of  claim 8  wherein the primary condensing module is used to cool the heat exchanger coolant unless the primary condensing module is inoperative, the lag module, if any, is used to cool the heat exchanger coolant if the cooling demand exceeds the cooling capacity of the primary module and any other lag module, and the redundant module, if any, is used to cool the heat exchanger coolant if any of the primary and lag, if any, modules is inoperative and the cooling demand exceeds the cooling capacity of the operative primary and lag, if any, modules, and is used to produce ice if the cooling capacity of the operative primary and lag, if any, modules at least meets the cooling demand. 
     
     
       11. The system of  claim 8  wherein the first and second condensing modules each have a cooling capacity that is no greater than an expected cooling demand for the heat exchanger coolant. 
     
     
       12. The system of  claim 8  wherein the first and second condensing modules each have a cooling capacity that is at least as great as an expected cooling demand for the heat exchanger coolant. 
     
     
       13. The system of  claim 8  wherein the second heat transfer mechanism is further configured to transfer heat through the second heat transfer mechanism from the heat exchanger coolant to a third coolant in the second heat transfer mechanism. 
     
     
       14. A system for cooling gas heated by passing the gas over heat-producing equipment to cool the equipment, the system comprising:
 a heat exchanger including a heat exchanger heat transfer mechanism configured to transfer heat from the heated gas to a heat exchanger coolant; 
 a first condensing module connected for fluid communication with the heat exchanger and including a first heat transfer mechanism, the first condensing module being configured to transfer heat through the first heat transfer mechanism from the heat exchanger coolant to a first coolant in the first heat transfer mechanism; and 
 a second condensing module connected for fluid communication with the heat exchanger and including a second heat transfer mechanism, the second condensing module being configured to transfer heat through the second heat transfer mechanism from the heat exchanger coolant to a second coolant in the second heat transfer mechanism; 
 wherein the system is configured to use excess cooling capacity of the second condensing module to produce ice for use in cooling the heat exchanger coolant if the first condensing module is inoperative. 
 
     
     
       15. The system of  claim 14  wherein the second heat transfer mechanism is further configured to transfer heat through the second heat transfer mechanism from the heat exchanger coolant to a third coolant in the second heat transfer mechanism. 
     
     
       16. A system for cooling gas heated by passing the gas over heat-producing equipment to cool the equipment, the system comprising:
 a heat exchanger including a heat exchanger heat transfer mechanism configured to transfer heat from the heated gas to a heat exchanger coolant; 
 a first condensing module connected for fluid communication with the heat exchanger and including a first heat transfer mechanism, the first condensing module being configured to transfer heat through the first heat transfer mechanism from the heat exchanger coolant to a first coolant in the first heat transfer mechanism; 
 a second condensing module connected for fluid communication with the heat exchanger and including a second heat transfer mechanism, the second condensing module being configured to transfer heat through the second heat transfer mechanism from the heat exchanger coolant to a second coolant in the second heat transfer mechanism, wherein the second heat transfer mechanism is further configured to transfer heat through the second heat transfer mechanism from the heat exchanger coolant to a third coolant in the second heat transfer mechanism, wherein the second heat transfer mechanism is further configured to transfer heat through the second heat transfer mechanism from the heat exchanger coolant to a third coolant in the second heat transfer mechanism; and 
 an ice storage tank connected to the second heat transfer mechanism, wherein the second condensing module includes a battery and a pump that is connected to the battery and the ice storage tank, and wherein the battery is configured to power the pump and the pump is connected and configured to circulate the third coolant between the second heat transfer mechanism and the ice storage tank to cool the third coolant with the ice and to cool the heat exchanger coolant with the third coolant. 
 
     
     
       17. The system of  claim 16  further comprising a processor coupled to the first and second condensing modules and configured to assign a cooling task to each of the condensing modules based upon expected cooling demand for the heat exchanger coolant and cooling capacities providable by at least the first and second condensing modules. 
     
     
       18. The system of  claim 16  wherein the second heat transfer mechanism is further configured to transfer heat through the second heat transfer mechanism from the heat exchanger coolant to a third coolant in the second heat transfer mechanism. 
     
     
       19. The system of claim  13  14 further comprising a processor coupled to the first and second condensing modules and configured to assign a cooling task to each of the condensing modules based upon expected cooling demand for the heat exchanger coolant and cooling capacities providable by at least the first and second condensing modules. 
     
     
       20. The system of claim 1 further comprising:
 a coolant distribution subsystem connected to the heat exchanger and the first and second cooling modules and configured to transfer the cooled first coolant from the first and second cooling modules to the heat exchanger and to transfer the heated first coolant from the heat exchanger to the first and second cooling modules; and   at least one processor coupled to the coolant distribution subsystem and the heat exchanger, and configured to:
 determine a dew point of the gas associated with the heat exchanger; 
 monitor a physical characteristic of the first coolant relevant to saturation of the first coolant; and 
 control supply of the first coolant to the heat exchanger such that a combination of temperature and pressure of the first coolant entering the heat exchanger put the first coolant at a saturation point of the first coolant with a first coolant temperature being above the determined dew point temperature. 
   
     
     
       21. The system of claim 20 wherein the coolant distribution subsystem further comprises a first coolant temperature sensor and a first coolant pressure sensor configured to monitor temperature and pressure of the first coolant exiting the first and second cooling modules, the at least one processor being coupled to the first coolant temperature sensor and the first coolant pressure sensor and configured to regulate the first and second cooling modules such that the temperature and pressure of the first coolant exiting the first and second cooling modules are at desired levels. 
     
     
       22. The system of claim 20 wherein the heat exchanger is part of a heat exchanger section that includes multiple heat exchangers and wherein the at least one processor is configured to:
 determine respective dew points of the gas in respective vicinities of each of the multiple heat exchangers;   monitor the physical characteristic of the first coolant near an entrance to each of the multiple heat exchangers; and   control supply of the first coolant to the multiple heat exchangers such that combinations of temperature and pressure of the first coolant entering respective ones of the multiple heat exchangers put the first coolant at saturation points of the first coolant with respective first coolant temperatures being above respective determined dew point temperatures.   
     
     
       23. The system of claim 20 further comprising a heat exchanger temperature (HET) sensor and a heat exchanger humidity (HEH) sensor configured to monitor a temperature and a humidity of the heated gas disposed adjacent to the heat exchanger, the at least one processor being coupled to the HET sensor and to the HEH sensor and being configured to use temperature and humidity indicia from the HET and HEH sensors to determine the at least one dew point. 
     
     
       24. The system of claim 1 further comprising:
 a first shutoff valve connected to an output of the first cooling module for receiving the first coolant and connected to an input of the heat exchanger to selectively permit flow of the first coolant from the first cooling module to the heat exchanger;   a second shutoff valve connected to an output of the heat exchanger and connected to an input of the first cooling module to selectively permit flow of the first coolant from the heat exchanger toward the first cooling module;   a third shutoff valve coupled to the heat exchanger; and   a pump arrangement connected to the third shutoff valve and configured to draw gas and the first coolant through the third shutoff valve from the heat exchanger.   
     
     
       25. The system of claim 24 wherein the pump arrangement is configured to vent the drawn gas to a region external to the system. 
     
     
       26. The system of claim 24 wherein the pump arrangement is further connected to the first cooling module and is configured to convey the drawn first coolant to the first cooling module. 
     
     
       27. The system of claim 24 further comprising a plurality of sets of first, second, and third shutoff valves connected to the output of the first cooling module, the input of the first cooling module, and the pump arrangement, respectively, the system further comprising a processor coupled to the first, second, and third shutoff valves of each of the plurality of sets and to the pump arrangement, the processor being configured to control the shutoff valves and the pump arrangement such that:
 in response to an indication to add a new heat exchanger to the system with the new heat exchanger being coupled to a new set of the first, second, and third shutoff valves, the processor will cause the first and second shutoff valves of the new set to be closed, the third shutoff valve of the new set to be opened, the pump arrangement to draw gas from the new heat exchanger until a desired pressure is attained in the new heat exchanger and then the processor will cause the third shutoff valve of the new set to be closed, and the first and second shutoff valves of the new set to be opened; and   in response to an indication to remove a certain heat exchanger from the system with the certain heat exchanger being coupled to a certain set of the first, second, and third shutoff valves, the processor will cause the first and second shutoff valves of the certain set to be closed, the third shutoff valve of the certain set to be opened, the pump arrangement to draw the first coolant from the certain heat exchanger until a desired pressure is attained in the certain heat exchanger and then the processor will cause the third shutoff valve of the certain set to be closed, and the first and second shutoff valves of the certain set to be opened.   
     
     
       28. The system of claim 16 further comprising:
 an outgoing pump coupled to the second condensing module and the heat exchanger and configured to pump the heat exchanger coolant from the second condensing module to the heat exchanger; and   wherein the second heat transfer mechanism comprises cooling means for transferring the heat from the heat exchanger coolant through at least one of a plurality of heat transfer elements into at least one of the second coolant or the third coolant.   
     
     
       29. The system of claim 28 wherein the cooling means is configured to select between which one of the second coolant and the third coolant to use to cool the first coolant. 
     
     
       30. The system of claim 28 wherein the cooling means includes primary cooling means for cooling the second coolant. 
     
     
       31. The system of claim 30 wherein the primary cooling means is configured to cool the third coolant, and the cooling means is configured to direct the third coolant cooled by the primary means to the ice storage tank to freeze water stored in the ice storage tank. 
     
     
       32. The system of claim 30 wherein the cooling means is configured to regulate amounts of the second coolant provided to the second condensing module to control at least a temperature of the first coolant pumped from the second condensing module. 
     
     
       33. The system of claim 30 further comprising pump regulator means for regulating the outgoing pump to control pressure of the first coolant such that the first coolant entering the heat exchanger will be at saturation while a temperature of the first coolant entering the heat exchanger is above a dew point temperature of the heated gas in a vicinity of the heat exchanger. 
     
     
       34. The system of claim 8 further comprising:
 a plurality of equipment racks configured to house the heat-producing equipment, the racks being arranged in rows such that equipment disposed in the racks will vent hot air into an aisle defined between the rows of racks; and   a heat exchanger unit including the heat exchanger, the heat exchanger unit including:   a housing configured to contain the heat exchanger; and   a mounting apparatus connected to the housing and to at least one rack, the mounting apparatus configured such that the heat exchanger is disposed at least partially vertically aligned with the aisle.   
     
     
       35. The system of claim 34 wherein the mounting apparatus is configured such that the heat exchanger is disposed at least partially directly over the aisle. 
     
     
       36. The system of claim 35 wherein the mounting apparatus is configured such that the heat exchanger is disposed substantially entirely directly over the aisle. 
     
     
       37. The system of claim 36 wherein the mounting apparatus is configured to connect to at least one rack in each of two different rows of the equipment racks such that the heat exchanger unit straddles the aisle.