For data centers, the refrigeration system is a key link in ensuring the stable operation of equipment.
If impurities in the pipeline block the water pump and heat exchange equipment, it will significantly
reduce the heat dissipation efficiency, which may cause server interruption and affect the continuous
operation of the business. In a refrigeration system optimization project, a data center effectively
improved the operational problem of "impurity blockage" by introducing a filtering solution that
meets technical specifications. Next, we will introduce the project and understand the important
role that filters play in refrigeration systems.
The original filtering scheme restricts the refrigeration efficiency and results in high operation and
maintenance costs
The original refrigeration system of the data center used ordinary filter screens, which had two main
problems:
One is that the filter mesh in small-diameter pipelines is corroded, and the pressure bearing capacity
of large-diameter pipeline valve bodies is insufficient. During long-term operation, there may be damage
to the filter mesh, leakage of impurities, and rusting of the valve body, resulting in water leakage;
Secondly, all filters need to be manually disassembled and cleaned. Each shutdown for cleaning will
result in a partial cooling pause, with an annual maintenance time exceeding 200 hours. There have
also been multiple instances where the efficiency of the heat exchange equipment has decreased
due to untimely cleaning.
To address these issues, the project team has customized a combination of Y-shaped filters and
self-cleaning filters for the two key nodes of the refrigeration system, namely the "water pump
inlet" and the "heat exchange equipment inlet".
Y-shaped filter put into use to enhance front-end protection
According to the regulatory requirements, the project team first installed Y-shaped filters with
different diameters in the "front-end pipeline" of the refrigeration system to block impurities
from the source.
Small caliber pipeline (DN32/DN40): corresponding to the fine pipeline at the inlet of the refrigeration
equipment, an integral forged brass valve body is selected, which is corrosion-resistant by circulating
water. The integral forged structure can withstand the working pressure of the refrigeration system of
0.8MPa, and there is no leakage after installation;
Large diameter pipeline (DN80/DN150): For the main pipeline at the inlet of the water pump, cast iron
QT450 valve body is used, with good pressure resistance and suitable for high flow water supply needs.
After multiple months of operation verification, the valve body has no deformation or corrosion.
Detail design reduces operation and maintenance pressure, with equal emphasis on corrosion
prevention and convenient sewage discharge
All Y-shaped filters are coated with epoxy resin on the surface, which can be in long-term contact with
refrigeration circulating water, effectively preventing scale and rust. The filter replacement cycle has been
extended from 3 months to 6 months;
Install a DN25 diameter drain ball valve for the DN200 main pipeline filter. In the past, cleaning such
large-diameter filters required dismantling the entire end cover. Now, only the ball valve needs to be
opened every month to discharge the pollutants. The maintenance time for a single operation has been
reduced from 2 hours to 15 minutes, and the operation and maintenance efficiency has been improved
by 80%.
Accurate matching of filter screen to avoid equipment blockage and flow impact
The inlet of the water pump adopts an 18 mesh (with a pore size of about 0.9mm) 304 stainless steel
stamped filter screen, which is reinforced with ribs and has a filtering area 3.2 times the area inside the
pipeline. It effectively intercepts large particles and impurities that may wear out the impeller of the
water pump, without affecting the water supply flow rate;
The inlet of the heat exchange equipment uses a 28 mesh (with a pore size of about 0.6mm) filter screen
of the same material, which meets the specification requirements of "filtration accuracy of 26-30 mesh
for inlet filters of refrigeration/heat exchange equipment". It accurately blocks small impurities, prevents
blockage of the heat exchange tubes, and improves the heat exchange efficiency by 12% compared to
before the upgrade.
Self cleaning filter put into use, achieving "non-stop maintenance"
The refrigeration system of the data center needs to operate continuously, and the "shutdown gap"
during the disassembly and cleaning of traditional filters is always a hidden danger. There has always
been operational risk. Therefore, self-cleaning filters that meet regulatory requirements are introduced
in the two core scenarios to achieve "online cleaning and non-stop maintenance".
Power supply matching:
The motor is powered by 270V DC, and the drain valve is powered by 24V DC, integrated into the cabin DC
power supply system, without the need for additional circuit modifications;
Cleaning does not affect flow: During the test, the simulated filter screen was clogged, and the filter
automatically started the cleaningprogram. The motor drove the internal 304 stainless steel cleaning device
to scrub the filter screen, and at the same time, the drain valve was opened to discharge sewage.
The cooling water supply flow remained stable throughout the process, meeting the standard
requirement of "uninterrupted system under drain conditions", eliminating the risk of shutdown cleaning.
Prefabricated cold source pipeline network for indoor corridors, efficient management solution
with intelligent monitoring
Electric control box+PLC control: The filter is equipped with an electric control box and an operation lock
is added to prevent accidental contact; Through PLC control, it is possible to flexibly set "differential
pressure cleaning" (automatically activated when the inlet and outlet pressure difference exceeds the
set value), "timed cleaning", or manually operate to adapt to different working conditions;
Fault alarm+data recording: When the pressure difference is too high due to an increase in impurities
in the circulating water, the filter immediately emits an audible and visual alarm. After remote cleaning
by the operation and maintenance personnel, the system returns to normal within 5 minutes; The
controller automatically records the number of cleaning times, making it easy to trace the operating
status and simplify operation and maintenance management.
The stable operation of the refrigeration system in data centers does not rely on large equipment,
but requires key components such as filters to provide effective protection.
This project aims to transform the "universal filtering product" into a "customized solution for data
center cooling scenarios". From material selection to intelligent functions, each requirement is tailored
to the actual operation and maintenance needs, ultimately making the filter a reliable support for the
cooling system.
Maintaining the cleanliness of pipelines is the key to ensuring cooling in data centers.
