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Research Papers

Effectiveness of Rack-Level Fans—Part I: Energy Savings Through Consolidation

[+] Author and Article Information
Richard Eiland

Mechanical and Aerospace Engineering Department,
University of Texas at Arlington,
P.O. Box 19023,
Arlington, TX 76013
e-mail: richard.eiland@mavs.uta.edu

John Edward Fernandes

Mechanical and Aerospace Engineering Department,
University of Texas at Arlington,
P.O. Box 19023,
Arlington, TX 76013
e-mail: john.fernandes@mavs.uta.edu

Bharath Nagendran

Amazon Lab 126,
Thermal Engineer,
Enterprise Way,
Sunnyvale, CA 94089
e-mail: bhanagen@amazon.com

Veerendra Mulay

Facebook Inc.,
Senior R&D Engineer,
Menlo Park, CA 425081
e-mail: vmulay@fb.com

Dereje Agonafer

Fellow ASME
Mechanical and Aerospace Engineering Department,
University of Texas at Arlington,
P.O. Box 19023,
Arlington, TX 76013
e-mail: agonafer@uta.edu

1Corresponding author.

Contributed by the Electronic and Photonic Packaging Division of ASME for publication in the JOURNAL OF ELECTRONIC PACKAGING. Manuscript received February 16, 2017; final manuscript received October 10, 2017; published online October 27, 2017. Assoc. Editor: Pradip Dutta.

J. Electron. Packag 139(4), 041011 (Oct 27, 2017) (7 pages) Paper No: EP-17-1021; doi: 10.1115/1.4038235 History: Received February 16, 2017; Revised October 10, 2017

In general, smaller fans operate at lower efficiencies than larger fans of proportional linear dimensions. In this work, the applicability of replacing smaller, 60 mm baseline fans from within the chassis of web servers with an array of larger, geometrically proportional 80 mm and 120 mm fans consolidated to the back of a rack is experimentally tested. Initial characterization of the selected fans showed that the larger fans operate at double peak total efficiency of the smaller fans. A stack of four servers were used in a laboratory setting to represent a rack of servers. When all four servers were stressed at uniform computational loadings, the 80 mm fans resulted in 50.1–52.6% reduction in total rack fan power compared to the baseline fans. The 120 mm fans showed similar reduction in rack fan power of 47.6–54.0% over the baseline. Since actual data centers rarely operate at uniform computational loading across servers in a rack, a worst case scenario test was conceived in which the array of larger fans were controlled by a single server operating at peak computational workload while the other three in the rack remained idle. Despite significant overcooling in the three idle servers, the 80 mm and 120 mm fan configurations still showed 35% and 34% reduction in total rack fan power compared to the baseline fans. The findings strongly suggest that a rack-level fan scheme in which servers share airflow from an array of consolidated larger fans is superior to traditional chassis fans.

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Topics: Fans , Temperature
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References

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Figures

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Fig. 1

Intel-based Open Compute server used for this study. The partition separates airflow of the motherboard fans from that of the power supply (PSU) fan air stream, simplifying the geometry for the analysis of this work.

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Fig. 2

Depiction of the consolidation of fans to a shared array at the back of the rack

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Fig. 3

Peak total efficiencies for the 60 mm, 80 mm, and 120 mm at their maximum fan speeds in the rack configuration

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Fig. 4

Laboratory test setup of four servers stacked to represent a rack. Pertinent testing equipment is identified accordingly.

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Fig. 5

Relation between total rack fan power and CPU die temperatures for each of the four servers when operated at uniform computational workloads of idle, 30%, and 98% CPU utilization in the baseline 60 mm fan configuration

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Fig. 6

Location of the discrete system operating temperatures when the fans are internally controlled lie directly one the curve fit lines of the externally controlled tests across all computational loadings

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Fig. 7

Comparison between cooling performance of 60 mm, 80 mm, and 120 mm fans at idle, 30%, and 98% CPU utilizations

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Fig. 8

Depiction of (a) the “best case scenario” for the 60 mm fans in which all servers are operating at idle computational load and (b) the “worst case scenario” for the rack-level fans in which a single, high computationally loaded server dictates the speed of all the fans in the array

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