Overcoming Critical Cooling Problems in Data Centers with Non-Contact Measurement

[Erkan Teskancan]

As the demand for artificial intelligence (AI) and high-performance computing (HPC) in data centers increases, so does the need for precise and reliable measurement solutions for cooling systems. One of the most critical elements for the uninterrupted operation of these infrastructures is the efficiency and reliability of their cooling systems.

### Challenges in Traditional Data Center Cooling Applications

In many data centers, cooling loops, especially before the AI boom, were equipped only with commercial-grade sensors due to limited budgets. These sensors rapidly degraded due to mechanical wear and calibration drift, increasing maintenance costs and leading to unexpected downtime. Today, the proliferation of liquid cooling systems has further complicated these issues.

### Precise and Reliable Measurement with Non-Contact Sensors

Clamp-on ultrasonic flow and temperature sensors solve painful problems by taking measurements from the external surface of the pipeline without physical intervention. These sensors offer:

• Diversity and reduced inventory: They adapt to different pipe diameters, reducing the need for a wide range of spare parts.
• Triple redundancy and voting logic: Advanced models like the Emerson Flexim FLUXUS compare measurements taken from various angles and channels to detect faulty devices.
• Seamless installation and maintenance: Allows installation anywhere you want without shutting down the pipeline.
• Mounting innovations: Special track and permalock systems guarantee stable and precise measurement even in vibrating environments.
• High accuracy: Equivalent precision to traditional methods with proper heat transfer and insulation, without the need for thermowells.
• Low flow detection: Ensures continuous flow control in critical systems.
• Planning and engineering ease: Advantage of space-saving and simple design.

### Application Example and Benefits

In a large North American data center, triple-redundant mechanical flow meters used in a critical cooling line were causing significant measurement discrepancies. When new Flexim FLUXUS non-contact ultrasonic meters were installed, it was determined that the actual flow rate was much higher. Improvements made with the new sensors resulted in annual energy savings of approximately $100,000 and significantly increased system reliability.

### Future-Ready Data Center Infrastructure

Data center infrastructures must also evolve to support high-performance chips. Given the maintenance and accuracy issues of commercial-grade instrumentation, clamp-on measurement equipment is preferred for monitoring cooling performance, optimizing energy consumption, and ensuring uninterrupted service.

Non-intrusive, i.e., non-contact and drift-resistant measurement tools, enable data centers to proactively manage their operations and maintenance processes, moving beyond old reactive methods. For critical water cooling, condenser loops, and backup fuel systems, it is essential to work with suppliers who understand industry needs and offer high-performance devices. This ensures uninterrupted and efficient operation to meet HPC demands.

All figures and visuals provided by Emerson and Tri-T Energy Solutions.