The goal of this project was to upgrade a data center supporting the broadcasts of an international media firm. When the center was initially designed, it was designed with two computer room air conditioning (CRAC) units, designed for one CRAC to operate while the other served as standby for redundancy. However, with advances in technology since the data center entered service, the thermal load has increased greatly and exceeded the capability of the original units. Both units were being run at all times, eliminating the designed redundancy and still at the limits of their combined cooling ability. WB Engineers+Consultants was consulted in July 2025 to upgrade the data center's cooling system to return system redundancy as well increase capacity and efficiency. 

My work on this project encompassed designing CAD representations of and coordinating the sequence of controls operations for the new system.

Using Autodesk Revit, I developed detailed layouts for the new cooling equipment, ductwork routing, and a cold aisle containment retrofit tailored to the constraints of the existing facility. The containment system was designed to separate hot and cold air streams, maximizing thermodynamic efficiency by minimizing mixing and allowing targeted airflow delivery to the servers. 

Beyond the physical design, I coordinated closely with equipment vendors and controls engineers to develop the sequence of operations for the new system. Because the new CRAC unit introduced significantly greater airflow, it required a dedicated return air fan to balance the system. I proposed and modeled a control strategy using duct-mounted airflow sensors driving a variable frequency drive (VFD) on the fan, ensuring optimal pressure balance and energy efficiency. I also authored two operational sequences to give the client flexibility: one configuration where the new CRAC operated continuously with one of the legacy units alternating for redundancy, and another where all three units operated together with the new CRAC at full capacity and the older units regulated to a lower cooling load maintain readiness. Ultimately, the client decided upon the former option for system operations.