
It is a perfect summer day here in Seattle, sunny at 65°F (18°C), and we're preparing the roof for the arrival of another AC unit. Lots of interesting things to share!
The new 70 Ton Aaon Air Handling Unit will arrive in less than two weeks. This will bring our total cooling capacity to 333 tons. Just like we did last time, the locations must be prepared ahead of time, first penetrating the roof to provide supply and return ducting, as well as mounting points attached to the building's steel frame. This latter task provides mounting for the steel superstructure that the air handling unit is secured onto. Unlike last time however, the weather is great and we don't have to plan our penetration work between rain squalls.
The first thing completed by our contractor MacDonald-Miller was the supply duct penetration. It was done in the very early hours of the day when it was still very cool outside to minimize the impact on datacenter temperature. This penetration provides a very large opening between the new HVAC system's supply and our facility's cold air plenum. The plenum runs the length of the datacenter and all the HVAC systems supply it with cold air. This allows a common air supply so that our HVAC units can share the duties of cooling the facility. By feeding a common plenum they can provide redundancy to each other.

Above: The completed and capped supply duct in the background. The return duct in the foreground is positioned and the blue paint shows where it will be countersunk into the roofing material.
In addition to the openings through the roof for air ducts, five smaller holes had to be prepared. Four will contain the steel supports for the superstructure, and one for the electrical service to operate the HVAC unit.

Above: One of the smaller penetrations in progress. Mt. Rainier in the background.

Above: Larry Mayrand (left) from MacDonald-Miller operates the sawzall on the roof's pandeck, while digital.forest Facilities Manager Kevin Teker runs the shop-vac to minimize the spread of collateral. Mike Klein from MacDonald-Miller (right) assists.
Directly below these support penetrations lie the steel I-beams that make up the skeletal structure of the building. Onto these will go the support columns for our HVAC superstructure.

Above: Larry Mayrand checks the plumb on the support. Downtown Seattle is in the background.
After these penetrations were completed a roofing crew arrived to re-seal the areas around the work. Our roof is insulated by a special foam, and sealed with a few layers of a tough but light/heat reflective material with tar in the joints. This keeps the heat, and rain out, while keeping the facility below nice and cool.
Other Changes:
Sharp-eyed observers will note a few subtle changes to digital.forest's rooftop landscape when they compare these photos to the ones referenced above concerning our last roof-related work. Kevin Teker took me around to show me these to share with all of you:

Above: Inlet screen filters.
Late Spring here brings on a veritable blizzard of pollen and airborne cottonwood seeds. We have found that these clog the HVAC filters very fast (sometimes within hours) reducing the efficiency of our cooling systems. To combat this we have constructed and installed various inlet screens on our air handling equipment. We keep a shop-vac on the roof and part of the regular schedule of the NOC staff 24 hours a day is to check the condition of the inlet screens and clean them off with the vacuum when they start to clog. This saves our filters which are better served handling routine airborne contaminants rather than a seasonal flora bloom. The screens will come off in another week or so, but now seems to be a good time to share them with you. The big box sections above are the large intakes for our original AC system. Our new systems are much more compact and easier to screen off. If you look closely at the top photo posted in this entry you can see a full rooftop shot that includes our twin systems installed last year. The inlets are the large horizontal areas near their tops. A close up view reveals that they are covered by a snap-on fabric inlet screen:

Above: A closeup view of the "cottonwood screen" on one of the inlets of our Aaon AC unit. Below: A wider shot of the installed screen.

We sweat all these details so you don't have to.
We'll have more updates as we get closer to completion, so stay tuned.
--Chuck Goolsbee
V.P. Technical Operations
digital.forest
posted by Chuck G. at 11:36 AM on Tuesday, June 24, 2008
Categories: Datacenter Expansion