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Freedom251 › Blog › airflow management

How to Improve Cooling Efficiency in an Existing Data Center

By Freedom251 Team · · 12 min read

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The most reliable way to improve cooling efficiency in an operating data center is to work in stages: measure the facility and IT load, stop hot-air recirculation and supply-air bypass, retune temperature, humidity and chilled-water controls, then evaluate economizers or major cooling changes against the site’s climate, equipment, water constraints and resilience requirements. Cooling efficiency is not determined by the chiller alone; rack density, airflow paths, controls and operating setpoints can dominate results.

Use a measured baseline and verify every change at rack inlets and plant meters. Published figures such as a potential 20% reduction in chiller energy describe conditions in a guidance example, not a guaranteed saving for an individual facility.

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1. Establish a measured baseline before changing equipment

A baseline prevents a common retrofit mistake: attributing a lower utility bill to a project when IT load, weather or production hours changed at the same time. Collect data for a representative operating period that includes normal load variation and, where practical, seasonal conditions. Record timestamps, sensor locations, units and data quality so post-change comparisons use the same boundaries.

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Measure facility, IT and cooling energy separately

At minimum, trend whole-facility electricity, IT equipment electricity, chillers, chilled-water pumps, condenser-water pumps, cooling towers, CRAC or CRAH units, computer-room fans and other packaged cooling equipment. Add power meters to major distribution boards when a building meter cannot separate these loads. Record IT utilization or measured rack power alongside cooling data; an empty or lightly loaded room can make a mechanical improvement look larger than it is.

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Measure the conditions equipment actually sees

Room-average temperature can conceal an overheated rack. Place calibrated sensors at representative rack inlets, including the highest-density rows, end-of-row positions and historically troublesome locations. Trend supply and return air, chilled-water supply and return temperature, flow, valve position, fan speed, pump speed, differential pressure and cooling-unit status. The 2024 U.S. Department of Energy Federal Energy Management Program (FEMP) guide discusses monitoring supply temperature and humidity at each CRAC or CRAH as part of integrated control: Best Practices Guide for Energy-Efficient Data Center Design.

Include water when towers or evaporative systems are involved

Record makeup water, blowdown, cycles of concentration, tower-fan operation and water-treatment events. A measure that cuts compressor electricity can increase tower operation or water consumption, so energy and water need a joint baseline.

Baseline item Useful measurements Decision it supports
IT load Aggregate kW, rack kW, utilization and operating hours Separates load growth from cooling performance
Air conditions Rack-inlet temperature and humidity, supply and return temperatures, pressure where relevant Finds hotspots, recirculation and overcooling
Cooling plant Chiller kW, capacity, chilled-water temperatures and flow, condenser-water temperatures Shows part-load efficiency and reset opportunities
Distribution equipment Pump and fan kW, speed, valve position and differential pressure Identifies excess flow, pressure and bypass
Outdoor conditions Dry-bulb temperature, wet-bulb temperature, humidity and air quality Tests economizer hours and lockout limits
Water systems Makeup, blowdown, treatment and tower operating hours Quantifies water trade-offs

Use power usage effectiveness (PUE) as an overall facility indicator: PUE = total facility energy ÷ IT equipment energy. FEMP’s 2019 guidance uses 2.0 as an average-efficiency context and 1.0 as the theoretical minimum; these figures are general reference points, not current universal targets or a diagnosis of your cooling system. Where water is material, calculate water usage effectiveness (WUE): WUE = annual site water use in liters ÷ IT energy in kWh. Neither metric identifies which component to change, so keep the underlying meter data.

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2. Correct airflow before adding cooling capacity

Airflow work is usually the least disruptive first intervention because it uses the existing plant more effectively. The goal is a predictable path from cool supply air to equipment inlets and from hot exhausts back to the return system, without the two streams mixing.

Map supply, exhaust and return paths

Walk every row and document rack orientation, perforated floor tiles or other supply openings, ceiling returns, raised-floor obstructions, cable penetrations and unused rack spaces. Check whether supply air is short-circuiting directly into a return, or whether hot exhaust from one row is entering the next row’s intakes. Compare the map with computational-fluid-dynamics studies or smoke visualization if available, but confirm conclusions with rack-inlet sensors.

Seal bypass openings and unused rack spaces

Close gaps around cables, floor cut-outs and empty rack positions that allow conditioned air to bypass IT equipment. Compatible rack blanking panels are a simple physical option for unused U-spaces; they do not replace a room airflow assessment and must not block required equipment vents. Repair missing floor grommets and seal penetrations without creating trip, fire or maintenance hazards.

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Keep cool and hot aisles distinct

Arrange racks so that equipment intakes face a common cool aisle and exhausts face a common hot aisle. Where the existing layout cannot be changed, use barriers or containment that fit the ceiling, return-air path, fire protection and service clearances. Containment should prevent mixing without trapping heat or obstructing emergency egress.

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Verify the result at the rack

After each physical change, trend inlet temperatures and humidity at the same sensor points used for the baseline. Check for a new hotspot at row ends, underfloor obstructions or high-density racks. Confirm that cooling units are not cycling excessively and that fan speeds or static pressure did not rise enough to erase the expected benefit.

FEMP says separating supply and exhaust air, closing bypass paths and using suitable barriers can enable higher chilled-water temperatures and reduced airflow. Its cooling-water guidance reports a potential 20% reduction in chiller energy for the practices described, citing the Best Practices Guide; that is a published potential under applicable conditions, not a promise for every data center: DOE FEMP cooling-water efficiency opportunities.

3. Tune temperature, humidity and room-unit controls

Set temperature from IT limits, not habit

Review the allowable inlet-temperature range for every installed server, storage system, network device and special-purpose appliance. A setpoint inherited from an older room design may be unnecessarily low. Raise supply or room targets only within the narrowest applicable equipment and operating-policy limits, and do it incrementally while watching the warmest rack inlet, not the room average.

Avoid unnecessarily narrow humidity bands

Tight humidity limits can force simultaneous humidification and dehumidification, increase compressor runtime and, in tower-cooled facilities, increase water use. Confirm the actual equipment requirements, sensor accuracy and local seasonal conditions before widening a band. Use humidity lockouts and dew-point logic where the control system supports them, but retain alarms for condensation risk and electrostatic-discharge limits defined by the IT and facilities teams.

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Coordinate CRAC and CRAH units

Review lead-lag sequencing, supply-air reset, fan-speed control, deadbands and sensor placement. Units that independently fight one another can cool and reheat the same air or run all fans at full speed at low load. Calibrate sensors, remove failed or drifting devices and ensure that a failed unit does not command the remaining units into an unsafe mode.

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Use rack-inlet alarms as the acceptance test

Define alert and critical thresholds for inlet temperature and humidity, then test alarms after each control change. A lower average room temperature is not a success if a high-density rack remains outside its limit. Keep a rollback procedure that restores the prior setpoint or sequence if an inlet alarm, equipment warning or loss of redundancy occurs.

4. Recommission the chilled-water plant and distribution

Chilled-water optimization requires engineering review because a change at one pump, valve or chiller can affect flow, freeze protection, control stability and N+1 capacity. The 2024 FEMP guide lists higher supply temperatures, variable flow, lower unnecessary pressure, two-way valves and differential-pressure reset as measures to consider in existing facilities: 2024 FEMP guide (PDF).

Measure What to examine Required safeguard
Raise chilled-water supply temperature Coil approach temperatures, valve authority, equipment limits and economizer compatibility Verify the warmest rack inlet and chiller operating envelope
Convert or improve variable flow Constant-flow sections, minimum chiller flow, pump curves and control-valve behavior Protect minimum flow and maintain stable control at low load
Use two-way valves and remove unnecessary bypass Three-way valves, open bypasses and decouplers that send water around coils Check pressure, coil flow and redundancy in every operating mode
Reset differential pressure Remote valve positions and the index circuit rather than a fixed high setpoint Retain adequate flow at the most demanding terminal
Optimize chiller and condenser sequencing Part-load efficiency, condenser-water reset, tower-fan staging and startup logic Commission lead-lag, failure and maintenance modes

Assess medium-temperature chilled water

FEMP’s 2024 guide identifies a chilled-water supply temperature of 55°F or higher as a medium-temperature approach that can improve chiller efficiency and permit more water-side economizer hours. Do not apply 55°F as a universal setting: confirm coil capacity, CRAH control range, humidity behavior, piping insulation, heat-exchanger approach and the inlet limits of the installed IT equipment.

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Match flow to actual demand

Trend valve positions and differential pressure at the hydraulically remote coil. If most valves are nearly closed, the pump setpoint may be excessive. If a terminal remains fully open while others are closed, investigate balancing, sensor location and control authority before reducing pressure. Eliminate bypass flow only after confirming minimum flow requirements for chillers, heat exchangers and control valves.

Commission part-load and failure modes

Test one-chiller, multiple-chiller, tower-fan, pump-failure and sensor-failure sequences. Verify that staging does not short-cycle equipment, that standby capacity starts within the facility’s required interval and that a reset strategy returns to a safe fixed value when a sensor fails.

5. Screen economizers against climate and existing configuration

Air-side economizers

An air-side economizer uses suitable outdoor air to reduce or replace mechanical cooling. Before considering one, analyze outdoor temperature and moisture, dew point, particulates, corrosive contaminants, filtration pressure drop, building pressure, humidity lockout and the controls needed to transition between modes. Existing data centers often lack the large supply and exhaust ducts an air-side system requires; FEMP notes that adding this ductwork can make retrofit difficult.

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Water-side economizers

A water-side system transfers heat through a cooling tower and heat exchanger, allowing chillers or compressors to be bypassed when outdoor conditions are favorable. Check tower capacity, heat-exchanger approach, water quality, freeze protection, chilled-water temperature, pump configuration and control sequences. It can fit some existing chilled-water plants better than an air-side retrofit, but the hours of useful operation depend on climate and the plant’s temperature limits.

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The 2024 FEMP guide presents wet-bulb temperatures below 55°F for 3,000 or more hours per year as a climate condition where water-side economizing is usually well suited. Treat this as a screening condition, not a universal qualification or a savings guarantee.

Question Air-side economizer Water-side economizer
Existing-building work May require large outdoor-air, exhaust and return ducts May connect to an existing chilled-water plant and tower
Primary constraints Humidity, contaminants, filtration, pressure and controls Wet-bulb hours, tower water, heat-exchanger approach and freeze protection
IT protection Requires filtration and strict lockouts for unsuitable outdoor air Keeps IT air loop closed but adds heat-exchanger and water-system dependencies
Evidence needed Hourly weather and contaminant data plus duct feasibility Hourly wet-bulb data, tower performance and water-treatment records

6. Consider liquid cooling or major plant changes only when the load warrants them

High rack power density can make air cooling impractical even after airflow and controls are optimized. Liquid cooling may then be relevant, but it is a facility-and-IT architecture decision rather than a universal efficiency upgrade. Evaluate server compatibility, coolant distribution units, heat rejection, leak detection, maintenance skills, water strategy, electrical interfaces and how the remaining air-cooled loads will be served.

A phased deployment can reduce risk: start with a compatible high-density cluster, provide isolation and monitoring, and verify heat-rejection capacity before expanding. Account for network, storage and management racks that remain air cooled. Keep a failure mode that protects the IT load if a coolant loop, pump or distribution unit is unavailable.

DOE’s 2024 discussion of the updated guide identifies NREL researchers David Sickinger and Otto Van Geet as contributors. Van Geet said, “Across the board—from the compute side to the facility side—data center technologies have changed dramatically since 2011,” while Sickinger said, “We just needed to modernize it, especially with the increasing rack compute densities, which was one of the big triggers for the update.” These comments explain why high-density retrofits deserve a current engineering study, not why liquid cooling is right for every existing room: DOE article on technology changes and efficiency principles.

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7. Choose among retrofit paths with a site-specific scorecard

Rank alternatives using the same baseline and the same operating boundary. A measure with a large theoretical energy benefit may be unsuitable if it consumes scarce water, requires a long outage or reduces redundancy.

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Option Most suitable when Benefits to test Questions that can disqualify it
Airflow correction and containment Hotspots, bypass openings or mixed aisles are documented Lower fan speed, higher usable supply temperature and fewer hotspots Can barriers obstruct service, fire protection or return paths?
Controls and setpoint tuning Setpoints are conservative or units operate against one another Lower compressor, fan and reheat runtime Do IT limits, sensor quality or alarm policies prevent the change?
Plant and pump optimization Flow, pressure or staging does not follow load Reduced pump energy and improved chiller part-load operation Will minimum flow, redundancy or control stability be compromised?
Air-side economizer Climate is favorable and duct routes are feasible Mechanical cooling displacement during suitable hours Are humidity, contaminants, filtration or construction risk unacceptable?
Water-side economizer Existing tower and chilled-water infrastructure can support it Chiller bypass during favorable wet-bulb conditions Are water availability, treatment, freeze protection or approach temperatures limiting?
Liquid cooling Rack densities exceed practical air-cooling capability Direct heat removal at high-density equipment Can IT, coolant distribution, maintenance and residual air loads be supported?

For each option, estimate measured energy reduction potential, water impact, capital and operating cost, maintenance skill requirements, implementation risk, redundancy impact and expected operating hours. No universal retrofit payback or savings percentage applies across facilities; require a project baseline and post-change measurement.

8. Use a staged implementation and commissioning plan

  1. Governance and safety: Define IT inlet limits, alarm thresholds, water constraints, outage windows, change-control authority and rollback criteria. Confirm that proposed barriers, sensors and piping changes meet fire, electrical and access requirements.
  2. Baseline: Validate meters, synchronize timestamps and collect facility, IT, cooling, rack-inlet and water data. Document weather and production changes that could affect comparison.
  3. Airflow: Correct rack orientation where feasible, close bypass openings, install compatible blanking panels and add containment only where the room can support it. Re-measure rack inlets and fan operation.
  4. Room controls: Review temperature and humidity bands, sensor placement, unit sequencing and supply-air reset. Change one control group at a time and watch alarms through normal and peak loads.
  5. Hydronics and plant: Test chilled-water temperature, variable-flow behavior, two-way valves, differential-pressure reset, chiller staging and condenser-water reset with engineering oversight.
  6. Economizer or major technology study: Use hourly climate, water, duct or piping feasibility and resilience analysis before approving construction. Pilot liquid cooling or an economizer where a bounded deployment can prove performance.
  7. Measurement and verification: Compare normalized cooling and facility energy with the baseline, report water separately, and retain rack-inlet and reliability results. Keep the new sequence only after commissioning demonstrates safe operation in normal, peak, standby and failure modes.

9. Troubleshoot common retrofit failures

Symptom Likely causes Checks and corrective action
Some racks remain hot after containment Blocked supply, end-of-row recirculation, poor tile placement or sensor blind spots Trace the local airflow path, inspect underfloor obstructions and rebalance supply before lowering the room setpoint
Fan energy rises after airflow work Excessive static-pressure setpoint, blocked filters or containment leakage Trend remote pressure and valve positions; reset pressure only after the index circuit remains satisfied
Humidity alarms increase after raising temperature Control deadband, sensor error, dew-point interaction or inadequate coil performance Calibrate sensors, review dew-point logic and verify coil approach before reverting or widening limits
Chillers short-cycle at low load Incorrect staging, minimum-flow violation or overly aggressive reset Review sequencing, minimum run times and bypass behavior with the controls engineer
Economizer mode is rarely available Local humidity, wet-bulb conditions, contaminants or conservative lockouts Use measured hourly weather and water data; do not assume the installed economizer will deliver projected hours
Water use rises while energy falls More tower hours, higher blowdown or treatment changes Track WUE and tower operating data; optimize cycles and water controls without violating water quality limits

10. Protect resilience while improving efficiency

Efficiency changes must preserve the facility’s required redundancy, maintenance access and response time. Test loss of a chiller, pump, tower cell, CRAH unit, sensor and control network. Confirm that standby equipment starts at the expected load and that an economizer or reset sequence fails safe rather than driving water temperature or airflow beyond IT limits.

Do not treat PUE as a cooling-only score, assume energy savings automatically reduce water use, or raise temperatures beyond equipment requirements. A new chiller, liquid-cooling system or controls platform should be justified by measured load, climate, configuration and reliability analysis—not by a generic percentage.

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The DOE guide states: “No design guide can offer ‘the most energy-efficient’ data center design, but these guidelines can provide efficiency benefits for a wide variety of data center scenarios.” That qualification applies especially to retrofits, where existing ducts, pipes, controls, equipment limits and operating policies constrain the available choices: DOE FEMP Best Practices Guide announcement.

A defensible retrofit decision

Start with measurement, remove airflow waste, tune controls, then optimize chilled-water distribution and screen economizers. Escalate to liquid cooling or major plant construction only when the measured IT load and site conditions justify the cost, water use, complexity and risk. The winning project is the one that lowers verified cooling energy while keeping every rack within its operating limits and preserving the resilience the data center exists to provide.

Product prices and availability are accurate as of the date/time indicated and are subject to change. Any price and availability information displayed on Amazon at the time of purchase will apply.

airflow managementchilled watercooling efficiencydata-center coolingeconomizersLiquid CoolingPUEWUE

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