Data centre

Abstract

A data centre comprises a plurality of sections assembled together to define a unitary structure such that there exists at least one personnel area that spans at least two sections; wherein the sections comprise a first section with which there is associated a first service-carrying chassis and a second section with which there is associated a second service-carrying chassis, each of the first and second service-carrying chassis comprising a frame onto which is mounted components of at least two different services; the first and second chassis are connected to each other by means of a junction between the first and second chassis; and the first and second sections each include a ceiling and the first service carrying chassis is mounted on the ceiling of the first section and the second service carrying chassis is mounted on the ceiling of the second section.

Claims

1. A method of constructing a modular data centre for accommodating a plurality of rows of racks of IT equipment, wherein the modular data centre comprises a plurality of modules and at least one personnel area spanning two or more modules, each module comprises a data centre ceiling section and a plurality of supporting members for supporting the data centre ceiling sections above a floor, and each data centre ceiling section is structured and configured to cooperate with the racks of IT equipment to define alternating hot and cold aisles, wherein the method comprises: arranging the data centre ceiling sections and the supporting members into a first transport configuration having a first transport sum volume, wherein in the first transport configuration, the supporting members are detached from the data centre ceiling sections; transporting the data centre ceiling sections and the supporting members to an installation location with the data centre ceiling sections and the supporting members so arranged in the first transport configuration; arranging the data centre ceiling sections and the supporting members into a second assembled configuration to form the modular data centre at the installation location, the second assembled configuration having a second assembled sum volume; wherein the first transport sum volume is less than the second assembled sum volume, and wherein in the first transport configuration, each ceiling section is transportable independently of the plurality of supporting members.

2. The method according to claim 1, wherein, in the second assembled configuration, the data centre ceiling sections comprise air entrainment panels for filling space between tops of racks of IT equipment and a ceiling defined by the data centre ceiling sections.

3. The method according to claim 2, wherein, in the first transport configuration, the data centre ceiling sections comprise the air entrainment panels.

4. The method according to claim 1, wherein the method additionally comprises a step of joining together the modules of the data centre.

5. The method according to claim 1, wherein the arranging step includes arranging at least one data centre ceiling section and a portion of the plurality of supporting members into a single volume.

6. The method according to claim 1, the first transport sum volume is less than half of the second assembled sum volume.

7. The method according to claim 1, wherein, in the assembled configuration, the data centre ceiling sections each comprise components of at least two different services.

8. The method according to claim 7, wherein said components of at least two different services are mounted on at least one service carrying chassis attached to each data centre ceiling section.

9. The method according to claim 7, wherein said components of at least two different services on each data centre ceiling section are connected to corresponding components on an adjacent data centre ceiling section.

10. The method according to claim 7, wherein the at least two different services include services providing electrical power, data transfer, and a fluid; said components including a cable tray, a length of network cable, and a lighting system.

11. A method of constructing multiple sections of a data centre building at an installation location, wherein the data centre building is configured to accommodate a plurality racks of IT equipment arranged in rows separated by alternating hot and cold aisles, the data centre building has a personnel area spanning at least two of said sections, the personnel area is selected from: a cold aisle, a hot aisle, an air supply corridor for transporting air to a cold aisle, and an air exhaust corridor for transporting air from a hot aisle, and, each section includes a data centre ceiling portion supported above a floor on a plurality of supporting members, the data centre ceiling portion being structured and configured so that, in conjunction with the racks of IT equipment and the floor, the data centre ceiling portion separates a hot aisle from a cold aisle; wherein the method comprises: reconfiguring at the installation location a plurality of data centre ceiling portions and supporting members from: 1) a first transport configuration in which the data centre ceiling portions and supporting members occupy a first sum volume, to 2) a second assembled configuration in which the data centre ceiling portions and supporting members form a section of the data centre building and occupy second sum volume, wherein the first sum volume is smaller than the second sum volume; wherein, in the first transport configuration, the supporting members are detached from the ceiling sections; and, wherein in the first transport configuration, each ceiling section is transportable independently of the plurality of supporting members.

12. The method according to claim 11, wherein the data centre ceiling portions comprise air entrainment panels for filling space between tops of racks of IT equipment and a ceiling defined by the data centre ceiling portions.

13. The method according to claim 11, wherein the method additionally comprises a step of joining together the data centre sections.

14. The method according to claim 11, wherein at least one data centre ceiling portion and a portion of the plurality of supporting members are arranged into a single volume in the first transport configuration.

15. The method according to claim 11, the first sum volume is less than half of the second sum volume.

16. The method according to claim 11, wherein the data centre ceiling portions each comprise components of at least two different services.

17. The method according to claim 16, wherein said components of at least two different services are mounted on at least one service carrying chassis attached to each data centre ceiling portion.

18. The method according to claim 16, wherein said components of at least two different services on each data centre ceiling portion are connected to corresponding components on an adjacent data centre ceiling portion.

19. The method according to claim 16, wherein the at least two different services include services providing electrical power, data transfer, and a fluid; said components including a cable tray, a length of network cable, and a lighting system.

20. A method of constructing a portion of a data centre building, wherein said data centre building portion comprises two or more data centre ceiling portions supported above a floor by a plurality of supporting members, the two or more data centre ceiling portions being structured and configured to cooperate with the floor and racks of IT equipment to separate a hot air zone from a cold air zone, at least one of the hot air zone and the cold air zone including a personnel area extending below and between the two or more data centre ceiling portions, wherein the method comprises: transporting the two or more data centre ceiling portions and the supporting members to an installation location, the two or more data centre ceiling portions and supporting members being arranged in a transport configuration having a transport sum volume, wherein, in the transport configuration, the supporting members are detached from the ceiling sections, and, assembling together the two or more data centre ceiling portions and the supporting members at the installation location to form said data centre building portion, the data centre building portion occupying an assembled sum volume; wherein, the transport sum volume is smaller than the assembled sum volume; and, wherein in the first transport configuration each ceiling section is transportable independently of the plurality of supporting members.

21. The method according to claim 20, wherein the two or more data centre ceiling portions comprise air entrainment panels for filling space between tops of racks of IT equipment and a ceiling defined by the two or more data centre ceiling portions.

22. The method according to claim 20, wherein the method additionally comprises a step of joining together the two or more data centre portions.

23. The method according to claim 20, wherein at least one of said two or more data centre ceiling portions and a portion of the plurality of supporting members are arranged into a single volume in the transport configuration.

24. The method according to claim 20, the transport sum volume is less than half of the assembled sum volume.

25. The method according to claim 20, wherein the two or more data centre ceiling portions each comprise components of at least two different services.

26. The method according to claim 25, wherein said components of at least two different services are mounted on at least one service carrying chassis attached to each said two or more data centre ceiling portions.

27. The method according to claim 25, wherein said components of at least two different services on each said two or more data centre ceiling portions are connected to corresponding components on an adjacent data centre ceiling portion.

28. The method according to claim 25, wherein the at least two different services include services providing electrical power, data transfer, and a fluid; said components including a cable tray, a length of network cable, and a lighting system.

Description

DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which:

(2) FIG. 1 shows a plan view of a data centre according to a first embodiment of the invention;

(3) FIG. 2a shows a perspective view of a section of the data centre of FIG. 1;

(4) FIG. 2b shows an exploded view of the components of a section of the data centre of FIG. 1;

(5) FIG. 3 shows a partial perspective view of the data centre of FIG. 1;

(6) FIG. 4 shows a perspective view of a service carrying chassis according to the first embodiment;

(7) FIG. 5 shows a perspective view of a different service carrying chassis according to the first embodiment;

(8) FIG. 6 shows a perspective view of a further different service carrying chassis according to the first embodiment;

(9) FIG. 7 shows a perspective view of yet another different service carrying chassis according to the first embodiment;

(10) FIG. 8 shows a perspective view from above of a ceiling portion and supports according to the first embodiment;

(11) FIG. 9 shows a perspective view from below of a ceiling portion, service carrying chassis and supports according to the first embodiment;

(12) FIG. 10 shows a perspective view of a floor portion and other components of a data centre section according to the first embodiment;

(13) FIG. 11 shows a perspective view of components of a data centre section according to the first embodiment;

(14) FIG. 12 shows a perspective view of packaged components of three data centre sections according to the first embodiment;

(15) FIGS. 13a and b show perspective views of a DX module and an air optimiser module respectively according to the first embodiment;

(16) FIG. 14 shows a perspective view of a partially assembled section of the data centre of FIG. 1;

(17) FIG. 15a shows a perspective view of all of the sections of the data centre of FIG. 1;

(18) FIG. 15b shows a perspective view of the data centre of FIG. 1;

(19) FIG. 16a shows a perspective view of part of a twostorey data centre according to a second embodiment;

(20) FIG. 16b shows an exploded perspective view of parts of the data centre shown in FIG. 16a; and

(21) FIG. 17 is a composite illustration showing on the right-hand side a perspective cut-away view of the two-storey data centre of the second embodiment and on the left hand side schematic representations of the construction of the ceiling of each storey.

DETAILED DESCRIPTION

(22) FIG. 1 shows the layout of a data centre building 10 according to a first embodiment of the invention. At either 15 end of the building 10 there is an entrance, 11. At the front of the building there is a fire exit 12. Also at the front of the building are two ambient air intake holes 13. Each ambient air intake 13 contains a set of controllable louvres which enable the amount of ambient air that is allowed into the building to be controlled. Ambient air entering the building is denoted by the white arrows.

(23) Between the two ambient air intakes 13 there are two holes defining a pair of exhaust air outlets 14. Exhaust air outlets 14 also each contain a set of controllable louvres. Exhaust air exiting the building is denoted by the black arrows.

(24) The data centre building is made up of eight sections 15a-h, with the joins between adjacent sections shown by dotted lines. The short ends of the rectangular sections form the front and back external side walls of the building. The left-hand side of section 15a and the right-hand side of section 15h form the left and right external side walls respectively of the building. All of the sections 15a-h have the same dimensions and basic construction, differing only in the provision and arrangement of internal and external doors and walls and air inlets and outlets.

(25) FIG. 2a shows section 15e (internal walls have been omitted for the sake of clarity) in isolation. FIG. 2b shows an exploded view of the components of section 15e with internal walls, but omitting external wall panels). All of the sections 15 consist of a floor portion 21, a ceiling portion 22, four corner support posts 23, four intermediate support posts 24, and six external wall panels (only the three front external wall panels are shown in FIG. 2a). Section 15e additionally includes a fire door in the front end wall, and sections 15d and 15f each additionally include an exhaust air outlet 14 in the front end wall. The external wall panels of these sections are shaped appropriately to accommodate these features. The external wall panels are formed from highly insulated aluminium panels, with a fire resistance of at least one hour.

(26) Floor portion 21 and ceiling portion 22 are both based on a framework consisting of two long side steel beams 26, two short end steel beams 27, and four steel corner elements 28, which are designed to connect with the corner posts 23. The beams and corner elements are welded together in a rectangular shape. Steel joists (not visible) extending between the side beams are provided at regular intervals. The steel beams may, if desired, be provided with weakened sections which allow them to flex, so that the data centre building will be more resilient in the event of an earthquake.

(27) Floor portion 21 additionally has a plywood floor deck supported on the joists, and a sheet of waterproof liner material fixed to the bottom of the joists. Ceiling portion 22 additionally has insulating material fixed above and below the joists, and a steel panel roofing system (such as Kingspan) including falls to both sides of the roof and external drainage collection, fixed over the top layer of insulating material. The lower surface (not visible) of the ceiling portion 22 is made from steel plate with a plastic coating finish.

(28) Inside the section 15e there is an internal wall consisting of three internal wall panels 29 (one of which includes a glass viewing pane) and a vented door assembly 19. Two further internal wall panels 29 are also provided at the opposite end of section 15e. These serve to seal off the end of a cold aisle in the data centre. The internal and external wall and ceiling portions may, if desired, be constructed with magnetic shielding, RF or X-ray protection. The internal finish of the walls and ceiling is a plastic coated galvanised steel finish.

(29) Data centre 10 comprises eight sections 15 arranged adjacent to each other and bolted together. Sections 15a and 15h, which will henceforth be referred to as air optimizer sections, each contain a region 16 which is designed to accommodate air treatment equipment such as adiabatic coolers, DX coolers, filters and fans. Sections 15a and 15h also each include an ambient air intake 13 through which ambient air can enter the data centre building 10, a controllable return air vent 17 through which warm air exhausted by IT equipment in the data centre can be returned to the air treatment equipment, and an air mixing box 18 for mixing the air from return air vent 17 and ambient air intake 13. Sections 15a and ISh additionally each have an internal wall running along most of the length of one side of the section. These walls include the return air vents 17 and several doors which provide access to the air treatment equipment.

(30) Sections 15b-g, which will henceforth be referred to as IT sections, are designed to accommodate IT equipment housed in standard server racks of up to 1200 mm depth. Each section 15b-g contains elongate rectangular rack storage areas (sections 15b-f each have two such rack storage areas whilst section 15g has just one, to allow for access to the adjacent air treatment region 16). Each rack storage area is effectively defined by a single row of racks 20 running lengthways along the section, i.e. widthways across the building.

(31) In each section 15b-g at the rear end of the rack storage area(s) there is an internal wall running across the entire width of the section. A vented door 19 having controllable louvres is provided in the wall to allow personnel access and the passage of cooling air into the space between the racks, which is therefore a cold aisle. An additional, smaller internal wall is provided at the opposite end of the rack storage areas, spanning the gap between the racks. This internal wall is designed to close off the cold aisle at the front end. At the top of both rows of racks 20 are over-rack blanking plates (not shown) designed to stop cold air passing between the top of the racks 20 and the ceiling of the section. Hence, air can only leave the cold aisle through the racks 20.

(32) When the sections are connected together a corridor running along and in between the rear external wall of the building and the rear internal walls is defined. This corridor runs along the entire length of the data centre building 10, terminating at each end in a wider area directly behind each air treatment region 16. The air treatment equipment supplies cooling air directly into this corridor at each end, hence it is a cold corridor. From this cold corridor, the cooling air passes through the vented doors 19 into the cold aisles.

(33) The spaces that are defined between the rear sides of adjacent rows of racks when the sections 15a-h are connected together receive warm air exhausted by IT equipment in the racks, and are therefore hot aisles. The hot aisles are directly connected to a larger hot corridor which runs adjacent to the front external wall of the building, between the two return air vents 17. Hot air can exit the hot corridor through exhaust air outlets 14 and/or return air vents 17.

(34) The data centre building 10 includes various services including lighting, smoke detection and fire suppression, power distribution, and controlling the air treatment equipment. As far as possible the mechanical and electrical apparatus is mounted on the ceiling of the data centre building 10. The arrangement of the mechanical and electrical apparatus in data centre building 10 will now be described with reference to FIGS. 3-7.

(35) The space behind the air treatment region 16 in section 15h, which is shown in detail in FIG. 3, contains a power metering panel for monitoring the power consumed by each rack in the rack room module, two electrical distribution panels 32, a control process panel 31, a VESDA (Very Early Smoke Detection Apparatus) fire detection monitoring panel, and an uninterruptible power supply and back-up batteries. These apparatus are mounted on the walls of section 15h, which is the only section of the data centre building 10 to have any wall-mounted mechanical and electrical apparatus. A metal grille 33 separates the electrical distribution panels from the other panels. The grille 33 includes a portion that can be opened to allow personnel access to the electrical distribution panels 32.

(36) Each of the IT sections 15b-g also has its own subcontrol panel, referred to as an outstation. The outstations 15 are located directly above the vented doors 19, and are integral with the door frames. Each outstation monitors and controls the position of the louvres in the vented door in its section, based on airflow velocity data for the cold aisle in its section. This data is provided by sensors located in ducts which link each cold aisle to an adjacent hot aisle.

(37) The control process panel 31 receives data, such as temperature and humidity data, from various sensors inside and outside the data centre building 10. It also receives information about the positions of the louvres in the vented doors 19 from the outstations. It uses this information to control the air treatment equipment and the various controllable intake and outlet vents in order to achieve effective and energy efficient cooling of IT equipment in the racks.

(38) The control process panel 31 communicates with the outstations, sensors, air treatment equipment and controllable vents using a wired network. Each outstation, sensor, item of cooling equipment and item of mechanical and electrical equipment which is monitored and/or controlled by the control process panel 31 must therefore be connected to it by a network cable. Network cables must also be connected to all of the IT equipment in the racks. Other services which must be distributed around the data centre building 10 include power, which is distributed using busbars, fire suppression gas, and lighting. In data centre 10 this is achieved by mounting all of these services to the ceiling using a system of service cassettes.

(39) FIG. 4 shows a cold corridor service cassette 40, for use in the cold corridor of data centre 10. The cassette 40 consists of a metal framework 41 which supports a length of main busbar 42, a length of back-up busbar 43, two lengths of UPS busbar 44 (which distributes power from the uninterruptible power supply), a cable tray 45, and a light fitting 46. A smoke sensor (not shown) is also attached to framework 41.

(40) The busbar lengths 42, 43, 44 are provided with connectors 47 at each end so that they can be joined to adjacent busbar lengths on neighbouring service cassettes. The main and back-up bus bar lengths 42, 43 are also provided with junctions 48 which allow right-angled connections to be made with other busbars. The UPS busbar lengths have similar junctions (not shown) at a different point along their length. It will also be seen that the main busbar length 42 and the back-up busbar length 43 are each actually made up of two separate sections connected together. The light 46 is connected directly into the main busbar, and is wired to infrared sensors (not shown) attached to framework 41. The infrared sensors detect when the area immediately surrounding the light 46 is occupied and activate the light 46 only when this is the case. There is therefore no need for light switches to be provided on the walls.

(41) The length of the cold corridor service cassette 40 is equal to the width of a section 15. One cassette 40 is mounted on the ceiling of each section 15 so that when the sections 15 are arranged adjacent each other, the busbar lengths in neighbouring service cassettes meet and can be connected together. Hence four busbars (main, back-up, small power UPS, and general lighting and power) are formed which run along nearly the entire length of the cold corridor, on the ceiling.

(42) FIG. 5 shows a cold aisle service cassette 50, for use in the cold aisles of data centre building 10. Service cassette 50 consists of a metal framework 51 which supports the UPS and general busbar lengths 52, a cable tray 53, a length of fire suppression gas pipe 54, a light fitting 55 and its associated infrared sensors, and a smoke sensor (not shown). The UPS and general busbar lengths 52 are provided with connectors at each end. As with the light 46, light 55 is arranged to activate automatically when the area immediately surrounding the light is occupied.

(43) The length of the cold aisle service cassette 50 is such that three cassettes 50 placed end-to-end are the same length as each of the cold aisles. Thus, when three cassettes 50 are mounted on the ceiling of a cold aisle and connected together they provide a small power UPS busbar, a general lighting and power busbar, and a fire suppression gas pipe which run the entire length of that cold aisle. The UPS busbar provides an uninterruptible power supply to the IT equipment in the racks facing onto that cold aisle.

(44) FIG. 6 shows a hot corridor service cassette 60, for use in the hot corridor of data centre building 10. Most of the mechanical and electrical services are routed through the cold corridor, so cassette 60 simply consists of a metal framework 61 which supports a cable tray 62. A light fitting (not shown) and its associated sensor, and a smoke sensor (not shown) are also fixed to the framework 61. The length of the hot corridor service cassette 60 is equal to the width of a section 15. One cassette 60 is mounted on the ceiling of each section 15 so that when the sections 15 are arranged adjacent each other, cable trays and lighting are provided along the entire length of the hot corridor.

(45) FIG. 7 shows a hot aisle service cassette 70, for use in the hot aisles of data centre building 10. Cassette 70 consists of a metal framework 71 which supports a length of main busbar 72, a length of back-up busbar 73, and a light fitting 74. Infrared sensors (for operating the light) and a smoke sensor are also fixed to framework 71. The busbar lengths 72 and 73 are provided with connectors at each end. The length of the hot aisle service cassette 70 is such that three cassettes 70 placed end-to-end are the same length as the hot aisles. Thus, when three cassettes 70 are mounted on the ceiling of a hot aisle and connected together they provide a main busbar and a back-up busbar which run the entire length of that hot aisle. These busbars provide the main power supply for the IT equipment in the racks backing onto that hot aisle.

(46) The service cassettes 40, 50, 60 and 70 are mounted to the ceiling via rails attached to the ceiling portions. The cassettes 40, 50, 60 and 70 have gripping members (not shown) which fit around the rails. These gripping members secure the service cassettes to the ceiling whilst also permitting sliding movement along the rails, which facilitates the task of connecting adjacent cassettes. Each gripping member includes a bolt which, when the service cassette is in the desired place, can be screwed in so as to press against the rail. When screwed in the bolts prevent the service cassette from sliding.

(47) Adjacent cassettes of the same type are connected end-to-end as described above. However, busbars carried by the hot aisle service cassettes 70 and the cold aisle service cassettes 50 must also be connected to the busbars carried by the cold corridor service cassettes 40. For the cold aisles this is achieved by connecting the ups busbars in the cold corridor to each of the outstations using the junctions provided on the UPS and general busbars. The UPS and general busbars in each of the cold aisles are then also connected to their respective outstations by the connectors at the end of the busbar lengths.

(48) The main and back-up busbars in the hot aisles are connected directly to the main and back-up busbars in the cold corridor at junctions 48, by way of additional lengths of busbar which pass through slots in the internal wall between the cold corridor and each of the hot aisles. These additional lengths of busbar connect at one end to connectors on the hot aisle service cassettes 70 and at the other end to the junctions 48. The slots in the internal wall are arranged to seal around the busbars (and any cables) which pass through them so as to prevent air passing between the cold corridor and the hot aisles.

(49) The fire suppression gas pipes carried by the cold aisle service cassettes 50 are sealed at the ends which terminate at the internal wall separating the cold aisles from the cold corridor. At their opposite ends, each of the pipes passes through a hole in the internal wall between the cold aisle and the hot corridor. These holes are sealed around the pipes so as to prevent air passing from the cold aisle to the hot corridor. In the hot corridor each gas pipe runs vertically down the internal wall to connect with a pair of cylinders in which fire suppression gas is stored.

(50) The method by which a data centre building 10 is constructed will now be described with reference to FIGS. 8-15.

(51) The air treatment sections 15a and 15h are composed of the set of components listed in table 1a. The IT sections 15b-g are composed of the set of components listed in table 1b. These components may all be manufactured in a central factory, alternatively the manufacture of some of the components may be outsourced to specialist manufacturers to reduce costs and build time. If the data centre building is to be located in a different country from the central factory, or even a considerable distance away in the same country, it is advantageous to source these components from a manufacturer local to the data centre site. In the case of the floor and roof coverings a particular local supplier is nominated to ensure high levels of consistency and quality.

(52) TABLE-US-00001 TABLE 1 Components of an air optimiser section Section Component Source Air optimizer Building Central factory section(15a and management system 15h) controls Power metering Central factory apparatus Fans Central factory Humidifier and Central factory humidifier control DX cooling Central factory controls and expansion Trim Packs Central factory Sensors Central factory Louvre actuators Central factory Building Central factory Management System Fire alarm and Central factory fire suppression systems Floor portion Locally Sourced Ceiling portion Locally Sourced Corner and Locally Sourced intermediate posts External wall Locally Sourced panels Internal Wall Locally Sourced panels Internal and Locally Sourced external doors Air intake and Locally Sourced return air vent louvres Coldlocks and Locally Sourced easipaths Transit covers/lifting Locally Sourced eyes/locating plates Fixings Locally Sourced Air Optimiser Locally Sourced chassis Low Voltage Locally Sourced electrical panels Service cassettes Locally Sourced Cabling Locally Sourced DX units Locally Sourced Floor Covering Locally Sourced Roof Covering Locally Sourced

(53) The components which are marshaled in the central factory include the controls for the building management system and for the DX cooling units, all of the power metering apparatus for the data centre building, the humidifiers and their associated controls, the various sensors used to control the data centre, and trim packs, which include the external cladding and fascias, internal skirting and ceiling trims, and trims for the doors and louvre frames. These components are packaged up and transported to a local assembly facility relatively near the site where the data centre is to be located.

(54) TABLE-US-00002 TABLE 2 Components of an IT section IT SECTION (15b-g) Outstation Central factory IT room network Central factory switches Vented doors and Central factory actuators Power metering Central factory apparatus Trim packs Central factory Floor portion Locally sourced Ceiling portion Locally sourced Corner and Locally sourced intermediate posts External wall Locally sourced Panels Internal wall Locally sourced panels Internal and Locally sourced external wall doors Blanking panels Locally sourced Exhaust air outlet Locally sourced louvres Coldlocks and Locally sourced easipaths Transit Locally sourced covers/lifting eyes/locating Plates Fixings Locally sourced Service cassettes Locally sourced Cabling Locally sourced Fire alarm and fire Locally sourced suppression systems Floor covering Locally sourced Roof covering Locally sourced

(55) Locally sourced components, which include the components making up the structural frame of the sections, are delivered to the local assembly facility from the local manufacturer from which they have been commissioned.

(56) At the local assembly facility, the roof and floor coverings are installed on the ceiling portions 22 and the floor portions 21. Then the service cassettes carrying most of the mechanical and electrical apparatus required in the data centre building 10 are fitted to the ceiling portions 10 22 for the IT sections 15b-g. To allow easy fitting of service cassettes to a ceiling portion 22, in the local assembly facility the ceiling portion is supported on columns 81 which are just tall enough to allow a person to stand underneath the ceiling portion, as shown in FIGS. 8 15 and 9.

(57) As a first step, rails are fitted to the underside of the ceiling portion 22, along the width of the portion in the regions that will form parts of the ceilings of the hot corridor and the cold corridor, and along its length in the regions that will form the ceilings of the hot aisle and the cold aisle. A cold corridor service cassette 40 is then engaged with the rails on the cold corridor ceiling region and slid into place so that the ends of the service cassette 40 line up with the long edges of the ceiling portion 22. When in place the bolts on the gripping members are screwed in to prevent further movement of the cassette 40.

(58) Three hot aisle service cassettes 70 are engaged (in series) with the rails on the hot aisle ceiling and slid into position. Connections are made between the busbar lengths 72 and 73 carried by the service cassettes 70 and the bolts on the gripping members are screwed in to secure the service cassettes 70 in position. This process is repeated for the three cold aisle service cassettes 50 and the hot corridor service cassette 60.

(59) Bulkheads 91 which fill the space between the top of the racks 20 and the ceiling are also fixed to the ceiling portion 22 at this point. The ceiling portion 22 is then ready to be packed up with rest of the structural components of the IT section.

(60) All of the structural components of the IT section can be arranged into a compact space for transit by arranging them as follows. The external wall panels 25, vented door assembly 19, corner posts 23, intermediate posts 24 and internal wall panels 29 are laid out flat on top of floor portion 21 as shown in FIG. 10, and temporarily fixed into place using any suitable removable securing means known in the art. The ceiling portion 22, with attached service cassettes and bulkheads is then placed on top of these components as shown in FIG. 11 to form a package 111.

(61) The corner elements 28 are formed such that the corner elements of the ceiling portion 22 have a wide section and a narrow section, with a lip where these two sections meet. The narrow section can be inserted into the corresponding corner element on the floor portion 21. The lip then rests on the top of the floor portion corner element and supports the weight of the ceiling portion 22. The height of the corner elements 28 is such that when the floor and ceiling portions are fitted together in this manner there is a small gap between the bottom of the service cassettes and the components laid out on top of the floor portion 21. Thus the ceiling portion 22 covers and protects the components laid out on the floor portion 21 but does not bear any weight onto them. The corner elements 28 of the floor and ceiling portions are then bolted together to allow the entire package 111 to be handled as a single unit.

(62) The process of assembling and packing the components of the air optimisation sections 15a and 15h is very similar to that described above for the IT sections 15b-g, however service cassettes are not used in these sections. The packing process for an air optimisation section therefore involves just arranging and securing the components of the air optimisation section between the floor and ceiling portions 21 and 22 and fixing the floor and ceiling portions together to form a package 112. Because the floor and ceiling portions of the air optimisation sections are identical to the floor and ceiling portions of the IT sections, the packages 111 and 112 are of identical shape and size. Three such packages stacked one on top of the other, as shown in FIG. 12, will fit into a standard ISO shipping container. A cover 121 protects the floor and ceiling portions 21, 22 from incurring cosmetic damage during transit.

(63) The remaining components of the data centre which are not packed up with the IT sections and air optimizer sections are packaged up separately. In particular, the DX units are packaged into self-contained DX modules 131. A DX module 131 is shown by FIG. 13a. In each DX module 131 the DX units 132 are secured into a stackable metal frame 133 which is designed to fit within a standard ISO shipping container. All of the DX condensers 132 in a DX module 131 are connected up to power and control cabling and refrigerant gas pipework which meets at a single connection point (not visible). The DX modules 131 can be installed onto the data centre building 10 in this form, and only require connection to the appropriate utilities (i.e. power, a supply of refrigerant gas, and the process control panel 31) before being ready for use.

(64) The other items of air treatment apparatus required by the data centre are also provided packaged in stackable metal frames 135 with single connection points, as shown by FIG. 13b. Five such frames carryall of the air treatment equipment required by a single air optimisation section 15a, 15h. Frame 134a carries sound attenuators. Frame 134b carries a bank of variable speed fans. Frame 134c carries humidifiers. Frame 134d carries the DX cooling coils.

(65) Finally, Frame 134 e carries air filters. Each frame 134a-e also carries a door 135 to allow access to the air treatment equipment. The frames 134a-e can be connected together to form an air optimisation module 136 which can then be inserted into an air optimisation region 16 in one of the air optimisation sections 15a, 15h.

(66) Once packed up, all of the components of the data centre building 10 are transported to the site where the data centre is to be located. This site must be provided with a flat, level foundation and connections to supplies of electricity and water, drainage facilities, and a communications network.

(67) Erecting the data centre building 10 from its constituent components requires no skills beyond what a typical construction worker would possess, and as such it is possible to use a construction team hired locally to the data centre site. The process of erecting the data centre building 10 will now be described with reference to FIGS. 14 and 15.

(68) The first step in the erection of the data centre building 10 is to separate the section packages 111, 112 and remove the components which are secured to the floor portions 21. Each section 15 is then erected as follows. The corner posts 23 and intermediate posts 24 are connected to the floor portion 21 and bolted in place. The ceiling portion 22 is then lifted onto the corner and intermediate posts. The corner elements 28 of ceiling portion 22 and the corner posts 23 are shaped such that the top portion of each corner post 23 receives within it the narrow part of the corresponding corner element 28. The corner elements of the floor portion 21 and the bottom portion of each corner post are similarly complementarily shaped, however the bottom portion of each corner post is received within the corresponding floor portion corner element. The top and bottom ends of the intermediate posts 24 are received into recesses in the ceiling portion 22 and floor portion 21 respectively. This ensures that the structure formed by the floor portion 21, corner posts and ceiling portion 22 remains securely in place until all of the corner elements 28 can be bolted to the corner posts 23.

(69) Once this basic section structure has been assembled, the internal wall panels 29 are fixed into place as shown by FIG. 14. The vented door 19 and outstation is installed at this stage, as are the busbar sections which connect the cold corridor busbars to the busbars in the hot and cold aisles. Then the external wall panels 25 are fixed to either end of the section and, where necessary, the external doors and/or louvres are fitted. This can be done simultaneously with the internal walls being installed. These are the only steps involved in the assembly of an IT section.

(70) For an air optimiser section 15a, 15h, the following additional steps are required. External wall panels 25 are fitted on one of the long sides of the section. Internal walls and doors are fitted to enclose the air treatment region 16. Power management zone panels (which include the control process panel 31 and electrical distribution panels 32) are fitted to the inside surfaces of the space behind the air treatment region 16. The air optimisation module 136 equipment is installed in the air treatment region 16.

(71) The assembled sections 15 can be moved around using the crane or combi-lifter. In this manner the sections are arranged adjacent each other as shown in FIGS. 15a and 15b. The left-hand air optimiser section 15a is placed in position first. Then IT section 15b is positioned and fixed next to section 15a. The remaining sections 15c-h are positioned and fixed together, including connecting the hot corridor service cassettes 60 and cold corridor service cassettes 40 in adjacent sections, to form the complete data centre building 10.

(72) By this stage, most of the mechanical and electrical apparatus is already installed in the building by virtue of the service cassettes. The remaining mechanical and electrical fitout tasks include installing a pair of fire suppression gas cylinders in the hot corridor of each section and connecting these to the fire suppression gas pipe on the ceiling of the hot aisle in that section, installing the control process panel 31 and the electrical distribution panels 32 into section 15a, running network cables around the building to connect the control process panel 31 to the various sensors, louvres, outstations and air treatment equipment which it monitors and/or controls, and connecting the busbars to the electrical distribution panels. It will be appreciated that these tasks are rendered fairly minor because the distribution of power, cables, lighting, sensors and fire suppression gas pipework throughout the IT sections of the data centre 10 has already been taken care of by the service cassettes.

(73) At this stage the data centre is ready for the racks to be installed and for it to be connected up to the local utility supplies, which is a simple matter of making a connection at a single point. The data centre building can then be commissioned and populated with IT equipment. Using the method described above, the entire manufacture and construction process from order to completion can take less than six weeks.

(74) FIGS. 16a, 16b and 17 show a data centre building 210 according to a second embodiment of the invention. FIG. 16b is an exploded view of the main parts shown in FIG. 16a. In contrast to the first embodiment, the data centre building of the second embodiment is a multi-storey data centre. The interior layout and operation of each storey of the data centre 210 is very similar to the single-storey data centre of the first embodiment, and for example each level comprises two air optimiser sections, and six IT sections. There are however differences between the first and second embodiments which are described below.

(75) In this second embodiment the ceiling portions 222 of the ground floor storey also serve as the floor portions 221 of the sections immediately above. This does not require any alteration to the basic structure of the ceiling portion; rather it is simply a matter of fixing flooring material to the top of the ceiling section 222 rather than roofing material. Thus, as shown in FIGS. 16a and 16b, the ceiling portion 222 comprises a framework consisting of two long side steel beams 226, two short end steel beams 227, and four steel corner elements 228, which are designed to connect with the ground floor corner posts 223a (shown in FIG. 16a) which support the ceiling portion 222. The lower surface (not visible) of the ceiling portion 222 is made from steel plate with a plastic coating finish.

(76) On top of the ceiling portion 222, the floor 221 is defined by means of a plywood floor deck supported on the joists of ceiling portion 222.

(77) In this second embodiment, the corner elements 228 also support the corner posts 223b of the first floor. Similarly, intermediate support posts 224b for the first floor extend upwardly from the ceiling portion 222.

(78) As best shown in the exploded view of FIG. 16b, a cold corridor service cassette 40, a cold aisle service cassette 50, a hot aisle service cassette 70, and a bulkhead 91 are mounted on the lower surface of the ceiling portion 222.

(79) FIG. 17 shows (on the right hand side) a cut-away perspective view of the two-storey data centre 210 once installed in a larger building. In this embodiment, the floor 300 of the building accommodating the data centre 210 provides the floor of the ground-level storey of the data centre 210. It will be appreciated that the larger building may, as a result of housing a data centre, itself be considered as a data centre or a data centre building, despite possibly performing other functions. In the case where a larger building is used to house the data centre, there may be less of a requirement for water-proofing of the top storey of the data centre 210. It may for example be provided without additional roofing elements. The uppermost ceiling portions 222 of the data centre 210 of FIG. 17 are not for example provided with any roof linings or sloped roof panels for draining rain water. As shown schematically on the left hand side of FIG. 17, the uppermost ceiling portion 222b comprises a steel structure 294 onto the underside of which are mounted the service cassettes (labelled collectively as item 299). The ceiling portion 222a between the ground and first floors, also shown schematically on the left hand side of FIG. 17, similarly comprises a steel structure 294 onto the underside of which are mounted the service cassettes 299, but also has floor covering (collectively represented by numeral 295) mounted on top of the joists.

(80) Whilst not shown in FIG. 17, an external metal staircase is fixed to the outside of the modules to provide access to the upper level of the data centre.

(81) Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated herein. By way of example only, certain possible variations will now be described.

(82) The data centre building 10 of the first embodiment is designed to be installed on an outside site. The present invention may equally well be used for a data centre (single or multi-storey) which is to be located inside an existing building, for example a warehouse. In this case the roof portions do not need to be covered with roofing material, and there is no need to provide floor portions at all. Instead corner elements 28 can be provided separately for fixing to the floor as supports for the corner columns.

(83) Packages 131 require a base board onto which the section components can be secured since there are no floor portions. This results in the packages being considerably lighter and slightly smaller in volume. When assembling the data centre building, each section must be constructed in its final position since the sections do not form complete volumetric units that can be moved around after being assembled.

(84) The data centre components which are centrally manufactured or locally sourced may be different from the lists set out above. It will be appreciated that any division is possible, and indeed all of the components may be sourced locally or manufactured centrally. If all of the data centre components are manufactured centrally then the sections 15 will be packed into packages 111, 112, and the DX units will be packed into DX modules 131, in the central factory and will be sent straight to the final site.

(85) The bulkheads 91 mentioned above could instead be provided as steel structure incorporated in the ceiling portions 22.

(86) The data centre building could be constructed as a multi-storey data centre building, having more than two storeys.

(87) Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.