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Product Prototyping

Development Notes

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Product Prototyping

Description

Mestex Mission Critical has developed a reputation for creativity and rapid response to unique cooling applications in the mission critical space. As a result, Mestex has created a number of solutions for specific customers over time. While none of these solutions might satisfy your needs, they do illustrate the capabilities of Mestex to help meet your data center requirements...at almost any scale.

Limited space requires precise

CFD Analysis

A Cryptocurrency Scalable Solution

This image of a CFD analysis is from a prototype project for a cryptocurrency mining company. The requirement was for an easily scalable cooling solution that had an equipment “footprint” that would match the top of a reconfigured 40’ container. Given the tight space requirements mandated by the “footprint” it was critical to carefully analyze the airflow and fan pressure characteristics. The design concept allowed for multiple individual “pods” that could be mounted on top of the container and interconnected for power, controls, and evaporative cooling water to provide the total cooling required for the container. The upper section of the image is a model of the cooling pod while the lower section of the image is a model of the hot and cold sides of the server racks. A similar concept was proposed for remote machine control computers in the oil field industry.

supplemental data centers in

Reconfigured Shipping Containers

quick deployment

Reconfigured shipping containers are often considered as “quick deployment” supplemental data centers or remote site data or cellular sites. Cooling of reconfigured containers becomes challenging because of tight spaces, costs, repeatable scale, and integration with the IT equipment racks. A prototype and “capabilities show product” was requested by AWS on a tight schedule. The objective was to develop an air distribution system that could be inserted under the IT racks inside a container. The solution needed to be scalable by the addition of individual modules with interconnecting power/controls. Mestex produced a fully tested air handling prototype within 8 weeks. AWS then asked Mestex to provide a reconfigured container in time for the show when their normal supplier was unable to meet the deadlines.

High density equipment requires

Liquid Cooling

indirect adiabatic cooling

The introduction of very high-density/high-performance processing equipment created a number of cooling problems for manufacturers. Very high densities produce heat removal requirements that can no longer be satisfied with air movement. Liquid cooling becomes the answer...but deploying water cooling into a container-based data pod is a unique problem...especially when the specification is for an evaporative cooling solution. Mestex Mission Critical was approached by European company ATOS/Bull to develop such a solution for their Sequana server products. Mestex developed a prototype indirect adiabatic cooling module concept that attached to the end of a container containing two racks of HD/HP servers. Water was to be cooled indirectly and piped below the racks to each server stack. The prototype design was used to bid a project for a US space agency.

coordinated design on

Modular Data Center cooling

shipped seperately, installed without issues

ActivePower is a company that specializes in flywheel-based back up power solutions. However, the company has also produced a number of container-style modular data centers. Mestex Mission Critical worked with ActivePower to develop a fresh air-cooling module that would attach to the end of one of their modules during installation in the field. This not only required an innovative arrangement for both supply and exhaust fan arrays but also for very tight dimensional coordination with ActivePower. The MDC was being produced by ActivePower in their location while the cooling module was being produced by Mestex Mission Critical in their Dallas facility and shipped separately to the job site. The completed sections were painted to match and deployed on a Microsoft site with virtually no coordination issues.

reducing complexity on a complete

Modular Data Center redesign

reduce training time

While not precisely a prototype project, Mestex Mission Critical was contracted to resurrect a Modular Data Center design that had been abandoned by the previous manufacturer due to its complexity. ActivePower and Mestex worked together to bring this MDC back to life in order to allow the customers to have matching equipment on their sites. This reduced on-site training and maintenance requirements for the customers so that they could become operational more quickly. Several pods were deployed by Hewlett Packard for the US Department of State and the Bank of America. The MDC actually consisted of four, 44 foot long, sections that had to be connected at the job site. The two “hot aisles”, one “cold aisle”, and one “exhaust” section were manufactured with built-in connecting bolts. When the sections were completed the entire MDC was assembled to assure proper fit and then disassembled in the factory for shipping to the job site.

cost reduction and technology sharing in

International Collaboration

Significant Savings

CommScope was responsible for providing MDC solutions to a number of customers including NASA. The MDC solution that they provided was a complete data center (less the servers) that used a direct evaporative cooling technology and fan arrays. The MDCs were originally produced in Italy and shipped in sections to the sites in the US. The cost of shipping was becoming unacceptable and CommScope contacted Mestex Mission Critical for help. Working directly with the Italians, Mestex was able to manufacture the MDCs to spec and save CommScope and their customers significant costs. The partnership with the Italians also produced collaboration with Mestex Mission Critical on a project in Middle East with a global hyperscale data center company. This arrangement also resulted in technology sharing between Mestex and the Italians in the areas of fan technology, water distribution methods, and cabinet manufacturing techniques.

Take a look at our complete Literature Library for even more information

Literature Library