TECHNOLOGY COOLING SYSTEM

TCS / Direct liquid cooling loop

The liquid cooling loop is a system, not a collection of CDUs. Configure the full chain from heat rejection to the GPU cold plate, check hydraulics and materials, then source the complete loop as one package.

SOURCE COMPLETE TCS LOOPDemo data

LIQUID LOAD

9.0MW

REQUIRED FLOW

13,617L/min

ESTIMATED SYSTEM VOLUME

86,798L

TCS LOOP COMPLETENESS

LOOP BRIEF — ENGINEERING INPUTS

IT LOAD (MW)LIQUID CAPTURE FRACTIONΔT (K)COOLANTLIQUID-COOLED RACKSROWSHEADER LENGTH (m, one way)BRANCH LENGTH (m, total)VELOCITY TARGET (m/s)CDU UNIT SIZE (MW)REDUNDANCY

ENGINEERING CALCULATIONFlow derived from load, specific heat and ΔT using PG25 (25% propylene glycol) (cp 3.85 kJ/kg·K, density 1030 kg/m³). Common DLC secondary-loop fluid with inhibitor package. Every value is an engineer-overridable assumption, not a final design.

TCS LOOP — CLICKABLE ARCHITECTURE

Strainer / filtration

Secondary supply header

NOT SELECTED

08 · Secondary

Control / balancing valves

Hose / flexible connection

Secondary return header

SYSTEM SUPPORT — NOT IN THE SERIAL CHAIN, STILL REQUIRED

Side-stream filtration Air separation / degassing Expansion & pressurisation Isolation / check / drain valves Instrumentation & leak detection Fittings & couplings Coolant Fill / flush equipment

TCS LOOP COMPLETENESS

0 of 20 required loop categories selected.

· Coolant selected
· QD interface not confirmed
· Pipe material not selected
· Filter micron rating missing
· Expansion tank not sized
· Heat rejection not selected
· Primary pump not selected
· Secondary pump not selected
· CDU not selected
· Plate heat exchanger not selected
· Strainer not selected
· Filtration not selected

HYDRAULIC MATCH

Total thermal load9.00 MW liquid

Required flow13,617 L/min

Selected CDU flowCDU not selected

CDU quantity5 × 2.5 MW (N+1)

Preliminary header sizeDN400 — PRELIMINARY PIPE SIZE

Preliminary branch sizeDN150 — PRELIMINARY PIPE SIZE

System pressure drop0 kPa partial — missing: Pipe / header, Control valve, Strainer / filter, Heat exchanger, Manifold, Hose, Quick disconnect, Cold plate

ENGINEERING REVIEW REQUIRED — hydraulic validation is not complete while any element has no published pressure drop.

PRESSURE DROP BUDGET

ELEMENT	ALLOWANCE	BASIS
Pipe / header	SELECT PRODUCT	Indicative allowance for header and branch runs.
Control valve	SELECT PRODUCT	Typical authority allowance for a PICV.
Strainer / filter	SELECT PRODUCT	Clean-element allowance; rises with loading.
Heat exchanger	SELECT PRODUCT	Secondary-side allowance.
Manifold	SELECT PRODUCT	Row and rack manifold combined allowance.
Hose	SELECT PRODUCT	Flexible connection allowance.
Quick disconnect	SELECT PRODUCT	Supply and return QD pair.
Cold plate	SELECT PRODUCT	Dominant secondary-loop resistance.

ESTIMATED SYSTEM VOLUME

Header volume

54,470 L

Branch volume

18,157 L

CDU volume

1,250 L

Manifold volume

960 L

Hose volume

640 L

Fill margin (15%)

11,321 L

Geometry-based estimate. CDU internal volume assumed at 250 L per unit, rack manifold 12 L, hose set 8 L per rack. Replace with manufacturer volumes once products are selected.

MATERIAL COMPATIBILITY CHECK

Copper

COMPATIBLE BASED ON SOURCE

Nickel-plated copper

COMPATIBLE BASED ON SOURCE

Stainless steel 316L

COMPATIBLE BASED ON SOURCE

Brass

REVIEW REQUIRED

Aluminium

REVIEW REQUIRED

Carbon steel

REVIEW REQUIRED

EPDM

COMPATIBLE BASED ON SOURCE

FKM

COMPATIBLE BASED ON SOURCE

NBR

REVIEW REQUIRED

PTFE

COMPATIBLE BASED ON SOURCE

PP-R / PP-RCT

REVIEW REQUIRED

PEX

REVIEW REQUIRED

CPVC

REVIEW REQUIRED

HDPE

REVIEW REQUIRED

Checked against PG25 (25% propylene glycol). Compatibility is indicative — confirm against the coolant and component datasheets before release for construction.

TCS LOOP BOM

ITEM	QUANTITY	BASIS / ASSUMPTION	SELECTION
CDU	5	2.5 MW units at N+1	SELECT
Secondary pumps	10	2 per CDU (N+1)	SELECT
Primary pumps	6	Facility loop duty + standby	SELECT
Plate heat exchanger	5	Where CDU is heat-exchanger only	SELECT
Supply header DN400	240 m	Velocity target 2 m/s	SELECT
Return header DN400	240 m	Mirror of supply route	SELECT
Branch piping DN150	640 m	8 rows	SELECT
Row manifolds	8	One per row	SELECT
Rack manifolds	80	One per liquid-cooled rack	SELECT
Quick disconnect pairs	160	Assumption: 2 pairs per rack — confirm per server architecture	SELECT
Flexible hoses	320	Assumption: 4 per rack (supply/return, redundant)	SELECT
Control / balancing valves	26	Row branches plus CDU primary control	SELECT
Isolation / check / drain valves	88	Isolation at every row and CDU, with drains and vents	SELECT
Strainers	10	Primary and secondary side per CDU	SELECT
Side-stream filtration skid	3	Assumption: one skid per two CDUs	SELECT
Air separator / degasser	5	One per secondary loop	SELECT
Expansion / pressurisation set	5	Sized against 86798 L estimated volume	SELECT
Sensors (flow, pressure, dP, temperature, leak, quality)	178	Row, CDU and rack instrumentation	SELECT
Fittings, couplings, supports and insulation	Per piping route	Quantified at detailed design	SELECT
Coolant — PG25 (25% propylene glycol)	86798 L	Estimated system volume including 15% fill margin	SELECT
Fill / flush cart	1	Commissioning and service	SELECT

TCS CRITICAL PATH

Heat rejectionNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Primary pumpNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Secondary pumpNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

CDUNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Plate heat exchangerNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

StrainerNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

FiltrationNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Air separation / degassingNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Expansion & pressurisationNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Control & balancing valvesNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Isolation, check & drain valvesNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Instrumentation & leak detectionNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

ManifoldsNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Distribution headersNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Hose / flexible connectionNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Quick disconnectNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Cold plateNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

PipingNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Fittings & couplingsNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

CoolantNo product selected · LEAD TIME — REQUEST CURRENT QUOTE

Small components control readiness as often as the CDU. Quick disconnects, control valves, hoses, filters and fittings are tracked on the critical path — when a QD is the longest item the loop is flagged QUICK DISCONNECT IS CONTROLLING LIQUID-COOLING READINESS.

RFP → TCS LOOP MAPPING

UPLOAD AN RFP

Pipe material

Detects: ss316, 316l, stainless, carbon steel, pp-r

Pipe size

Detects: dn, nps, pipe size, diameter

Flow

Detects: lpm, l/min, gpm, m3/h, flow rate

Pressure

Detects: bar, kpa, psi, design pressure, working pressure

Delta T

Detects: delta t, δt, approach, supply temperature, return temperature

Coolant

Detects: pg25, pg 25, propylene glycol, glycol, treated water

Filtration

Detects: micron, filtration, strainer, side stream, particle count

Valve type

Detects: picv, balancing valve, control valve, butterfly, kvs

Manifold

Detects: manifold, header, branch

Detects: uqd, nvqd, quick disconnect, dripless, blind mate

Hose

Detects: hose, flexible connection, braided, epdm

Expansion tank

Detects: expansion, pressurisation, pressurization, buffer tank, make-up

Water treatment

Detects: water treatment, chemistry, inhibitor, biocide, conductivity

Leak detection

Detects: leak detection, leak sensor, tracetek, seahawk

Controls

Detects: bacnet, modbus, bms, sequence of operation

TCS COMMISSIONING

01Pressure test
Hydrostatic test of primary and secondary loops at design test pressure.
02Leak test
Held-pressure leak test across every joint, manifold and QD before energisation.
03Flushing
High-velocity flush of headers and branches; new piping is never assumed clean.
04Cleaning
Chemical clean where the pipe material and coolant programme require it.
05Filter replacement
Change flush elements to service elements after cleanliness acceptance.
06Air removal
Degassing and venting until stable dP and pump readings.
07Coolant fill
Fill with the specified fluid via the fill cart, recording batch and volume.
08Coolant concentration test
Verify glycol concentration and inhibitor level against datasheet.
09Water-quality test
Conductivity, pH, hardness and particle count against the cold-plate spec.
10Pump rotation
Direction, current draw and VFD parameter verification.
11Flow balancing
Balance rows and racks against design flow per rack.
12Valve commissioning
Stroke, authority, fail position and signal verification.
13Controls testing
Sequence of operation, setpoints, alarms and failover.
14Leak detection test
Simulate leak at rack and CDU; confirm alarm and isolation response.
15BMS integration
Point-to-point verification of BACnet / Modbus objects.
16Thermal load test
Load-bank or live-load verification of approach temperature and ΔT.

SYSTEM CLEANLINESS

Initial flush
Record flush velocity, duration and discharge condition.
Filter changes
Log every element change with differential pressure at change-out.
Particle level
Particle count against the cold-plate manufacturer limit.
Water quality
Conductivity, pH, chloride and hardness results.
Coolant quality
Concentration, inhibitor level and biological control.
Final acceptance
Cleanliness certificate issued before GPU load is applied.

New piping is never treated as clean. Cleanliness acceptance is required before GPU load is applied.