I was driving to work and happened to listen to this podcast hosted by Legrand – Data Center Solutions. This podcast presents latest innovations, challenges, and trends shaping the future of data center technology. The experts on the panel answer questions and share tips on how to optimize airflow, reduce cooling costs, and improve overall data center efficiency.
A core theme was the importance of sealing techniques to prevent the mixing of hot and cold air. This seemingly simple concept seems to be a significant hurdle in real-world data centers. Experts in this podcast highlighted the challenge of identifying and addressing all potential air leaks, from small gaps in server racks to larger openings in raised floors.
Learning Outcomes for Data Center Professionals
The podcast offered valuable learning outcomes for anyone involved in data center operations, I’m sharing some of them below:
- Containment is Fundamental: The core principle is the strict separation of hot and cold air streams. Experts repeatedly stressed that effective containment (hot or cold aisle) is foundational for efficient cooling and preventing air mixing.
- Small Gaps, Big Impact: Even seemingly minor unsealed openings in racks, floors, or containment systems can significantly undermine cooling efficiency by allowing air bypass. Identifying and sealing these “small details” was highlighted as a major practical challenge and opportunity for savings.
- Measurement Drives Efficiency: The importance of continuously monitoring temperature, pressure, and airflow data was emphasized. This data provides the insights needed to identify inefficiencies, confirm the success of improvements, and make ongoing adjustments for optimal performance.
- Airflow is Dynamic, Requiring Continuous Effort: It’s not a one-time fix. Data centers constantly change, so airflow management requires a proactive, ongoing approach of monitoring, analysis, and adaptation to maintain efficiency and realize energy savings.
Driving Continuous Improvement in Airflow Efficiency: Two Project Ideas from the Frontlines
As I learned from this podcast, even small improvements in air distribution and containment can translate into substantial energy savings and better Power Usage Effectiveness (PUE). But behind the scenes, it’s not just about better blanking panels or smarter fans. it’s also about the engineers and quality leaders driving sustained, measurable improvements in how infrastructure performs over time.
Here are two continuous improvement project ideas that I brainstormed to tailor to Supplier Quality Engineers and Infrastructure Reliability Engineers that align directly with airflow efficiency goals:
Project 1: “Zero Leakage Initiative”
Objective:
Eliminate air leakage from raised floor systems, containment panels, grommets, and blanking plates across 90% of new builds and retrofits.
Why this matters:
From the podcast, we know even tiny gaps in containment lead to bypass airflow—forcing CRAC units to work harder. This directly increases PUE.
Key Steps:
- Audit 10 recent installations for airflow bypass issues using smoke testing and thermal imaging.
- Develop a standardized inspection checklist with pass/fail tolerances for tile gaps, seal quality, panel fitment.
- Implement a supplier training and requalification program focusing on mechanical tolerance and seal materials.
- Launch a Smartsheet-based QC tracker for commissioning teams to report leakage risks.
- Close the loop using quarterly scorecards and SCARs to drive vendor accountability.
Expected Outcome:
- Reduction in airflow-related commissioning rework.
- Improvement in localized PUE via better containment.
- Improved supplier compliance and first-pass yield.
📚 References for “Zero Leakage Initiative” Project
- Geng, Hwaiyu. (2015).
Data Center Handbook: Plan, Design, Build, and Operations of a Smart Data Center. Wiley. This source highlights that air leakage, especially through unsealed floor tiles, cable cutouts, and gaps in blanking panels can lead to bypass airflow and reduce cooling system efficiency.
Quote:
“Leaks through floor tiles, cable cutouts, or missing blanking panels can significantly reduce airflow efficiency, increase bypass airflow, and contribute to hot spots.”
— Geng, H., Data Center Handbook, p. 354 1. Data Center Handbook… - Fogarty, V., & Flucker, S. (2014).
Data Centre Essentials: Design, Construction, and Operation of Data Centres for the Non-expert. British Computer Society. The book discusses common airflow inefficiencies and best practices for blanking panels, containment design, and commissioning walk-throughs.
Quote:
“Blanking panels and proper aisle containment are essential to reduce mixing of hot and cold air and avoid recirculation issues.”
— Fogarty & Flucker, Data Centre Essentials, Chapter 5 Sr. Infrastructure Reli… - Podcast Reference – Data Center Insights, Legrand x Equinix Roundtable (2024). Experts emphasized that airflow inefficiencies are often the result of overlooked gaps and poorly implemented containment systems. Small improvements such as sealing blank spaces or using proper grommets yield measurable energy savings and better PUE.
Watch the full roundtable
Project 2 : “Smart Filter Longevity Program”
Objective:
Extend the operational life of CRAC/CRAH unit air filters and optimize filter replacement intervals using real-time airflow monitoring and predictive analytics.
Why this matters:
As highlighted in the airflow efficiency podcast, filters are often overlooked but clogged filters increase fan load, reduce airflow volume, and cause CRAC units to consume more power to maintain cooling. Overly frequent replacements waste resources; delayed replacements degrade PUE.
Key Steps:
- Conduct a baseline study of static pressure increase across filters in multiple sites using historical BMS data.
- Install differential pressure sensors or use existing telemetry to track real-time filter performance degradation.
- Use regression modeling or AI to predict optimal replacement intervals based on humidity, particulate load, and airflow velocity.
- Pilot MERV 13 low-resistance filter upgrades at two test sites to evaluate impact on energy draw and airflow CFM.
- Develop a visual dashboard for reliability/maintenance teams showing filter life, performance slope, and risk flags.
Expected Outcome:
- Extend filter change-out intervals without compromising air quality.
- Reduce unnecessary fan energy spikes caused by clogged filters.
- Improve airflow uniformity, reducing the need for overprovisioned CRAC capacity.
📚 References Used for the Project Idea 2:
- Geng, Hwaiyu. (2015).
Data Center Handbook: Plan, Design, Build, and Operations of a Smart Data Center. Wiley. This book outlines the importance of air filter maintenance in CRAC/CRAH units, emphasizing timely replacement, use of differential pressure gauges, and ASHRAE’s MERV filtration standards.
Quote:
“Timely replacement of prefilters, primary and final filters not only protects the electronic equipment but also maintains optimum performance of the air handling equipment.”
— Geng, H., Data Center Handbook, p. 358 1. Data Center Handbook… - Geng, H. (2015). “Filtration effectiveness can be measured using real-time particle counters… Excess particle counts or concentrations can indicate filter failure or bypass.”
— Data Center Handbook, p. 359 1. Data Center Handbook… - ASHRAE Filtration Guidelines (Referenced in Geng, 2015): The book references MERV-rated filters per ASHRAE 52.2 standard, noting that MERV 13 or higher is often recommended for energy-efficient data center cooling while balancing airflow resistance.
🔄 Why These Projects Matter
Both initiatives translate operational insights into systemic improvements to move PUE in the right direction not just once, but every day. More importantly, they empower engineers and supplier quality leaders to create airflow ecosystems that can keep up with the next wave of high-density compute loads.
In the words of the podcast panel: “Every gap we close, every airflow trend we catch early, saves thousands—not just in watts, but in future capacity.”
Quality Thinking 