Difficulties and Solutions in Prefabricated Design of Liquid-Cooled Piping Ring Network

1. Data Center Liquid-Cooled Ring Network  

The Data Center Liquid Cooling Ring Network is a layout of liquid cooling systems that provides stable and efficient heat dissipation capabilities for IT equipment in computer rooms. It circulates cooling liquid to the liquid cooling equipment of each cabinet (such as cold plates, liquid-cooled servers, immersion liquid tanks, etc.) through closed-loop pipelines and brings the absorbed heat back to the heat exchange device for cooling.

A data center liquid-cooled ring network usually consists of ring network main pipelines, branch interfaces, heat exchange equipment, circulating pumps and valves, and monitoring and sensing components.

2. Design Difficulties and Solutions for Data Center Liquid-Cooled Ring Network

Liquid-cooled ring network piping prefabrication (prefab piping) aims to minimize on-site construction work, improve assembly quality, and accelerate delivery speed. However, in data center scenarios, high heating power, limited available space, extremely high reliability requirements, and complex interfaces with multi-vendor equipment such as servers, cold plates, and CDUs make prefabricated ring network design face many technical and management difficulties.

2.1 Space Layout and Path Conflicts

Difficulties: The space for the primary and secondary sides is compact, and the ring network usually needs to bypass cable trays, air ducts, and fire protection systems. The cabinet density is high, and the equipment layout is inconsistent, so the pipeline routing must take into account both the shortest path and obstacle avoidance.

Solutions:BIM 3D collaborative design: Complete 1:1 3D modeling in the design stage and conduct multi-disciplinary collision detection in advance.

Segmented prefabrication + modular joints: Divide the ring network into standard sections (straight pipes, elbow sections) and custom sections (special transitions) to avoid the entire pipeline being restricted by a single point.

Standardized elevation control: Specify unified elevation levels for the main pipes, branch pipes, and bypasses of the ring network to reduce crossings.

2.2 Prefabricated Dimensional Accuracy

Difficulties: The cumulative actual construction tolerances in the computer room are relatively large, and the closed section of the ring network may be 'misaligned' or require on-site cutting and rework. Liquid-cooled pipelines are usually made of stainless steel, copper, or polymer materials, and on-site cutting will affect cleanliness and anti-corrosion performance.

Solutions:Laser measurement reverse modeling: After the main structure and brackets are completed, use laser scanning to obtain real dimensions, and then adjust the prefabricated model in reverse.

Flexible compensation units: Add length-adjustable expansion joints/soft joints in the closed section or key interfaces to absorb dimensional deviations.

Interface tolerance design: Leave an adjustable margin of ≥ 50mm at both ends of the prefabricated section.

2.3 Transportation and Hoisting Restrictions

Difficulties: The internal passages of data centers are narrow, and the size of elevators is limited, making it difficult to transport large-sized prefabricated sections of the ring network as a whole. The transportation routes for high-rise computer rooms or underground computer rooms are complex, which may easily cause 磕碰 and deformation of prefabricated parts.

Solutions:Modular decomposition: Decompose the ring network into standard modules with a length of ≤ 3m, which are assembled on-site through quick connections or flanges.

Special transport brackets: Use anti-vibration brackets + anti-scratch protective sleeves when transporting prefabricated sections.

Transportation route planning: Confirm the hoisting, handling routes, and temporary opening positions with the construction unit in advance during the design stage.

2.4 Connection Method and Sealing Reliability

Difficulties: The liquid cooling system needs to operate without leakage for a long time, and there are many interfaces in the ring network, which increases the risk of leakage. High flow rate + temperature changes may cause joint loosening or seal failure.

Solutions:Unified interface standards: It is recommended to use clamp quick connections (Victaulic), high-pressure flanges, or welded joints to avoid mixing.

Double sealing design: Key interfaces use double O-rings or a combination of metal washers + elastic seals.

Installation torque control: Formulate joint installation torque standards and conduct on-site inspection with torque wrenches.

2.5 System Debugging and Operation and Maintenance

Difficulties: The ring network is a closed structure, and the temperature difference effect will cause stress concentration in the closed loop, affecting the matching of prefabricated dimensions. When the temperature difference between hot and cold areas in the computer room is large, the relative displacement between the support and the pipeline will cause joint stretching.

Solutions:Thermal compensation design: Add corrugated compensators or L-shaped compensation sections every 20 - 30m in the straight section.

Sliding brackets: Use sliding/rolling supports for key node brackets to allow thermal displacement.

Material matching: The main ring network and branch pipes should use materials with the same thermal expansion coefficient as much as possible.

2.6 Cleaning and Pollution Prevention

Difficulties: Once the ring network design is closed, the flow and pressure distribution of some branches may be uneven. Closing a certain section during maintenance may affect the operation of the entire network.

Solutions:Zoning control valves + bypass design: Add isolation valves and bypasses to each zone to ensure that the system can continue to operate during local maintenance.

Online monitoring point layout: Arrange temperature, pressure, and flow sensors at key nodes of the ring network.

Quick exhaust and drain ports: Facilitate quick handling of air blockage and liquid replacement during debugging and maintenance.

2.7 Cleaning and Pollution Prevention

Difficulties: Liquid cooling has high requirements for medium cleanliness, and particles or oil stains are easily introduced during prefabrication and on-site installation.

Solutions:Factory pre-flushing + on-site secondary flushing: After factory prefabrication, perform pressure flushing and sealing, and conduct recirculation cleaning again after on-site installation.

Clean packaging and transportation: Add blind plates at both ends of the prefabricated section and transport them in vacuum packaging.

Installation environment control: Keep the installation process clean, and strictly prohibit grinding and welding slag from entering the pipeline.

The core of prefabricated design for data center liquid-cooled pipeline ring networks is 'embedding data center characteristics into standardization'—responding to high-density nodes through dynamic flow balance, solving space constraints through compactness and digitization, ensuring zero leakage with multiple seals and monitoring, supporting flexible expansion with modular design, and controlling vibration and noise. Its ultimate goal is to shorten the on-site construction cycle by more than 50% and control the leakage rate below 0.1 times per 10,000 interfaces per year, meeting the core needs of data centers for 'high availability, low risk, and easy operation and maintenance'. As liquid cooling density breaks through to 150kW per cabinet, prefabricated ring networks will also evolve towards 'intelligent ring networks integrated with sensors' to achieve real-time digital management of flow, pressure, and leakage.

3. Advantages of Prefabrication for Data Center Liquid-Cooled Ring Network

3.1 Construction Period Shortening

Advance factory production: Pipes complete cutting, welding, pressure testing, insulation, and other processes in the factory, and only need hoisting and interface connection on-site, which greatly reduces the on-site construction cycle.Parallel operation: Civil engineering and mechanical and electrical installation can be carried out simultaneously without waiting for the building to be closed before large-scale pipeline construction.Rapid delivery: Suitable for the needs of rapid launch of data center services and rapid shelving of IT equipment.

3.2 Controllable Quality

Factory standardized manufacturing: Using CNC cutting, automatic welding, non-destructive testing (X-ray/ultrasonic), etc., the welding quality and dimensional accuracy are higher than on-site operations.Unified testing: Complete water pressure, air tightness, flow, and other tests in the factory to reduce on-site debugging problems.Strong consistency: Mass production can ensure uniform pipeline standards in different computer rooms and different modules, facilitating subsequent operation and maintenance.

3.3 Cost Optimization

Reduce rework: Prefabrication can reduce on-site measurement errors and installation deviations, and reduce demolition and modification caused by collisions or errors.Reduce labor costs: The number of on-site construction personnel is reduced, especially the labor usage of highly skilled welders.Improve material utilization: Optimize the layout of factory cutting to reduce the scrap rate.

3.4 Friendly Construction Environment

Reduce on-site welding: Avoid the impact of high-temperature sparks, smoke, etc. on the cleanliness and safety of the data center.Reduce noise and dust: Conducive to expansion or transformation in existing operating computer rooms.Space operation optimization: Prefabrication can reduce complex operations when the on-site space is narrow and the floor height is limited.

3.5 Design Flexibility and Scalability

Modularity: The combination of ring network structure and prefabrication enables rapid expansion of computer room modules.Standard interfaces: Quick connections or flanges are used between prefabricated sections, facilitating subsequent replacement, upgrading, or maintenance.Adapt to BIM and digital twins: Through BIM modeling in the design stage, prefabricated sections can directly match the on-site installation position.

Kres(Suzhou) Power Systems Technology Co., Ltd is an emerging company focused on fluid power solutions, and serve for the markets of Energy, Construction, Agriculture, Manufacturing, Transportation, Medical, Data Centers, etc., and was founded in 2022 with leading-edge engineering capabilities and innovative products to keep up with the changing customer needs. Including OCP standard UQD, UQDB, BMQC, manifold, EPDM hose and hose assemblies, FF9 full flow dual interlock quick disconnect coupling (a better replacement for FD83 series products), API heat transfer products, Gates EPDM hose and Wika products.

KRES FF9 connectors are specifically engineered for fluid transmission, electronic cooling, and data center liquid cooling applications, where full flow, fluid compatibility, and safety are of paramount importance. The FF9 series ball valve quick-disconnect couplings adopt a full-flow design and are now available in 2-inch, 1.5-inch, and the popular 1-inch sizes. The FF9 double interlock liquid cooling quick-change connector features a swivel structure at its tail, facilitating easy connection and disconnection. Additionally, its two connector halves are completely identical, simplifying maintenance, installation, and service processes.

· 100% full-flow interlock ball valve: The FF9 double interlock ball valve has a diameter of up to 21mm, ensuring large flow while reducing pressure drop, achieving large flow and low pressure drop, and has obtained SGS ROHS reports and Huace performance test reports.

· KRES interlock ball valve adopts a double interlock design with two locking mechanisms to prevent accidental disconnection and ensure data security.

· The FF9 liquid cooling quick-change ball valve has identical connector halves, making maintenance, installation, and service simple.

· As a liquid cooling quick-change ball valve for data centers, it has reliable and stable performance with minimal leakage, meeting the maintenance needs of safe machine relocation or shutdown.

· Standard body material of the liquid cooling quick-change connector: 304 stainless steel, with wide fluid compatibility, and other materials can be provided upon request.

· Standard sealing material of the liquid cooling quick-change connector: EPDM ethylene propylene diene monomer synthetic rubber, and other materials can be provided upon request.

· Operating temperature range of the liquid cooling-specific ball valve: -40℃ ~ 120℃