As a rule, project design goes through several stages, from preliminary design, to verification of technical accuracy and full compliance with the previously stated requirements, followed by the complete correction of any identified errors and final approval. The design process may include an overall project assessment and preparation of a cost estimate.

Under modern conditions, the design stage is a complex process that includes such activities as designing power density, determining criticality levels (using TIER levels as an example), planning cooling capacity, and accounting for the overall growth in active power consumption in the data center. The basic foundation for the design is the equipment layout, covering both the engineering infrastructure and active equipment in the machine room. Subsequently, this document will become an integral part of the work of the review commission when developing a strategy for testing engineering infrastructure components.

Data Center Engineering Infrastructure Testing Process

The key aspects of the testing procedure are as follows:

1. Planning - The testing process begins one month before the physical installation of engineering equipment in the data center. The committee holds regular meetings. Equipment suppliers must provide commissioning documentation in a timely manner as an integral part of the data center testing planning process. At this stage, the committee’s objective is to identify as many potential «failure points» as possible that may arise during subsequent operation.
   

2. Approval of the Commission Composition - Experience in forming commissions shows that the best testing results are achieved when one or two independent members are present. The commission should also include representatives of all interested parties, such as the finance department, which may in turn engage external auditors. Once the final composition of the commission has been approved by all parties involved, its members should begin reviewing the project at the earliest stages, as this is the most effective way to identify and promptly eliminate the maximum possible number of “failure points.” This will also help avoid significant overspending of the budget allocated for the project.

3. Documentation - Based on the integration testing of all equipment, comprehensive documentation of every stage of the process is an important component. Documentation is also essential for developing the schedule and “roadmap” for implementing all project stages. The initial documentation stage begins with a thorough inspection of all subsystems based on the startup forms provided by the equipment manufacturers. Vendors must provide this information. All documentation must be reviewed at regular commission meetings. Upon completion of the subsystem inspection stage, a comprehensive documentation process for the engineering infrastructure must be implemented based on its results.

4. Testing - Each piece of equipment must be tested in accordance with the applicable procedure, based on restarting it and returning it to normal operating mode. At this stage, interrelated “failure points” may be identified (for example, a diesel generator set) that could trigger a cascade of numerous other unforeseen failures (for example, power loss to the pump group of the cooling system). Ignoring this may result in a complete loss of power without the timely activation of backup power, or an unplanned automatic restart.

   1. Electrical Power: At this stage of the commissioning process, the high-voltage electrical inputs are tested. The process then advances to the medium-voltage portion of the main power distribution system, including parallel switchgear, transfer switches, the emergency generator, the UPS system, the data center control system, and rack-level power distribution. All lighting and life-safety systems, including the emergency power-off system (EPO), must also be comprehensively tested.

   2. Cooling: Testing of the cooling system components begins with filling the chillers with coolant, followed by testing the piping, pumps, variable-speed drives, chemical or other water-treatment systems, and filtration systems. This also includes testing humidification, ventilation, and heating systems.

   3. Fire Suppression: Here, the testing process begins with analyzing incoming water and post indicator valve assemblies (PIVs), as well as testing alarm and automatic reporting systems, and concludes with the actual analysis of the gas used in the fire suppression system.

   4. Monitoring and Control Systems: Commissioning and building energy management. Monitoring and control systems are integrated with each primary test system. Every alarm signal must be tested.

   5. Physical Security Systems: The central security systems are tested here, including video surveillance, physical security devices (such as card readers), and the central public address system. All points of entry for communications cabling must undergo a secondary inspection to determine the level of security in the event that intruders attempt to enter the data center through the air ducts.

   6. Spare Parts Inventory: When modern modular and scalable UPS systems or similar equipment are used, a spare parts pool must be defined in advance, including backup power modules, which are an integral part of the commissioning process. All spare modules must be stored properly, for example, in sealed plastic packaging to prevent dust from entering until they are ready to be deployed as replacements for failed equipment.

   
   

5. Documentation - All data obtained during the thorough testing of engineering infrastructure components must be properly documented and approved by the commission, followed by approval from all other stakeholders. Documentation may take various forms, including protocols, certificates, and reports that reflect the actual condition of the engineering infrastructure and serve as the basis for the final decision to place the system into commercial operation. The formats of the reports and certificates may be arbitrary, but their content must satisfy the representatives of both parties. The final documentation must also include all logs and records maintained at every stage of project implementation. These documents will subsequently contribute to the creation of a so-called “knowledge base,” enabling the seamless transfer of all accumulated data center operational experience.