A mid-sized technology provider supporting a client’s operations in Grand Rapids, Michigan experienced persistent thermal alerts and rising energy costs. The facility relied on two cooling units (a front AC Unit and Rear AC Unit) to maintain optimal server room conditions. However, performance data from the NRGHawk platform revealed that these units were operating in conflict, leading to inefficiencies and potential hardware risks.
Diagnosis
Using NRGHawk’s SmartDetect alerting process, the system compared live readings to historical benchmarks and identified the conflict.
NRGHawk’s dashboard flagged abnormal DeltaT readings:
- Front AC Unit: Input 71.9°F → Output 53.2°F → DeltaT 18.8°F
- Rear AC Unit: Input 73.3°F → Output 51.4°F → DeltaT 11.9°F
These discrepancies indicated that both units were cooling in the same space but at different intensities. The result was:
- Turbulent airflow, causing uneven temperature zones
- Energy inefficiency
- Overcompensation, with each unit trying to correct the other's impact
- Short cycling and excessive humidity
- Increased energy consumption and alert fatigue
- Accelerated wear and tear
Solution: NRGHawk Platform
The facilities team implemented a multi-step resolution:
- Unified Setpoints: Both units were recalibrated to a consistent temperature target.
- Operational Staggering: A control system was installed to alternate unit operation based on real-time load.
- Sensor Repositioning: Sensors were remounted closer to coil and airflow points to improve readings.
- Airflow Optimization: Adjustments to tile layout and rack positioning improved circulation.
Results That Matter
- Table cooling reduces chances of thermal shutdowns or hardware failures.
- Keeps servers within the recommended ASHRAE range (usually 64–81°F), reducing thermal stress on hardware.
- Aligning all units to the same mode can cut unnecessary power consumption by 10–30%, lowering operational costs. rol
- Correcting modes extends the lifespan of HVAC components and reduces maintenance frequency.