A leading engineering firm, AEI, was tasked by a Big Six tech client to optimize the water-cooling systems used to prevent their servers from overheating. To achieve this, they wanted a fluid skid equipped with a leak detection system for lifecycle testing of various seals used in their server cooling system.
The client required an autonomous testing apparatus capable of simulating the entire lifecycle of different seals in an accelerated timeframe. The test system needed to maintain precise pressure and temperature setpoints while being versatile enough to test multiple seal types for performance and durability comparisons.
A key challenge was designing a system that could operate unsupervised for extended periods while ensuring safety, particularly given the risk of leaks. The client sought a resilient, reliable, low-maintenance solution that could provide accurate data on seal performance under stress without constant oversight.
To address this complex challenge, AEI collaborated with ACS to leverage its deep expertise in designing, fabricating, and programming test skids. AEI designed the electrical components, while ACS handled the mechanical system design, controller programming, and fabrication of the entire fluid test skid.
The result is a fluid skid with precise temperature and pressure control that can safely run continuously for months without operator supervision. ACS engineers carefully selected components rated for sustained operation that could withstand the stress of prolonged testing. The ACS fabrication teams constructed the skid, including the electrical control panel designed by AEI. The panel achieved UL 508A certification, ensuring each component met rigorous safety and reliability standards.
ACS engineers programmed an HMI control screen for users to configure pressure and temperature setpoints and monitor testing. An air-pressurized expansion tank establishes a baseline system pressure, while two Variable Frequency Drive (VFD) pumps in a lead/lag configuration maintain consistent pressure to the Units Under Test (UUTs), ensuring redundancy and even wear distribution of the pumps.
The test skid pumps circulate a glycol/water mixture, managing liquid temperature with a heater, fan, and bypass loop. To adjust the fluid temperature, a precise mix of heated and unheated fluid gets diverted to the bypass loop to achieve the setpoint temperature. This allows for finer control over the fluid temperature reaching the UUTs, especially when rapid cooling or temperature stabilization is needed. An automatic glycol fill system maintains proper fluid levels throughout testing.
This design allows the system to self-regulate and quickly respond to temperature or pressure changes, maintaining the configured setpoints as long as necessary. To ensure safety and uninterrupted operation, ACS engineers design a leak detection mechanism with a sloped drip pan and automatic shut-off control sequence.
ACS provided an integrated approach, with engineering, fabrication, and mechanical teams working closely in the same facility, allowing for swift problem-solving that enabled the teams to meet the client’s tight deadline.
The innovative fluid test skid developed by ACS and AEI allows the Big Six tech firm to simulate years of seal usage within test cycles lasting just months. Capable of testing multiple UUTs simultaneously, autonomous operation of the server cooling system, coupled with advanced safety features and redundancies, ensures continuous testing for extended periods without constant supervision.
The test system can cycle through multiple setpoints over time, mimicking real-world variations in operating conditions. This flexibility resulted from a late-stage client request, which ACS software engineers adeptly incorporated by reprogramming the control system from maintaining steady-state conditions to offering dynamic, programmable test scenarios.
To capture more comprehensive data during these variable test cycles, they implemented a Modbus server that transmits gathered data to the client’s systems for ongoing analysis and performance comparisons. The client can select the variable conditions for each test cycle and also set the intervals for data capture and delivery.
Responding to another late-stage request, the ACS engineers configured the Modbus server to enable remote access. This feature allows the client’s personnel to log in remotely and observe test status and conditions in real-time.
By accommodating these significant changes and delivering a highly adaptable system, ACS demonstrated its agility and breadth of technical expertise, providing the client with a powerful tool for optimizing seal selection for their server cooling system.