5.4 MW Air-Cooled Data Rack Expansion
A 5.4 MW air-cooled data rack expansion delivered inside a fully active facility producing data-center components, from a 208V to 480V substation conversion through redundant distribution and an arc flash study of the expanded equipment.
The challenge
The client, a confidential high-tech manufacturer of data-center components, needed 5.4 MW of additional air-cooled rack capacity added to a facility that stayed in operation throughout. There was very little overhead room for new conduit pathways, and the site could not go down during the build.
What we did
Rather than add new service, we converted an existing unit substation from 208V to 480V to draw the required power from the equipment already in place. Large feeders were routed through the limited available headspace, and every run was coordinated in BIM against the new cooling ductwork before installation so conduit and duct did not conflict overhead.
Keeping it live
The facility is fed from two separate utilities, and all gear runs on A and B main-tie-main feeds for redundancy. That topology let the expansion proceed on a live site without putting the existing load at risk.
Project facts
- Critical load
- 5.4 MW
- Site status
- Active during construction
- Distribution
- A/B main-tie-main, dual utility
- Capacity gained
- 208V to 480V conversion
Scope delivered
- Medium-voltage service & distribution
- A/B main-tie-main redundancy
- BIM feeder & cooling-duct coordination
- Arc flash analysis to NFPA 70E
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